STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE CONSTRUCTION
St. Louis County, Missouri Department of Transportation September 1, 2023
(This Page Intentionally Left Blank)
Standard Specifications for Road and Bridge Construction Division Index Division
Description
Latest Revision Date
COVER, DIVISION INDEX & TABLE OF CONTENTS
9/1/2023
100
GENERAL PROVISIONS
9/1/2023
200
EARTHWORK
9/1/2023
300
BASES AND AGGREGATE SURFACES
7/1/2016
400
FLEXIBLE PAVEMENT
9/1/2023
500
RIGID PAVEMENT
9/1/2023
600
INCIDENTAL CONSTRUCTION
9/1/2023
700
STRUCTURES
9/1/2023
800
ROADSIDE DEVELOPMENT
2/1/2016
900
TRAFFIC CONTROL FACILITIES
9/1/2023
1000
MATERIAL DETAILS
9/1/2023
9/1/2023
i
Division Index
Table of Contents Section
Page Number or Revision Date
Cover Sheet..........................................................................................................................9/1/2023 Division Index ................................................................................................................................... i Table of Contents ....................................................................................................................... ii - x
Division 100
General Provisions
101......Definition of Terms .................................................................................................. 7/1/2015 Abbreviations .............................................................................................. 101-4 Metric Abbreviations and Symbols ............................................................. 101-7 Units of Measurement ................................................................................ 101-7 Definitions ................................................................................................... 101-8 102......Bidding Requirements and Conditions .................................................................... 7/1/2015 103......Award and Execution of Contract ............................................................................ 7/1/2015 104......Scope of Work ......................................................................................................... 7/1/2015 105......Control of Work........................................................................................................ 7/1/2015 106......Control of Material ................................................................................................... 7/1/2015 107......Legal Relations and Responsibility to the Public ....................................................10/1/2018 108......Prosecution and Progress ....................................................................................... 7/1/2015 109......Measurement and Payment .................................................................................... 9/1/2023 110......State Wage Rate Requirements .............................................................................. 7/1/2015
Division 200
Earthwork
201..... Clearing and Grubbing ...................................................................................... 10/1/2012 202..... Removals ............................................................................................................ 7/1/2015 202.20 ...... Removal of Improvements ................................................................ 202-2 202.30 ...... Removal of Rigid Pavement .............................................................. 202-5 203..... Roadway and Drainage Excavation, Embankment, and Compaction ................. 9/1/2023 204..... Embankment Control ......................................................................................... 10/1/2012 204.10 ...... Settlement Gauges ........................................................................... 204-2 204.20 ...... Pore Pressure Measurement Devices ............................................... 204-4 205..... Modified Subgrade ............................................................................................ 10/1/2012
9/1/2023
ii
Table of Contents
Section
Page Number or Revision Date
206..... Excavation for Structures.................................................................................... 9/1/2023 207..... Linear Grading................................................................................................... 10/1/2012 209..... Subgrade Preparation ........................................................................................ 9/1/2023 217..... Ditching ............................................................................................................. 10/1/2012
Division 300
Bases and Aggregate Surfaces
304......Aggregate Base Course .......................................................................................... 7/1/2016 309......Portland Cement Concrete Base (Moved to 509 on 12/9/2013).............................................
Division 400
Flexible Pavement
403......Geosynthetic Interlayer for Roadway Applications .................................................. 7/1/2015 404......Superpave Asphaltic Concrete Pavement ............................................................... 9/1/2023 405......Bituminous Pavements and Base ........................................................................... 7/1/2016 406......Joint and Cracksealing .......................................................................................... 3/15/2022 407......Tack Coat ................................................................................................................ 2/1/2017 408......Prime Coat............................................................................................................... 5/1/2010 409......Seal Coat ................................................................................................................. 7/1/2015 410......Micro-Surfacing ....................................................................................................... 9/1/2023 412......Pavement Surfacing and Texturing ......................................................................... 9/1/2023 413......Asphaltic Concrete Incorporating Reclaimed Asphaltic Pavement or Shingles (RAP or RAS) .................................................................7/1/2015
Division 500
Rigid Pavement
501......Ready-Mixed Concrete ............................................................................................ 9/1/2023 502......Portland Cement Concrete Base and Pavement .................................................. 3/15/2022 503......Bridge Approach Slab.............................................................................................. 2/1/2017 504......Concrete Approach Pavement ................................................................................ 1/1/2016 505......Reinforced Concrete Pavement .............................................................................. 1/1/2016 507......Strength of Concrete Using the Maturity Method .................................................... 1/1/2016 508......Subdivision Concrete Replacement ........................................................................ 9/1/2023 509......Portland Cement Concrete Base (formerly Section 309) ........................................ 9/1/2023
9/1/2023
iii
Table of Contents
Section
Division 600
Page Number or Revision Date
Incidental Construction
601......Field Laboratories .................................................................................................... 1/1/2016 602......Markers and Monuments......................................................................................... 1/1/2016 603......Miscellaneous Water Equipment ............................................................................. 1/1/2016 603.10.......Water Main Installation (Greater than 2 Inches) .................................. 603-1 603.20.......Water Service Connections ............................................................... 603-10 604......Miscellaneous Drainage .......................................................................................... 9/1/2023 604.10.......Concrete Headwalls, Drop Inlets and Manholes ................................. 604-1 604.20.......Adjusting Drainage Facilities ............................................................... 604-6 604.30.......Adjusting House Sewer Connections .................................................. 604-7 604.40.......Pipe Collars ......................................................................................... 604-8 604.50.......Connecting Pipe to Existing Structures ............................................... 604-9 605......Underdrainage ......................................................................................................... 1/1/2016 605.10.......Class A Underdrain ............................................................................. 605-1 605.20.......Class B Underdrain ............................................................................. 605-3 605.30.......Class C Underdrain ............................................................................. 605-4 606......Guardrail and Roadway Barriers ............................................................................. 1/1/2016 606.10.......Guardrail .............................................................................................. 606-3 606.20.......Guard Fence ....................................................................................... 606-7 606.30.......Crashworthy End Terminals ................................................................ 606-8 606.40.......One-Strand Access Restraint Cable.................................................... 606-9 606.50.......Three-Strand Guard Cable ................................................................ 606-10 607......Fencing .................................................................................................................... 1/1/2016 607.10.......Chain-Link Fence ................................................................................ 607-1 607.20.......Woven Wire Fence .............................................................................. 607-3 607.30.......Handrails ............................................................................................. 607-5 608......Concrete Medians, Median Strips, Sidewalks, Curb Ramps, Steps and Paved Approaches ................................................................................................. 9/1/2023
9/1/2023
iv
Table of Contents
Section
Page Number or Revision Date
609......Paved Drainage ....................................................................................................... 9/1/2023 609.10.......Concrete Curb, Gutter and Paved Ditch ............................................... 609-1 609.20.......Integral Curb ......................................................................................... 609-3 609.30.......Asphalt Curb ......................................................................................... 609-5 609.40.......Drain Basin ........................................................................................... 609-7 609.60.......Ditch Liner ............................................................................................ 609-8 609.70.......Rock Lining ........................................................................................... 609-9 610......Masonry Construction...............................................................................................1/1/2016 611......Embankment Protection ...........................................................................................1/1/2016 611.10.......Rock Fill ................................................................................................ 611-1 611.20.......Fully Grouted Rock Fill ......................................................................... 611-2 611.30.......Rock Blanket ........................................................................................ 611-3 611.40.......Grouted Rock Surface .......................................................................... 611-4 611.50.......Revetment ............................................................................................ 611-5 611.60.......Concrete Slope Protection.................................................................... 611-6 611.70.......Gabions ................................................................................................ 611-7 612......Traffic Control Devices .............................................................................................1/1/2016 612.30.......Standard Traffic Control Devices.......................................................... 612-3 612.40.......Detour Lighting ..................................................................................... 612-6 612.50.......Project Information Signs ..................................................................... 612-7 612.60.......Temporary Excavation Fencing ............................................................ 612-8 612.70.......Advanced Warning Arrow Panel .......................................................... 612-9 612.80.......Nighttime Worksite Lighting Requirements ........................................ 612-10 613......Pavement Repair ....................................................................................................3/15/2022 614......Drainage Fittings ......................................................................................................1/1/2016 614.10.......Grates and Bearing Plates ................................................................... 614-1 614.20.......Automatic Floodgate............................................................................. 614-2 614.30.......Gray Iron Castings for Manhole or Inlet Frame, Cover and Gratings ... 614-3 615......Office for Engineer....................................................................................................1/1/2016 616......Traffic Control Plan ...................................................................................................1/1/2016 617......Concrete Median Barrier ..........................................................................................1/1/2016 618......Mud Jacking .............................................................................................................1/1/2016 619......Mobilization...............................................................................................................1/1/2016
9/1/2023
v
Table of Contents
Section
Page Number or Revision Date
620......Inlaid Pavement Markers ......................................................................................... 1/1/2016 621......Temporary Pavement Markings ............................................................................. 9/1/2023 622......(removed) ................................................................................................................ 9/1/2023 623......Concrete Bonding and Epoxy Mortar ...................................................................... 1/1/2016 623.10.......Concrete Bonding Compound ............................................................. 623-1 623-20 ......Epoxy Mortar ....................................................................................... 623-2 624......Geotextile Construction ........................................................................................... 1/1/2016 625......Flowable Fill (Controlled Low-Strength Materials) ................................................... 1/1/2016 625.10.......Excavatable Flowable Fill .................................................................... 625-1 612.20.......Non-Excavatable Flowable Fill .......................................................... 625-10 626......Temporary Steel Plate Trench Bridging .................................................................. 1/1/2016 627......Diamond Grinding of Portland Cement Concrete or Bituminous Pavement ............ 9/1/2023 628......Keyhole Coring and Repair ..................................................................................... 1/1/2016
Division 700
Structures
701..... Drilled Shafts ...................................................................................................... 5/1/2010 702..... Bearing Pile .................................................................................................... 12/12/2012 703..... Concrete Masonry Construction ......................................................................... 9/1/2023 704..... Concrete Masonry Repair ................................................................................... 5/1/2010 705..... Prestressed Concrete Members for Bridges ....................................................... 5/1/2010 706..... Reinforcing Steel for Concrete Structures ........................................................... 5/1/2010 707..... Conduit System on Structure .............................................................................. 5/1/2010 710..... Epoxy Coated Reinforcing Steel ......................................................................... 5/1/2010 711..... Protective Coatings for Exposed Concrete Surfaces .......................................... 5/1/2010 712..... Structural Steel Construction .............................................................................. 5/1/2010 713..... Bridge Guard Rail ............................................................................................... 5/1/2010 715..... Vertical Drain at End Bents................................................................................. 5/1/2010 716..... Neoprene Bearings............................................................................................. 5/1/2010 717..... Neoprene and Silicone Joint Systems ................................................................ 5/1/2010
9/1/2023
vi
Table of Contents
Section
Page Number or Revision Date
720..... Mechanically Stabilized Earth Wall Systems....................................................... 5/1/2010 724..... Pipe Culverts (New Section) ............................................................................... 7/1/2016 725..... Metal Pipe and Pipe-Arch Culverts ..................................................................... 5/1/2010 726..... Rigid Pipe Culverts, Storm Drains and Sewers ................................................... 9/1/2023 727..... Structural Plate Pipe and Structural Plate Pipe-Arch Culverts ............................ 5/1/2010 728..... Corrugated Polyvinyl Chloride (PVC) Culvert Pipe ............................................. 5/1/2010 730..... Thermoplastic Culvert Pipe................................................................................. 7/1/2016 731..... Precast Reinforced Concrete Manholes and Drop Inlets .................................... 5/1/2010 732..... Flared End Sections ........................................................................................... 5/1/2010 733..... Precast Concrete Box Culverts ........................................................................... 9/1/2023 734..... Installation of Pipe by Horizontal Boring Methods ............................................... 5/1/2010 736..... Bridge Deck Sealer............................................................................................. 9/1/2012
Division 800
Roadside Development
800..... General Notes (Page 800-3)............................................................................... 6/6/2008 801..... Lime and Fertilizing ............................................................................................ 6/6/2008 802..... Mulching ............................................................................................................. 6/6/2008 803..... Sodding .............................................................................................................. 6/6/2008 804..... Topsoil................................................................................................................ 8/1/2012 805..... Seeding .............................................................................................................. 2/1/2016 806..... Pollution, Sediment and Erosion Control ............................................................ 2/1/2016 806.10 ...... Temporary Berms ............................................................................ 806-3 806.20 ...... Temporary Slope Drains .................................................................. 806-4 806.30 ...... Temporary Ditch and Inlet Checks ................................................... 806-4 806.40 ...... Sediment Basins .............................................................................. 806-6 806.50 ...... Temporary Seeding and Mulching ................................................... 806-7 806.70 ...... Silt Fence ......................................................................................... 806-7 806.80 ...... Temporary Pipe ............................................................................... 806-9 806.90 ...... Temporary Erosion Control Blankets................................................ 806-9 806.100 .... Temporary Stream Crossing .......................................................... 806-10 808..... Planting Trees, Shrubs and Other Plants............................................................ 2/1/2016
9/1/2023
vii
Table of Contents
Section
Page Number or Revision Date
Division 900
Traffic Control Facilities
902..... Roadway Striping ............................................................................................... 7/1/2015 903..... Roadway Signing ............................................................................................... 7/1/2015 904..... St. Louis County Traffic Signals ......................................................................... 9/1/2023 Index .......................................................................................................... 904-1 St. Louis County Traffic Signals ............................................................... 904-9
Division 1000
Material Details
1001 ...General Requirements for Materials...................................................................... 9/16/2008 1002 ...Aggregate for Superpave Asphaltic Concrete ....................................................... 9/16/2008 1003 ...Aggregate for Seal Coats ...................................................................................... 9/16/2008 1004 ...Aggregate for Bituminous Concrete ........................................................................ 3/1/2016 1005 ...Aggregate for Concrete ........................................................................................... 2/1/2017 1006 ...Aggregate Surfacing Material ................................................................................ 9/16/2008 1007 ...Aggregate for Base.................................................................................................. 7/1/2016 1009 ...Aggregate for Drainage ........................................................................................... 2/4/2011 1010 ...Select Granular Backfill for Structural Systems and Box Culvert Bedding ............. 9/1/2023 1011 ...Geotextile .............................................................................................................. 12/9/2013 1012 ...Geocomposite Drainage Material .......................................................................... 1/31/2007 1013 ...Miscellaneous Drainage Material ............................................................................ 2/3/2014 1015 ...Bituminous Material ................................................................................................. 2/1/2017 1016 ...Silica Fume (Microsilica)........................................................................................ 2/13/2013 1017 ...Ground Granulated Blast Furnace Slag ................................................................ 12/9/2013 1018 ...Fly Ash for Concrete ................................................................................................ 2/4/2011 1019 ...Cement .................................................................................................................. 12/9/2013 1020 ...Corrugated Metallic Coated Steel Culvert Pipe, Pipe Arches & End Sections ...... 1/31/2007 1021 ...Bituminous Coated Corrugated Metal Culvert Pipe & Pipe Arches ....................... 1/31/2007 1022 ...Corrugated Metallic Coated Steel Pipe Underdrain............................................... 10/1/2012 1023 ...Structural Plate Pipe and Pipe Arches .................................................................. 1/31/2007 1024 ...Corrugated Aluminum Alloy Culvert Pipe and Corrugated Aluminum Alloy Structural Plate ...................................................................... 1/31/2007
9/1/2023
viii
Table of Contents
Section
Page Number or Revision Date
1025 ...Corrugated Aluminum Alloy Pipe Underdrains ........................................................ 2/4/2011 1026 ...Reinforced Concrete Culvert, Storm Drain and Sewer Pipe.................................. 1/31/2007 1027 ...Polymer Coated Corrugated Metal Culvert Pipe and Pipe Arches ........................ 1/31/2007 1028 ...Corrugated Poly Vinyl Chloride (PVC) Culvert Pipe .............................................. 1/31/2007 1029 ...Prestressed Concrete Members for Bridges ......................................................... 1/31/2007 1030 ...Vitrified Clay Products ........................................................................................... 1/31/2007 1032 ...Precast Concrete Flared End Sections ................................................................. 1/31/2007 1033 ...Precast Drainage Units.......................................................................................... 1/31/2007 1034 ...Reinforced Concrete Elliptical Culvert, Storm Drain and Sewer Pipe ................... 1/31/2007 1035 ...Reinforced Concrete Arch Culvert, Storm Drain and Sewer Pipe ......................... 1/31/2007 1036 ...Reinforcing Steel for Concrete ................................................................................ 4/8/2013 1037 ...Shear Connectors ................................................................................................. 1/31/2007 1038 ...Bearing Pads for Structures .................................................................................. 1/31/2007 1039 ...Epoxy Resin Material............................................................................................. 1/31/2007 1040 ...Guardrail, End Terminals, One-Strand Access Restraint, Cable and Three-Strand Guard Cable Material ......................................................... 10/1/2012 1041 ...Polypropylene Culvert Pipe ................................................................................... 12/9/2013 1043 ...Fence Material ....................................................................................................... 1/31/2007 1044 ...Posts for Markers and Delineators ........................................................................ 1/31/2007 1045 ...Paint for Structural Steel........................................................................................ 1/31/2007 1047 ...Corrugated Polyethylene Culvert Pipe .................................................................. 1/31/2007 1048 ...Pavement Marking Material ................................................................................... 11/1/2016 1049 ...Precast Concrete Box Culvert ............................................................................... 1/31/2007 1050 ...Lumber, Timber, Piling, Posts and Poles .............................................................. 11/1/2016 1051 ...Slotted Drain .......................................................................................................... 1/31/2007 1052 ...Mechanically Stabilized Earth Wall System Components ..................................... 11/1/2016 1053 ...Penetrating Protective Sealer Material .................................................................... 2/4/2011 1054 ...Concrete Admixtures ............................................................................................. 12/9/2013 1055 ...Concrete Curing Material....................................................................................... 12/9/2013 1056 ...Concrete Tinting Material ........................................................................................ 2/4/2011
9/1/2023
ix
Table of Contents
Section
Page Number or Revision Date
1057 ...Material for Joints .................................................................................................. 10/1/2017 1058 ...Polyethylene Sheeting ........................................................................................... 10/1/2012 1059 ...Protective Coating Material ..................................................................................... 2/1/2017 1060 ...Electrical Conduit................................................................................................... 1/31/2007 1063 ...Temporary Traffic Control Devices .......................................................................... 7/1/2016 1064 ...Temporary Concrete Traffic Barrier ....................................................................... 1/31/2007 1065 ...Concrete Traffic Barrier Delineators ...................................................................... 1/31/2007 1066 ...Mortars and Grout ................................................................................................. 1/31/2007 1068 ...Calcium Chloride ..................................................................................................... 2/1/2015 1070 ...Water ....................................................................................................................... 2/1/2017 1071 ...Asphalt Release Agents and Liquid Anti-Strip Additives ....................................... 11/1/2016 1073 ...Joint Material for Structures................................................................................... 1/31/2007 1075 ...Centrifugally-Cast Fiberglass-Reinforced Polymer Mortar Pipe ............................ 1/31/2007 1080 ...Structural Steel Fabrication ................................................................................... 10/1/2012 1081 ...Coating of Structural Steel..................................................................................... 1/31/2007
9/1/2023
x
Table of Contents
Division 100
GENERAL PROVISIONS
10/1/2018
100-1
General Provisions
(This Page Intentionally Left Blank)
10/1/2018
100-2
General Provisions
Standard Specifications for Road and Bridge Construction Division 100 - General Provisions Section
Description
Revision Date
101..... Definition of Terms .............................................................................................. 7/1/2015 Abbreviations .............................................................................................. 101-2 Metric Abbreviations and Symbols ............................................................. 101-5 Units of Measurement ................................................................................ 101-5 Definitions ................................................................................................... 101-6 102..... Bidding Requirements and Conditions ................................................................. 7/1/2015 103..... Award and Execution of Contract ........................................................................ 7/1/2015 104..... Scope of Work ..................................................................................................... 7/1/2015 105..... Control of Work ................................................................................................... 7/1/2015 106..... Control of Material ............................................................................................... 7/1/2015 107..... Legal Relations and Responsibility to the Public................................................ 10/1/2018 108..... Prosecution and Progress ................................................................................... 7/1/2015 109..... Measurement and Payment................................................................................. 9/1/2023 110..... State Wage Rate Requirements .......................................................................... 7/1/2015
9/1/2023
100-3
Division 100 - Index
(This Page Intentionally Left Blank)
9/1/2023
100-4
Division 100 - Index
Section 101
Definition of Terms
101.0 General. These specifications are generally written in the active voice-imperative mood. In sentences using the imperative mood, the subject "the Contractor" is implied. These directions to the Contractor are written as commands. Also implied in this language are “shall”, "shall be", or similar words and phrases. The word "will" generally pertains to decisions or actions of the Department and/or the Engineer. All other requirements to be performed by others, with the exception of the Method of Measurement and the Basis of Payment Articles, have been written in the active voice, but not in the imperative mood. In these specifications or on the drawings: •
The following words or similar words refer to the actions of the Department and/or the Engineer, unless otherwise stated: "directed", "established", "permitted", "ordered", "designated", "prescribed", "required", "determined".
•
The words "approved", "acceptable", "authorized", "satisfactory", "suitable", "considered", "rejected", or words with similar intent, mean by the Department and/or Engineer, subject in each case to Section 105 of these Standard Specifications.
•
"As shown", "shown", "as indicated", or "indicated", mean "as indicated on the contract plans".
In these specifications: •
Reference to a Section of the specifications includes all applicable requirements of the Section.
•
When referring to a subsection, only the number of the subsection is used: the word "subsection" is implied. When section and subsection numbers are not consecutive, the interval is intended for use in the Special Provisions or future expansion of the Standard Specifications.
Any reference to the words "he", "his", "him", "man", or "men" used in plans, specifications, or other contract documents is for descriptive purposes only and shall not, in any way, be construed to limit the application of this document to the masculine gender.
7/1/2015
101-1
General Provisions
101.1 Abbreviations. Wherever the following abbreviations, terms, or descriptive words are used in the plans, specifications, or other contract documents, the intent and meaning shall be interpreted as follows: AAN ..............................................................................American Association of Nurserymen AAR .................................................................................. Association of American Railroads AASHTO ..................... American Association of State Highways and Transportation Officials ACI ............................................................................................. American Concrete Institute AGC .................................................................... Associated General Contractors of America AISC .........................................................................American Institute of Steel Construction ANSI ........................................................................... American National Standards Institute AREA...................................................................American Railway Engineering Association ARS ................................................................................................ Asphalt Roofing Shingles ASME ..................................................................American Society of Mechanical Engineers ASTM.................................................................. American Society for Testing and Materials AWG .................................................................................................... American Wire Gauge AWPA ...................................................................... American Wood Preservers' Association AWS ............................................................................................. American Welding Society AWWA ............................................................................ American Water Works Association CFR ...........................................................................................Code of Federal Regulations CRSI ............................................................................... Concrete Reinforcing Steel Institute CS...................................................... Commercial Standard, U.S. Department of Commerce CSR .............................................................................................. Code of State Regulations DBE ................................................................................ Disadvantaged Business Enterprise EEI ............................................................................................ Electrical Engineer's Institute EEO ....................................................................................... Equal Employment Opportunity EPA ............................................................. United States Environmental Protection Agency ESAL ............................................................................... Equivalent 18 kip Single Axle Load 7/1/2015
101-2
General Provisions
FHWA ................................................................................... Federal Highway Administration FSS ........................... Federal Specifications and Standards, General Service Administration FTM ....................................................................................................... Federal Test Method GGBFS ......................................................................Ground Granulated Blast Furnace Slag GRI .......................................................................................Geosynthetic Research Institute GSA ..................................................................................... General Services Administration HBA ............................................................................................. Home Builders Association HMA .............................................................................................................. Hot Mix Asphalt ICEA .......................................................................... Insulated Cable Engineers Association IEEE ............................................................. Institute of Electrical and Electronics Engineers IES ....................................................................................... Illuminating Engineering Society IMSA........................................................................ International Municipal Sign Association ISO ............................................................................... International Standards Organization IPCEA............................................................. Insulated Power Cable Engineers Association ITE ..............................................................................................Institute of Traffic Engineers JMF ..............................................................................................................Job Mix Formula LED ........................................................................................................ Light Emitting Diode MDNR .................................................................. Missouri Department of Natural Resources MESA .......................................................... Municipal Engineers and Surveyors Association MIL .......................................................................................................Military Specifications MoDOT ...................................................................... Missouri Department of Transportation MSD ............................................................................... Metropolitan St. Louis Sewer District MSDS .........................................................................................Materials Safety Data Sheet MUTCD ....................... Manual on Uniform Traffic Control Devices for Streets and Highways, FHWA, United States Department of Transportation
7/1/2015
101-3
General Provisions
NBSVPS .................................... National Bureau of Standards Voluntary Product Standards NEC .................................................................................................. National Electrical Code NFPA .............................................................................. National Fire Protection Association NEMA .............................................................. National Electrical Manufacturers Association NESC ..................................................................................... National Electrical Safety Code NIST ............................................................. National Institute of Standards and Technology NRMCA ............................................................. National Ready Mixed Concrete Association NSPE ................................................................... National Society of Professional Engineers OSHA ............................................................Occupational Safety and Health Administration PAL ........................................................................................................ Pre-Acceptance List PCA .......................................................................................... Portland Cement Association PCI ............................................................................. Precast/Prestressed Concrete Institute PS ..................................................... U.S. Product Standard, U.S. Department of Commerce PVC ............................................................................................................Polyvinyl Chloride RAP ......................................................................................... Reclaimed Asphalt Pavement RETMA ........................................... Radio Electronics Television Manufacturer's Association SAE .....................................................................................Society of Automotive Engineers SI ...............................................................................................International System of Units SITE ......................................................................................... Site Improvement Association SSPC .................................................................................. Steel Structures Painting Council UL ............................................................................................. Underwriters Laboratory, Inc. VOC ............................................................................................ Volatile Organic Compound
7/1/2015
101-4
General Provisions
101.1.1 Metric Abbreviations and Symbols. These specifications refer to international System of Units as defined by ASTM E 380, Standard Practice for Use of the International System of Units (SI). Frequently used units in these specifications and their abbreviations are as follows: A ......................................... Ampere cal ......................................... calorie cd ........................................ candela C .......................................... Celsius cm ................................... centimeter dB .........................................decibel g ............................................... gram h ................................................ hour ha ......................................... hectare H ............................................. henry Hz............................................. hertz j ................................................ joule kg ........................................kilogram km ......................................kilometer km/h.................... kilometer per hour kPa ................................... kilopascal
L ................................................ Liter lx ................................................. lux µ .............................................. micro m .............................................meter m2 ................................ square meter m3 .................................. cubic meter Mg ................................... Megagram mm ....................................millimeter mm2....................... square millimeter Mpa ...............................Megapascal N........................................... newton N-m ............................ newton-meter Ω ............................................... ohm s ........................................... second V ................................................. volt W ............................................... watt
101.1.2 Units of Measurement. A listing of standard abbreviations used can be found in Section 95.00 of the "Design Criteria for the Preparation of Improvement Plans" manual published by the Department. Some of the symbols for units of measurement used in the specifications and in the Engineer's Estimate are defined as follows: ABS ............... composite sewer pipe CY or yd3 ......................... cubic yard DIP .......................... ductile iron pipe EA ............................................ Each ft................................................. feet gal. .........................................Gallon H:V ..................... horizontal : vertical Ga ............................. gage or gauge in. .............................................. Inch lb. ...........................................Pound LF..................................... linear feet LNMI .................................. lane mile
7/1/2015
LNKM .........................lane kilometer LS..................................... lump sum Mo .......................................... month NR ............................. non-reinforced oz ........................................... ounce psi ..................... pounds/square inch RCP ............ reinforced concrete pipe SF or ft2.......................... square feet STA ....................................... station SY or yd2 ....................... square yard VCP ........................vitrified clay pipe yd. ............................................. yard
101-5
General Provisions
101.2 Definitions. Definitions of terms, words or phrases used in the specifications, on the plans, or in other contract documents, except for other definitions found in the individual sections, are as follows: Accounting Officer ................... Accounting Officer of St. Louis County, Missouri. Administrative Director ............ Administrative Director of the St. Louis County Council (County Clerk). Advertisement .......................... The public announcement, as required by law, inviting bids for work to be performed or materials to be furnished. Aggregate ................................. Rock of specified quality and gradation. Appreciable Error ..................... An increase in excess of 125% or decrease below 75% of the original contract quantity of an item where final measurements are not made to determine quantity for payment. Article ........................................ The numbered prime subdivision of a Section of these Specifications. Auxiliary Lane........................... The portion of the roadway adjoining the travel way and designated for speed change, or for other purposes supplementary to through traffic movement. Award ........................................ The action of the County Council accepting the bid of the lowest responsible bidder for the work, subject to the execution and approval of a satisfactory contract therefore and bond to secure the performance thereof, and to such other conditions as may be specified or as required by law. Backfill ...................................... Material used to replace or the act of replacing material removed during construction; also may denote material placed or the act of placing material adjacent to structures. Base .......................................... A course of specified material of specified thickness placed below the pavement. Bicycle Lane ............................. A lane in the traveled way designated for use by bicyclists. Bicycle Path .............................. A public way, physically separated from the roadway, which is designated for use by bicyclists. Bid ............................................. The written offer submitted by the bidder in the required manner on the bid form to perform the work contemplated at his bid prices. Bid Form ................................... The approved form furnished by the County on which the bid prices for the work is to be submitted.
7/1/2015
101-6
General Provisions
Bid Guaranty............................. The security furnished with a bid to insure that the bidder will enter into the contract if his proposal is accepted. Bidder........................................ Any individual, partnership, corporation, or joint venture submitting a bid to perform the work contemplated. Borrow ...................................... Material lying outside of planned or required roadbed excavation used to complete project earthwork. Bridge........................................ A structure having a clear span greater than 20 feet measured on a horizontal plane along the centerline of the roadway; also a multiple span structure where the total length of spans is in excess of 20 feet. For both a single and multiple span bridge, the clear span shall be construed to mean the total distance from stream face to stream face of end bents or outer walls of the structure. Business Day............................ A day that St. Louis County is open for business, excluding holidays, Saturdays and Sundays. Calendar Day ............................ Any day of the calendar year, including Saturdays, Sundays and legal holidays, beginning and ending at midnight. Camber...................................... A surface or structure slightly arched, as specified, to compensate for loading. Change Order ........................... A written order from the Director to the Contractor as authorized by the contract, directing changes in the work as made necessary or desirable by unforeseen conditions or events discovered or occurring during the progress of the work. Change in the Work.................. A written order from the Engineer to the Contractor, as authorized by the contract, directing changes in the work as made necessary or desirable by unforeseen conditions or event discovered or occurring during the progress of work. Claim ......................................... A written request or demand for adjustment to the compensation due or time of performance of the contract made within the time, in the form, and pursuant to the provisions for such contract adjustment specified elsewhere in the contract documents of which these specifications are a part. Clay ........................................... Soil passing a No. 200 sieve that can be made to exhibit plasticity (putty-like properties) within a range of water contents.
7/1/2015
101-7
General Provisions
Close Conformance ................. Where working tolerances are given, close conformance means compliance with those tolerances. Where working tolerances are not given on the plans or in the specifications, close conformance means compliance, in the Engineer's judgment, with reasonable and customary manufacturing and construction tolerances. Coarse Aggregate .................... Crushed rock or crushed gravel retained on a No. 4 sieve, with allowable undersize. Contract .................................... The written agreement between the County and the Contractor covering the performance of the work for the proposed construction. It may cover a single project, or a combination of projects awarded as a single unit. Contract Bond .......................... The form of security approved by the County Council, furnished by the Contractor and his surety or sureties, guaranteeing complete performance of the contract and the payment of all legal debts pertaining to the construction of the project, and conditioned as may be required by the laws of the State of Missouri and Ordinances of St. Louis County. Contract Documents ................ The contract shall include Notice to Contractors, Plans, Bid, Contract Bond, Contract Agreement, Acknowledgment, Special Provisions, Standard Specifications, Supplemental Contracts and Change Orders. Contract Time or Completion Date....................... The number of working days or calendar days shown in the proposal as the time allowed for the completion of the work contemplated in the contract. If a calendar date for completion is shown in the proposal, the work contemplated shall be completed by that date. Contractor................................. The individual, partnership, corporation, or joint venture undertaking performance of the work under the terms of the contract, and acting directly or through his or its agents, employees, or subcontractors. Compaction .............................. The process of densifying a layer of soil or rock, asphalt, or concrete material by using static, pneumatic or vibratory rollers made specifically for this purpose. County....................................... St. Louis County, Missouri. County Council......................... The County Council of St. Louis County, Missouri. County Counselor .................... The County Counselor of St. Louis County, Missouri.
7/1/2015
101-8
General Provisions
County Clerk ............................. See Administrative Director of the St. Louis County Council. County Executive ..................... County Executive of St. Louis County, Missouri. Course....................................... A specified surfacing material placed in one or more lifts to a specified thickness. Coverage ................................... One pass over the entire designated surface. Cross Section ........................... The exact image formed by a plane cutting through an object, usually at right angles to a central axis, to determine area. Culvert....................................... A structure not classified as a bridge, which provides an opening under any portion of a roadway. Delay ......................................... Any event, action, force or factor that causes the established contract time to be exceeded for performance of the contract. 1) Compensable Delay - An excusable delay for which the contractor may be entitled to additional monetary compensation 2) Excusable Delay - A delay to the contract or milestone completion date that was beyond the contractor's control and not caused by the contractor's fault or negligence and for which a contract or milestone time extension may be granted. 3) Noncompensable Delay - An excusable delay for which the contractor may be entitled to an extension of time, but no additional monetary compensation. 4) Nonexcusable Delay - A delay to the contract or milestone completion date that was reasonably foreseeable and within control of the contractor, for which no monetary compensation or time extension will be granted. Department .................... The St. Louis County Department of Transportation. Design Criteria Book ..... The Department's design guide manual containing policies and procedures for the preparation of Improvement Plans. Differing Site Conditions ..................... Subsurface or latent physical conditions at the site differing materially from those indicated in the contract, or unknown physical conditions of an unusual nature differing materially from those ordinarily encountered and generally recognized as inherent in the work
7/1/2015
101-9
General Provisions
Disadvantaged Business Enterprise or DBE .................... A contracting firm certified to participate in U.S. Department of Transportation financial assistance programs as a DBE by MoDOT or by the Missouri Unified Certification Program (UCP) pursuant to Title 49 CFR, Part 26, and pursuant to Title 7 CSR Division 10, Chapter 8, governing MoDOT's DBE Program. Director ..................................... The Director of the St. Louis County Department of Transportation and Public Works. Drainage Ditch .......................... An open depression constructed for the purpose of carrying off surface water. Easement .................................. A grant by a property owner to the County for the purpose of road maintenance, improvement or widening. Emergency ................................ A national emergency creating a shortage of materials, labor, or equipment and that such emergency will probably continue for an unreasonable length of time, by reason of which the Contractor will be unable to proceed with the contract. Engineer.................................... The Director or their authorized representative. Extra Work ................................ An item of work not provided for in the contract awarded, but found to be essential by the Engineer for the satisfactory completion of the contract. This may be paid on a negotiated price, force account or established price basis. Once a price has been negotiated and a basis of payment established, any changes to this extra work will be handled as "changed" work, which cannot be paid on a force account basis. Fine Aggregate ......................... Material that will pass a No.4 sieve naturally produced by the disintegration of rock of a siliceous nature, or, when approved by the Engineer, manufactured from igneous rock or chert gravel. Highway .................................... A public way for purposes of vehicular or pedestrian travel including the entire area within the right-of-way. Same as road or street.
7/1/2015
101-10
General Provisions
Holidays .................................... Public Legal Holidays observed by County. They are: January 1 .......................................................................... New Year's Day Third Monday in January...................................... Martin L. King's Birthday Third Monday in February ................................................. Presidents' Day Last Monday in May ............................................................. Memorial Day July 4 ........................................................................... Independence Day First Monday in September ........................................................ Labor Day November 11 ....................................................................... Veteran's Day Fourth Thursday in November........................................ Thanksgiving Day Fourth Friday in November ............................. Day after Thanksgiving Day December 25 ...................................................................... Christmas Day When any holiday listed above falls upon Saturday, the previous Friday shall be considered the holiday. When any holiday listed above falls upon a Sunday, the following Monday shall be considered the holiday. Laboratory ................................ The Materials Testing Laboratory of the Department or any other testing laboratory that may be designated by the Engineer for inspecting and determining the suitability of materials. Law ............................................ Any Federal, State, County, Municipal law, ordinance, code, regulation or rule. Layer ......................................... Specified material placed in one or more lifts to less than specified maximum thickness. Leveling .................................... A course of construction to restore horizontal and vertical uniformity to existing pavements - normally continuous throughout project limits. Lift ............................................. The nominal compacted thickness of material placed by equipment in a single pass. Major and Minor Items of Work ........................... Any item having an original value in excess of 10% of the original contract amount will be considered as a major item or items. All other original contract items will be considered as minor. Where major contract items are not identified, the original contract item of greatest total cost, computed from the original contract price and estimated quantity, and such other original contract items next in sequence of lower total cost, computed in like manner, necessary to show a total cost at original prices and quantities of no less than 60% of the original contract cost will be considered as a major item or items.
7/1/2015
101-11
General Provisions
Material ..................................... Any natural or manmade substance or item specified for use in the construction of the project. Median....................................... The portion of the street, roadway or highway separating the travel ways for traffic in opposite directions. Neat Line ................................... Theoretical line specified or indicated on the plans for measurement of quantities. Notice of Letting ....................... The notification provided prospective bidders, containing a description of the proposed work, instruction, information, and the reservation of the right of the County Council to reject any and all bids. Notice to Contractors............... The document contained in the bid form describing the work to be performed and including information and requirements for the submission of bids. Notice to Proceed ..................... The written notice from the Director notifying the Contractor of the date on or before which he is to begin prosecution of the work. Obliterate .................................. To remove from existence, destroy all traces, cover, or change appearance so the original object can no longer be recognized. Organic Soil .............................. A soil with sufficient organic content to influence the soil properties. In general, organic soils are very highly compressible and have poor load-sustaining properties. Outer Roadway or Service Road ............................ A roadway auxiliary to and located on the side of the throughway for service to abutting property and adjacent areas. Pass .......................................... The movement of a piece of equipment over a given spot. Patching .................................... A variable thickness course of construction to correct sags, dips, and/or bumps to the existing grade and cross section - normally intermittent throughout the project limits. Pavement .................................. Asphalt Concrete or Portland Cement Concrete placed for vehicular use on highway, road and street traveled ways, shoulders, auxiliary lanes and parking areas. Pay Item .................................... An item of work specifically described and for which a price, either unit or lump sum, is provided. It includes the performance of all work and the furnishing of all labor, equipment, and materials contemplated or described on the plans or in the text of the specification item included in the contract. 7/1/2015
101-12
General Provisions
Plans ......................................... Drawings or reproductions thereof approved by the Director, which show the location, character, dimensions and details of the work. Plans shall prevail over standard and supplemental specifications when in conflict therewith. Project ....................................... The specific section of the street, roadway or highway together with all appurtenances and construction to be performed thereon under the contract. Railroad..................................... A road composed of parallel steel rails supported by ties and providing a track for trains, trams, or other rolling stock. Request for Bid ........................ The document furnished by the Commission that includes a complete set of bidding forms and appendices, and certain contract terms, which are made a part of the bidding document by reference. Right-of-Way (or Right of Way) ...................... Land acquired by the County, generally in a strip, for the construction and maintenance of a street, roadway or highway. Rights-of-Way (or Rights of Way) .................... More than one right-of-way, plural of right-of-way. Road .......................................... Same as street or highway. Roadbed.................................... The graded portion of a highway between the outside shoulder lines including the base course, surface course, shoulders, and median. Roadway ................................... The portion of the highway within limits of construction including bridges and other structures. Rock .......................................... Natural solid mineral matter occurring in large masses or fragments. Sand .......................................... Particles of rock that will pass the No. 4 sieve and be retained on the No. 200 sieve. Scarify ....................................... To loosen, break up, tear up and partially pulverize the surface of soil, or of a road. Section (or Sec.) ....................... A number of prime division of these Specifications.
7/1/2015
101-13
General Provisions
Shoulder ................................... The portion of the roadway contiguous with the travel way for accommodation of stopped vehicles, for emergency use, and for lateral support of base and surface courses. Sieve ......................................... In accordance with ASTM E 11, sieves are constructed of woven wire cloth mounted in a frame for use in testing for the classification of materials according to designated particle size. Silt ............................................. Soil passing the No. 200 sieve that is non-plastic or exhibits very low plasticity and exhibits little or no strength when air-dried. Special Provisions ................... Directions or requirements, peculiar to the work and not otherwise thoroughly or satisfactorily detailed or set forth in the standard or supplemental specifications. Special provisions shall prevail over standard specifications, supplemental specifications, and plans whenever in conflict therewith. Specifications ........................... The directions, provisions, and requirements contained in these standard specifications, together with such as may be added or adopted as supplemental specifications or special provisions, for the performance of the work and for the quantity, quality, and proportion of materials. Standard Drawings................... Detailed drawings for work or methods of construction. State .......................................... The State of Missouri, acting by and through the Missouri Department of Transportation (MoDOT) or State Highway Commission of Missouri. Street ......................................... Same as road or highway. Subarticle.................................. A headed and numbered subdivision of an Article of a Section of these Specifications. Subcontractor........................... Any individual, partnership, corporation, or joint venture to whom the Contractor, with the written consent of the Director, sublets any part of the work under the contract. Subgrade .................................. The portion of the roadbed immediately below the base course or pavement, including below the curb and gutter, shoulder and driveway pavement. The subgrade limits ordinarily include those portions of the roadbed shown in the plans to be constructed. Where no limits are shown on the plans, the subgrade section extends to a depth of 12 inches below the bottom of the base or pavement and outward to 6 inches beyond the base, pavement, or curb and gutter.
7/1/2015
101-14
General Provisions
Substructure ............................. That part of a bridge structure below the bearings of simple and continuous spans; all buttresses and piers below the skewbacks of arches; all parts of rigid frames, or integral bents below tops of footings or tops of caissons; and also, all parts of the abutments, back walls and wingwalls, excepting handrail and handrail posts. Superintendent ......................... The Contractor's authorized representative in responsible charge of work. Superstructure ......................... All parts of bridge structure not defined in substructure. Supplemental Specifications ........................... Specifications adopted subsequent to the publication of the standard specifications. Supplemental specifications shall prevail over the standard specification whenever in conflict therewith. Surety ........................................ A corporate body duly authorized to do business in the State of Missouri, and which has executed a bid bond with the bidder or a contract bond with the Contractor. Temporary Structures .............. Structures required for the use of traffic while construction is in progress and not to remain a part of the permanent roadway. Topsoil ...................................... Soil ready for intended use in a planting bed, containing organic matter. Throughway .............................. A general term denoting a highway primarily for through traffic, usually on a continuous route. Traveled Way ............................ The portion of the roadway for the movement of vehicles, exclusive of shoulder and auxiliary lanes. Unsuitable Material .................. Frozen materials or materials that contain organic matter, muck, humus, peat, sticks, debris, chemicals, toxic matter, or other deleterious materials not suitable for use in earthwork unless otherwise specified. Utility ......................................... A line, facility, or system for producing, transmitting, or distributing communications, power, electricity, heat, gas, oil, water, steam, waste, storm water not connected with highway drainage, or any other similar commodity which directly or indirectly serves the public. The term utility shall also mean the utility company, district, or cooperative, including any wholly owned or controlled subsidiary.
7/1/2015
101-15
General Provisions
Work .......................................... The furnishing of all labor, materials, equipment, small tools and other incidentals necessary or convenient to the successful completion of the project and the carrying out of all the duties and obligations imposed by the contract. Working Drawings .................... Stress sheets, shop drawings, erection plans, falsework plans, framework plans, cofferdam plans, bending diagrams for reinforcing steel, or any other supplementary plans or similar data which the Contractor is required to submit to the Engineer for approval.
7/1/2015
101-16
General Provisions
Section 102
Bidding Requirements and Conditions
102.1 Bidding Documents. Upon request, the County will furnish the bidding documents to the prospective bidder. The documents will state the location and description of the contemplated construction and will show the estimate of the various quantities and kinds of work to be performed or materials to be furnished, and will have a schedule of items for which unit bid prices are invited. The bidding documents will state the time in which the work shall be completed, the amount of the bid guaranty, and the date, time and place of the opening of bids. The bidding documents will also include any special provisions or requirements that vary from or are not contained in the standard specifications. 102.1.1 All papers bound with or attached to the bid form are considered a part thereof and shall not be detached or altered when the bid is submitted. 102.1.2 The plans, the St. Louis County Standard Specifications for Road and Bridge Construction, St. Louis County Standard Drawings and other items referenced in the bidding documents, will be considered a part of the bid whether attached or not. 102.1.3 The prospective bidder will be required to pay the County the sum stated in the Notice to Contractors for each copy of the project's bidding documents. A prospective bidder will be expected to separately acquire the most current "Manual on Uniform Traffic Control Devices" (MUTCD), available at http://mutcd.fhwa.dot.gov/, and the current editions of the St. Louis County Standard Specifications for Road and Bridge Construction, the Design Criteria for the Preparation of Improvement Plans, and the St. Louis County Standard Drawings. The current editions of these St. Louis County publications are available on the St. Louis Department of Transportation Internet website at www.stlouisco.com/YourGovernment/CountyDepartments/HighwaysandTraffic/HighwayPublicationsManuals. 102.2 Interpretation of Quantities in Bid Schedule. The quantities appearing in the bid schedule are estimated only and are prepared for the comparison of bids. Payment to the Contractor will be made only for the actual quantities of work performed and accepted in accordance with the contract, except where final measurements are not made, as hereinafter provided. The quantities of work to be done and material to be furnished may each be increased, decreased, or omitted as hereinafter provided. 102.3 Examination of Plans, Specifications, Special Provisions, and Site of Work. The County will prepare plans and specifications giving such directions as will enable the Contractor to carry them out. Conditions indicated on the plans and in the bidding documents represent information available from surveys and studies. The bidder is expected to examine carefully the site of the proposed work and the bidding documents before submitting a bid. Submission of a bid will be considered proof that the bidder has made an examination and is satisfied as to the conditions to be encountered in performing the work and as to the requirements of the plans, specifications, supplemental specifications, special provisions, and contract. It is the responsibility of the bidder to ensure that prospective subcontractors are aware of any addendums issued to the plans, special provisions, or construction contract for this project.
7/1/2015
102-1
Bidding Requirements and Conditions
102.3.1 Other documentary information, consisting of boring logs and other factual subsurface information, which does not constitute part of the contract or contract documents, is available from the Engineer upon the bidder's written request. This information, used for project design and quantity estimation purposes, was not obtained to determine actual subsurface conditions, actual quantities of subsurface material or appropriate construction methods, nor shall it be considered a representation of actual conditions to be encountered during construction. Furnishing this information does not relieve a bidder from the responsibility of making an investigation of conditions to be encountered and basing their bid on information obtained from these investigation, or the professional interpretations and judgment of the bidder. The bidder assumes the risk of error if the information is used for any purposes for which it was not intended. The County makes no representation as to the accuracy of the logs or other subsurface information, since their accuracy is limited by the equipment used, the personal judgment of the persons making the investigation, and by the limited number of samples taken. The records indicate conditions encountered only at the times and the specific locations shown. Ground water observations are not routinely recorded in boring logs. The absence of such data does not mean ground water will not be encountered. An indication of ground water constitutes no representation or warranty as to where ground water will be found, nor its volume or artesian character, during the project work. Any assumption a bidder may make from this data is at the bidder’s risk; none are intended by the County. 102.3.2 Certain other documents in the County's possession relating to subsurface investigations are not included in the records made available to bidders under Section 102.3.1. These include correspondence and reports containing interpretations, opinions and recommendations that may or may not be factual, accurate or consistent with design decisions. Any such information, which does not constitute part of the contract or contract documents, is available, at a nominal cost, from the Engineer upon specific, written request of the prospective bidder. The bidder is cautioned that any and all such interpretations, conclusions and recommendations are not represented or warranted to be accurate or reliable, and the County cannot be bound by them, whether or not it may appear to have "relied" on them. These subjective findings, opinions or assumptions have not been confirmed or shown to be reliable, and the bidder assumes the sole risk of liability or loss if the bidder does rely on these documentary interpretations and conclusions to its detriment, delay or loss. 102.3.3 The bidder assumes all risks it may encounter in basing its order of work, equipment or personnel determinations, time of performance, cost of performance, working days needed, item bid prices or any other element of the work, on documents which the bidder obtains from the County, which are not expressly warranted. 102.3.4 Unless stated specifically and expressly in the bidding documents, no project involving excavation, which may include either borrow or the disposal of excess material, is represented or warranted to be a "balanced" job or project, regardless of whether the bidding documents use terms such as "balance points", or other terms which could be interpreted to suggest balance. Whether or not such projects involving excavation contain bid items for borrow or disposal of excess material, the bidder should assume that both are possible and investigate those possibilities accordingly in determining a bid.
7/1/2015
102-2
Bidding Requirements and Conditions
102.3.5 Utilities are often in the process of being relocated at the time a project is bid. Regardless of what utilities are shown in the bidding documents, and their locations listed, the bidder is responsible to contact each area utility to determine the presence and location of the utility lines. The bidder shall also determine, and shall assume the risk of its failure to determine, whether utilities which are to be relocated by the utility companies have in fact been relocated, and if not, when the utility company anticipates the relocation shall be completed. The bidder shall independently determine the reliability of the information received from the utility companies, and shall make its own determination as to the sequence and timing of utility relocations in determining its bid. 102.3.6 The bidder and contractor has an affirmative duty to inquire and obtain from the National Oceanic and Atmospheric Administration (NOAA), National Climatic Data Center (NCDC), from the USACE and any other cognizant government agency, historic weather and water stage information which the bidder may consider important as guides for bidding and scheduling the work. Some of that information may be contained among the bidding documents solely as a convenience and is not warranted nor represented to any degree to be complete and accurate historic data. No warranty or representation whatsoever is made or intended by the County of future weather conditions during the project. Water stages and depths of water at any place or at any time within the area of the project are acknowledged to be beyond control of the County and dependent upon future weather conditions and actions by other governmental bodies, such as the government of the USA or third parties. The County makes no representation that other governmental bodies or third parties will not take action during the period of the contract or any extended time of contract performance, which will affect water stages or depths. Bidders are put on notice that the bidder’s operations may be affected by water flows, siltation and other causes over which it is acknowledged the County has no control. 102.4 Sales and Use Taxes. St. Louis County intends to take advantage of its sales tax exemption status on construction contracts by utilizing procedures outlined in RSMo Section 144.062. Inasmuch as all Missouri sales and use tax will be exempt, Contractors need not include any sales tax in their bidding of the construction contract. Compliance with these tax savings procedures is compulsory and for the benefit of St. Louis County. Requirements Include: 1) St. Louis County: a) Furnish the Contractor a "Project Tax Exemption Certificate" which shall include the following: i)
St. Louis County's name, address, Missouri tax identification number and signature of authorized representative;
ii)
The project location, description, and unique identification number;
iii) The date the contract is entered into, which is the earliest date materials may be purchased for the project on a tax-exempt basis; iv) The estimated project completion date; and
7/1/2015
102-3
Bidding Requirements and Conditions
v)
The certificate expiration date. Such certificate is renewable for a given project at the option of Saint Louis County, only for the purpose of revising the certificate expiration date as necessary to complete the project.
2) Contractor: a) The Contractor shall furnish the certificate prescribed in Section "A" of this provision to all subcontractors, and any Contractor purchasing materials shall present such certificate to all material suppliers as authorization to purchase, on behalf of St. Louis County all tangible personal property and materials to be incorporated into or consumed in the construction of this project and no other on a tax-exempt basis. Such suppliers shall execute to the purchasing Contractor invoices made out to the Contractor. The invoices must also bear the name of St. Louis County and the unique project identification number. Nothing in this section shall be deemed to exempt the purchase of any construction machinery, equipment or tools used in constructing, repairing or remodeling facilities for St. Louis County. All invoices for all personal property and materials purchased for this project utilizing St. Louis County's Project Tax Exemption Certificate shall be retained by the purchasing Contractor for a period of five years and shall be subject to audit by the Missouri Director of Revenue. b) Any excess resalable tangible personal property or materials which were purchased for this project by a Contractor under the Project Tax Exemption Certificate but which were not incorporated into or consumed in the construction of this project shall either be returned to the supplier for credit or the appropriate sales or use tax on such excess property or materials shall be paid by such Contractor not later than the due date of the Contractor's Missouri sales or use tax return following the month in which it was determined that the materials were not to be used in the project. c) No Contractor or material supplier shall, upon audit, be required to pay tax on tangible personal property and materials incorporated into or consumed in the construction of the project, due to the failure of St. Louis County to revise the certificate expiration date as necessary to complete any work required by the contract. If it is determined that tax is owed on such property and materials due to the failure of St. Louis County to revise such certificate expiration date, St. Louis County shall be liable for the tax owed. d) Order all necessary materials and equipment (materials) to complete the work in accordance with the specifications. e) Inspect all delivered materials for conformance to specifications, damage, or breakage and subsequently accept materials if found to be satisfactory. f) Purchase of materials on behalf of St. Louis County does not relieve Contractor of obligations to order, schedule deliveries, inspect, accept or reject, store, handle or install materials or perform any other duties required by the Contract Documents or customarily performed in conjunction with providing materials to complete the work.
7/1/2015
102-4
Bidding Requirements and Conditions
g) The Contractor shall not be entitled to receive any additional compensation for complying with these requirements. 102.5 Preparation of Bidding Documents. All bids shall be properly signed and sealed, and submitted as set forth in Section 102.8. Each bidder shall specify in the bid, in figures, a unit price for each of the separate items listed in the bidding documents except a unit price entry is not necessary for those items having a quantity of one and only the amount for that item need be entered. The bid shall not contain interlineations, alterations, or erasures except as noted in Section 102.5.1. The bidder shall show the products of the respective unit prices and quantities in the amount column provided for that purpose. These extensions shall be totaled and in case of errors or discrepancies in extensions, the unit prices shall govern. All entries on the bid form shall be in ink. If, in the sole discretion of the Engineer, an obvious and apparent clerical error exists in the unit price listed for an item due to a misplaced decimal, but the extension appears to be correct and as intended in all respects, the Engineer may correct the unit price bid in accord with the extension listed. All errors in extensions or totals will be corrected by the County and such corrected extensions and totals will be used in comparing bids. 102.5.1 A bidder may alter or correct a unit price, lump sum bid or extension entered on the bid form or the computer-generated itemized bid form by crossing out the figure with ink and entering a new unit price, lump sum bid or extension above or below in ink, with the bidder’s initials. 102.5.2 A bidder may submit a separate bid on any or all projects except that bids shall be submitted for all projects in a required combination. The bidder may specify in the bidding document the maximum monetary value of awards that will be accepted in the bid opening. The County Council reserves the right to make awards that will be to the best interest of the County, provided they are in conformance with the invitations for bids. 102.5.3 The bid of an individual, including those doing business under a fictitious name, shall include the signature and address of the individual. 102.5.4 A bid by a partnership or joint venture, including individuals doing business under fictitious names, or corporations, shall be executed by at least one of the partners followed by the title "Partner," or one of the joint venturer followed by the title "Joint Venturer" and the business address of the partnership or joint venture shown. The true legal name and address of each partner or joint venturer shall be shown. 102.5.5 The bid by a corporation, whether acting alone or as a joint venture, shall show the address and shall include the signature and title of a person authorized by its Board of Directors to bind the corporation. 102.5.6 If this successful bidder is doing business in the State of Missouri under a fictitious name, such bidder shall have on file with the Administrative Director of the County Council before the award, a certified copy of his registration of fictitious name issued by the Secretary of State, State of Missouri. No contract will be executed by the County Council until such certificate is furnished by the bidder.
7/1/2015
102-5
Bidding Requirements and Conditions
102.5.7 All successful bidders who are corporations organized in states other than Missouri, shall furnish, at their cost, a certified copy of a certificate of authority and license to do business in Missouri, said certificate to remain on file with the Administrative Director of the County Council. Such certified copy may be secured from the corporation supervisor in the office of the Secretary of State, Capitol Building, Jefferson City, Missouri. No contract will be executed by the County Council until such certificate is furnished by the successful bidder. If this successful bidder already has on file with the Administrative Director of the County Council such a certificate, an additional certificate will not be required. The successful bidder agrees to cause its authority and license to do business as a foreign corporation to be continued and extended through the life of the contract, and until all claims thereon and there under shall have been finally settled. 102.5.8 Each bidder shall submit with each bid a sworn statement, executed by or on behalf of the bidder to whom a contract may be awarded, certifying that such bidder has not, either directly or indirectly, entered into any agreement, participated in any collusion, or otherwise taken any action in restraint of free competitive bidding in connection with such bid, or any contract which may result from its acceptance. 102.5.9 A Bid will not be accepted or considered if it is a product of collusion among bidders, if the bidder is disqualified or determined not responsible, or if the bid is irregular as specified in Sections 102.6 or 102.12. 102.5.10 Computer-Generated Itemized Bids. generated itemized bid sheets.
The bidder may utilize computer-
102.5.10.1 The computer-generated itemized bid sheets shall be 8.5 inches x 11 inches. Any printer may be used provided the type is clear, distinct and legible. Any common typeface or font may be used except italic or script fonts. There shall be nine bid item lines per page, with a horizontal line separating each bid item. The header shall have the same information as the itemized bid sheets provided in the bidding documents and include the bidder's name. Each page of the computer-generated itemized bid shall match the itemized bid sheets provided in the bidding documents, line for line, including all section headings, sub-totals, totals for project and totals for combinations. Each page of the computer-generated itemized bidding documents shall match the itemized bid sheets provided in the bid, column for column, including all the line numbers, item numbers, descriptions, units and quantities. Abbreviations of item descriptions and units will be permitted provided sufficient wording is used to identify the item. The product of the bidder's unit price and the County's quantity for that same line number will be used in comparing bids and in the successful bidder's contract. 102.5.10.2 An example of the bidder's computer-generated itemized bid sheet shall be submitted to the County for pre-approval no less than four weeks prior to the first bid opening in which it is used. Any revisions made to the bidder's approved computergenerated format shall be submitted to the County no less than four weeks prior to the bid opening for which the revised computer-generated itemized bid sheet is to be used. 102.5.10.3 Any computer-generated itemized bid sheet not meeting the above requirements may cause the bid to be considered irregular and subject to rejection.
7/1/2015
102-6
Bidding Requirements and Conditions
102.5.10.4 The computer-generated itemized bid sheets shall be stapled together and attached to the last itemized bid sheet of the bid form. When the bidder submits computer-generated itemized bid sheets, the itemized bid sheets included in the bidding documents shall not be completed. If both are completed and submitted, only the computer-generated itemized bid sheets will be recognized and used as the official bid. 102.5.10.5 When the bidder submits a computer-generated itemized bid for projects listed in a permitted combination, the bidder may include itemized bid sheets for all projects bid, and include sheets with only the header information and "NO BID" indicated for those projects not bid. 102.6 Irregular Bids. Bids that show any omissions, false statements or certifications, alterations of form, additions not called for, conditional or alternate bids unless called for, irregularities of any kind, or which are not responsive to the invitation for bids may be rejected. Bids combining or otherwise tying sections of project not listed in the bidding documents as being in combination will be rejected. Any comment in the bid limiting or qualifying the reserved right of the County Council to make awards that will be to the best interest of the County shall constitute an irregular bid. 102.6.1 A bid will be considered irregular and may be rejected as non-responsive if any of the unit bid prices are mathematically or materially unbalanced to the detriment of the County. 102.6.2 A bid submitted on the "Request For Bid" document and that is otherwise complete and fully executed, will not be deemed an irregular bid and will not be subject to rejection by the County Council. 102.7 Bid Guaranty. Each bid shall be accompanied by a certified check or cashier’s check equal to ten (10) percent of the Director's estimate of cost, payable to "Treasurer, St. Louis County", to the use of the County, or a bidders bond, in like sum, executed by a surety company authorized to do business in the State of Missouri, as a guarantee on the part of the bidder that if its bid be accepted, it will, within ten (10) days after receipt of notice of such acceptance, enter into a contract and bond to do the work advertised; and, in case of default, forfeit such bid guaranty. The provisions of Section 103.4.1 shall also apply to this bid guaranty. 102.7.1 A bid will be considered irregular and may be rejected as non-responsive if any of the unit bid prices are mathematically unbalanced to the detriment of the County Council. 102.8 Delivery of Bids. Each bid shall be furnished in an envelope that is marked so as to indicate its contents clearly. If forwarded by mail, the above-mentioned envelope shall be enclosed in another envelope, addressed to the Administrative Director of the St. Louis County Council, and should be sent preferably by Registered Mail. If forwarded otherwise than by mail, it shall be delivered at the Office of the Administrative Director of the St. Louis County Council, Administrative Building, 41 South Central, St. Louis, MO 63105. All bids shall be filed prior to the time and at the place specified in the Notice of Contractors. Bids received after the time for opening of bids will be returned to the bidder unopened.
7/1/2015
102-7
Bidding Requirements and Conditions
102.8.1 No bid will be considered unless accompanied by a certified check or cashier's check on any bank or trust company insured by the Federal Deposit Insurance Corporation, payable to the "Treasurer, St. Louis County" for not less than the amount specified in the Bid Bond document, or by a bond secured by an approved surety or sureties described in Sections 103.4.2 and 103.4.3, for not less than the amount specified in the Bid Bond document. Bid Bonds shall be submitted on forms furnished by the County. Bid bond forms will be furnished to the prospective bidder upon request. Bid bond forms shall be complete and correct at the time of submittal or the bid may be considered non-responsive. Only the version of the bid bond form provided with the request for bid shall be submitted, unless the request for bid or notice of bid opening authorizes the use of alternate bid bond forms. 102.8.2 Bids accompanied by bid guaranties that do not meet the requirements of Section 102.8.1 may be rejected. Those bids accompanied by bid bonds that are not issued by an approved surety will be rejected. 102.8.3 Bid forms should be submitted with the bidding documents and submitted in the special envelope furnished by the County. The blank spaces on the envelope shall be filled in to clearly indicate its contents. If an envelope other than the special one furnished by the County is used, it shall be similarly marked clearly to indicate its contents. If sent by mail, the sealed bid shall be addressed to the County at the address specified in the bidding documents. All bids shall be filed prior to the time and at the place specified in the notice to Contractors. Bids received after the time for opening of bids will be returned to the bidder unopened. 102.9 Withdrawal or Revision of Bids. A bidder may withdraw or revise a bid after it has been deposited with the County provided the revision or the request for such withdrawal is received in writing by the County, at the address specified in Section 102.8, in writing, before the time set for opening bids. 102.10 Combination Bids. Combination bids for two or more sections or projects of work may be made only if provided for in the bid, and if submitted on the proper bid form. A separate and complete bid for each section of work shall be included in the combination bid and only sections on which individual bids are submitted will be considered as in the combination. The bidder will be allowed to combine sections or projects in the combination listed in the bidding documents as follows: (1) bidding on all sections or projects by stating, "All or None", or (2) by listing any sections or projects desired to be bid, in which case each section or project will be considered separately. 102.10.1 Two or more sections or projects bid in combination shall be considered to be covered by a single contract. If during construction an item for which a unit price has not been bid is encountered in one section or project of a combination, the unit price bid for the same item in another section or project of the combination shall apply, unless there is conclusive proof that conditions are changed sufficiently to effect a definite increase or decrease in the cost of the operations. 102.11 Public Opening of Bids. Bids will be opened and the bid totals read publicly at the time and place indicated in the Notice to Contractors.
7/1/2015
102-8
Bidding Requirements and Conditions
102.12 Disqualification of Bidders. Any one or more of the following reasons may be considered as being sufficient for the disqualification of a bidder and the rejection of this bid or bids: 1) More than one bid for the same work from an individual, firm, joint venturer, or corporation under the same or different name. However, a bidder may submit a bid as principal and as a subcontractor to some other principal, or may submit a bid as a subcontractor to some other principals as the bidder desires, and by so doing will not be liable to disqualification in the intent of this specification; 2) There is reason for believing that collusion exists among the bidders. Participants, in such collusion will receive no recognition as bidders for any future work of the County until any such participant shall have been reinstated; 3) The bidder, or any officer, shareholder, owner or director of the bidder, has been terminated, debarred or suspended as an eligible contractor or bidder by any agency of the United States, the State of Missouri, or any other state, or any city, county, municipal corporation or other political subdivision; 4) The County has determined or finds that the bidder is not responsible; 5) The bidder is a person or firm not a resident of Missouri and has failed or refused to comply with the Missouri laws relating to nonresident or transient employers, or is prohibited by Section 285.230 RSMo from contracting for or performing labor on a Missouri public works project. 102.13 Right to Reject Bids. The County Council reserves the right to reject any or all bids, to advertise for new bids, or to proceed to do the work otherwise, if, in its judgment, the best interest of the County will be thereby served. 102.13.1 All bids may be rejected for, without limitation, the following reasons: 1) If in the opinion of the majority of the members of the County Council, the lowest bid or bids shall be excessive; 2) The advertised bidding or contract documents are inadequate, ambiguous or otherwise deficient in any respect; 3) The construction of all or any part of the project is no longer required; 4) The bids received indicate that the quality requirements in the bidding or contract documents were overstated; 5) The bidding and contract documents did not include all the intended evaluation factors; 6) The bids were not independently arrived at in open competition;
7/1/2015
102-9
Bidding Requirements and Conditions
7) There are indications that any of the bids were collusive or were submitted in bad faith; 8) The bids received did not provide sufficient competition to ensure adequate price. 102.14 Disadvantaged Business Enterprise Program Bidding Requirements. Refer to the Special Provisions for DBE Program Requirements. 102.15 Certifications. The bidder makes the following certifications by signing and submitting the bid. 102.15.1 Certification Regarding Affirmative Action and Equal Opportunity. If the bidder does not meet all requirements set forth in sub-paragraphs (a), (b) and (c) of this section, then the bidder shall submit a statement indicating which elements the bidder has complied with and those elements that are not in fact true and correct. The statement shall be on company letterhead, signed by the bidder and inserted inside the submitted bid. The bidder shall provide the following elements: 1) The bidder has developed and has on file at each of the bidder's establishment's affirmative action programs pursuant to 41 CFR Part 60-2. 2) The bidder has participated in a previous contract or subcontract subject to the equal opportunity clause set forth in 41 CFR 60-1.4 and Executive Order No. 11246. 3) The bidder has filed with the Joint Reporting Committee, the Director of the Office of Federal Contract Compliance Programs or the Director’s designate or the EEO Commission, all reports due under the applicable filing requirements contained in 41 CFR Part 60-1. This certification applies to and shall be executed by each bidder or proposed subcontractor if the proposed contract or subcontract on this project will equal or exceed $10,000. This certification will also apply to any Contractor or Subcontractor that has contracts or subcontracts on federally assisted projects in any 12-month period that have or can reasonably be expected to have an aggregate total value exceeding $10,000, 41 CFR 601.5(a)(1). The prime contractor shall assure that each of the subcontractors that meet the criteria will also execute and submit this certification to the County. 102.15.2 Certification Regarding Disbarment, Eligibility, Indictments, Convictions or Civil Judgments. The president or authorized official of the bidder, under penalty of perjury under the laws of the USA, shall certify that, except as noted in the exceptions, the company or any person associated therewith in the capacity of owner, partner, director, officer, principal investor, project director, manager, auditor or any position involving the administration of federal funds: 1) Is not currently under suspension, debarment, voluntary exclusion or determination of ineligibility by any federal agency; 2) Has not been suspended, debarred, voluntarily excluded or determined ineligible by any federal agency within the past three years;
7/1/2015
102-10
Bidding Requirements and Conditions
3) Does not have a proposed debarment or suspension pending; 4) Has not been indicted, convicted or had a civil judgment rendered against any of the listed parties by a court of competent jurisdiction in any matter involving fraud or official misconduct within the past three years. 102.15.2.1 If there are any exceptions, the bidder shall submit the exceptions on company letterhead, signed by the bidder and inserted inside the bid submitted. 102.15.2.2 Exceptions will not necessarily result in denial of award, but will be considered in determining bidder responsibility. 102.15.2.3 For any exception noted, the bidder shall indicate to whom it applies, the initiating agency, and dates of action. 102.15.2.4 Providing false information may result in criminal prosecution or administrative sanctions. 102.15.3 Certification Regarding Anti-Collusion. In accordance with 23 USC 112, the bidder shall certify, under penalty of perjury, that the bidder has not, either directly or indirectly, entered into any agreement, participated in any collusion or otherwise taken any action in restraint of free competitive bidding in connection with this contract.
7/1/2015
102-11
Bidding Requirements and Conditions
(This Page Intentionally Left Blank)
7/1/2015
102-12
Bidding Requirements and Conditions
Section 103
Award and Execution of Contract
103.1 Consideration of Bids. After the bids are opened and the bid totals read, they will be compared on the basis of the summation of the products of the approximate quantities shown in the bid schedule multiplied by the unit bid prices. The result of such comparisons will be immediately available to the public. 103.2 Award of Contract. 103.2.1 The contract will be awarded by Council Order to the lowest responsible bidder as soon as practicable after the opening of the bids. The responsibility of the Contractor will be determined by the Director, in accordance with the provisions of the Purchasing Code, Chapter 107, St. Louis County revised Ordinances, 1964, as amended. The successful bidder will be notified by letter mailed to the address shown on the bid that the bid has been accepted and the contract has been awarded. 103.2.1.1 The Council may make a contingent award to the second lowest responsible bidder. If the low bidder fails to execute the contract in accordance with this section, the contract will be offered to the second lowest responsible bidder in accordance with the contingent award made by the Council within 25 days after the original award date. The second low bidder shall then be bound by the same requirements as specified for the lowest responsible bidder. The Notice to Proceed may be extended by the number of days between the original Council award and the day the contract has been mailed to the second lowest responsible bidder. If the contract time for completion of the work is set solely by completion date, then the completion date may be extended by the number of days between the original Council award and the day the contract was mailed to the second lowest responsible bidder. The new contract will be adjusted to reflect these changes, if appropriate. 103.2.1.2 If the second low bidder is not able to perform the work at the unit prices bid by the second low bidder due solely to the fact that the low bidder is unable to perform as a subcontractor in accordance with Section 103.6, and the second low bidder based its bid upon an offer by the low bidder to perform subcontract work for the second low bidder, the second low bidder will not be required to forfeit its bid bond, providing the second low bidder submits to the Council proper documentation that its bid was based on the low bidder’s quote. Proper documentation shall include, but is not limited to, a letter to the Council describing the work that was to be performed by the low bidder as a subcontractor, all quotes the Contractor received and all documentation for the work in question. 103.2.1.3 When the second low bidder is required to execute the contract and the low bidder was a DBE firm that was identified on the second low bidder's Identification of Participating DBE's, the second low bidder shall attempt to replace the low bidder with another DBE firm. If the second low bidder is unsuccessful in attaining another DBE firm for that work, the second low bidder shall certify that a good faith effort was made in accordance with 49 CFR 26.53. The DBE goal will be adjusted accordingly.
7/1/2015
103-1
Award and Execution of Contract
103.2.2 By virtue of statutory authority, a preference will be given on other than Federal Aid Projects, to materials, products, supplies, provisions, and all other articles produced, manufactured, made, or grown within the State of Missouri. 103.2.2.1 For every St. Louis County contract or any subcontract thereto in excess of $10,000 for construction, alteration, repair or maintenance of County public works the Contractor or subcontractor shall use or supply American products in the performance of the contract or any subcontract thereto whenever the quality and price are comparable with other products. 103.2.3 Alternate Bids. In making the award, if alternate bids have been requested, that alternate will be used that will be to the best interest of the County. 103.2.4 Federal Concurrence. If the Federal Government or any other agency thereof is paying all or a portion of the cost of construction of the project, the award made by the County Council shall be tentative until proper Federal concurrence therein has been received. 103.3 Return of Bid Guaranty. The bid guaranty, whether check or bid bond, of the low bidder will be retained until the contract has been executed by the successful bidder, all insurance requirements met, and satisfactory contract bond furnished. The check of the low bidder will then be returned. The bid guaranty of the second low bidder will be returned when the County Council has determined that the award will not be made to that firm. If errors or irregularities appear in the bid of either of the two apparent low bidders, which create doubt as to the status of such bid, the bid guaranties of other bidders may be retained. When the two lowest bidders have been definitely established, the checks of the other bidders will be returned. A bid bond furnished as a bid guaranty will be returned only upon request of the bidder furnishing it. If an award is not made, all checks will be returned to the bidders. 103.4 Contract Bond Required. 103.4.1 The successful bidder shall at the time of the execution of the contract furnish a contract bond in a sum equal to the contract price. The bond shall be to St. Louis County, in a form and with surety, or sureties, acceptable to the County Counselor, to insure the proper and prompt completion of the work in accordance with the provisions of the contract, and plans, and specifications, and to insure payment for all labor performed and materials consumed or used in the work. The bond, if executed by a surety which is a corporation organized in a state other than Missouri, shall be countersigned by an agent or broker licensed by the Missouri Department of Insurance. All bids shall be submitted on the basis of furnishing a contract bond executed by an approved surety, or sureties, as herein set out. 103.4.2 Certificate of Authority. Any surety company which proposes to execute a bond as required by the Contract shall have on file with the Administrative Director of the St. Louis County Council, or furnish, at its own cost, a certified copy of its Certificate of Authority to transact business in the State of Missouri, such certificate to remain on file with the Administrative Director of the St. Louis County Council. No surety bond will be approved by the County Counselor until such certificate is furnished.
7/1/2015
103-2
Award and Execution of Contract
103.4.3 Surety Acceptability. A surety is acceptable to the County Council if it is listed in the current "United States Department of Treasury, Fiscal Service, Department Circular 570, Companies Holding Certificates of Authority as Acceptable Sureties on Federal Bonds and as Acceptable Reinsuring Companies". Individual contract bonds may not be in excess of the underwriting limitation listed in the circular. 103.5 Execution of Contract. The individual, partnership, joint venturer, or corporation awarded the contract shall return the prescribed number of copies of the contract and bond, together with the required insurance certificates, properly executed, to the office of the Director, Department of Transportation, within fifteen (15) days after its receipt of Notice of Acceptance. No bid shall be considered binding upon the County until the contract has been awarded by an order of the County Council, made and entered of record, and until the successful bidder has executed and returned the contract and a satisfactory bond, and until the contract has been signed by the County Executive; attested by the Administrative Director of the St. Louis County Council; approved by the Director, Department of Transportation; and the County Counselor; and certified by the Accounting Officer. No contract shall be effective until it has been executed by all of the parties. 103.6 Failure to Execute Contract. Failure to file an acceptable contract bond or to execute the contract within fifteen (15) days after its receipt of Notice of Acceptance shall be cause for the cancellation of the award. In the event of the cancellation of the award of the contract, the certified check deposited with the bid shall become the property of the County as provided by law. If, in lieu of a certified check, a bidder's bond has been furnished, the obligation of such bond will remain in full force and effect until the sum of ten (10) percent of the Director's estimate of cost has been forfeited and paid to the County Treasurer to the use of the County, not as a penalty but as liquidated damages. A bidder failing to file an acceptable bid or contract bond from an approved surety or failing to execute the contract within the time provided, resulting in the cancellation of award to that bidder, disqualifies that bidder, and any other firm having common ownership or control with that bidder, from performing any work on the County project or projects which are the subject of that bid, as a prime contractor, a subcontractor or a supplier.
7/1/2015
103-3
Award and Execution of Contract
(This Page Intentionally Left Blank)
7/1/2015
103-4
Award and Execution of Contract
Section 104
Scope of Work
104.1 Intent of Contract. The intent of the contract is to provide for the construction and completion in every detail of the work described. The Contractor shall furnish all labor, materials, equipment, tools, transportation, and supplies required to complete the work in accordance with the plans, specifications, and terms of the contract. 104.2 Alteration of Plans. 104.2.1 The Director reserves the right to make, at any time during the progress of the work, without notice to the surety, such increases or decreases in quantities up to 25% of the total contract price for each individual project and such alterations in the details of construction, including alterations in the grade or alignment of the road or structure or both as may be found necessary or desirable. 104.2.2 Under no circumstances shall alterations of plans or of the nature of the work involve beyond the termini of the proposed construction, except as may be prescribed by the Director to satisfactorily complete the project. 104.2.3 Contract plan changes may include addition, elimination, reduction, or increase of any one or more items or units. When the contract plan change results in the increase of the quantity of a major item by more than 25%, the Director or Contractor may require negotiation of unit prices for that portion of the major item above 125% of the quantity stated in the bid. When the contract plan change results in decrease of the quantity of a major item by more than 25%, the Director or Contractor may require negotiation of the unit price for that item. For the purpose of this section, a major item will be considered to be a bid item, the total cost of which exceeds 12½% of the total contract price for the individual project involved, computed on the basis of the bid quantity and the contract unit price. When the contract plan change involves an increase or decrease of more than 25% of a major item, the Director will submit to the Contractor a supplemental contract covering the revision in contract plan and a proposed unit price, the same, if executed, to be a part of the contract and to be approved by the surety on the Contractor's bond. If the parties cannot agree upon a unit price within the time fixed by the Director with the submission of the proposed supplemental contract, then the Contractor shall proceed to perform the work as set out in Section 104.3. When an item is eliminated in its entirety, the Contractor may submit for consideration a request for reimbursement of costs incurred prior to notification of elimination. 104.2.4 For contract plan changes involving work for which there is no unit price, the Director and Contractor shall, if possible, agree by supplemental contract, before the work is commenced, on a fair unit price or sum to be added or deducted as appropriate. When a unit price cannot be agreed upon, compensation shall be determined by the method set out in Section 104.3. 104.2.5 All provisions of Section 104.2 relating to contract plan changes are changes by the Director only, and the weather, physical, or other conditions other than direct intentional change of plans, are not considered to be an alteration as contemplated herein.
7/1/2015
104-1
Scope of Work
104.3 Changes in the Work. 104.3.1 The Contractor shall perform unforeseen work, for which there is no provision included in the contract, whenever it is deemed necessary or desirable to complete the work as contemplated. Such work shall be performed in accordance with the specifications and as directed by the Engineer. 104.3.2 Payment for extra work will be based on unit prices previously agreed to in writing by the parties to the contract, or where such prices cannot be agreed to, the work shall be done in accordance with Section 109.4, if so ordered by the Director. 104.3.3 If the alterations or changes in quantities do not cause a significant change in the work to be performed under the contract, payment for the altered work will be determined as provided in Section 109.3 for all work for which a contract unit price exists and Section 109.4 for all other work. The basis for the adjustment for work for which no unit price exists shall be agreed upon prior to the performance of the work. If a basis cannot be agreed upon, then an adjustment will be made either for or against the Contractor in such amount as the Engineer may determine to be fair and equitable. If the directed changes require additional time to complete the contract, adjustments in the contract time will be determined under Section 108.7. 104.3.4 If the alterations or changes in quantities cause significant change in the work under the contract as defined in Section 101, an adjustment, excluding anticipated profit, will be made to the contract. This adjustment shall occur whether such alterations or changes are in themselves a significant change in the work or by affecting other work cause such other work to become significantly different. Payment will be determined as provided in Section 109.3 or 109.4. The basis for the adjustment shall be agreed upon prior to the performance of the work. If a basis cannot be agreed upon, then an adjustment will be made either for or against the Contractor in such amount as the Engineer may determine to be fair and equitable. If the directed changes require additional time to complete the contract, adjustments in the contract time will be determined under Section 108.7. 104.4 Notification of Differing Site Conditions and Changes in the Work. The Contractor shall promptly notify the Engineer of alleged changes to the contract due to differing site conditions, altered work beyond the scope of the contract, or actions taken by the County that changed the contract terms and conditions. Within five (5) calendar days of the date the alleged change or action was noted, the Contractor shall provide the following information to the Engineer in writing: 1) The date of occurrence and the nature of circumstances of the occurrence; 2) The name, title and activity of knowledgeable County representatives; 3) The identity of any documents and the substance of any oral communications involved; 4) The basis for a claim of accelerated schedule performance; 5) The basis for a claim that the work is not required by the contract;
7/1/2015
104-2
Scope of Work
6) The particular elements of contract performance for which additional compensation, compensable or excusable delay may be sought under this section including: a) Pay items that have been or will be affected; b) Labor or material, or both, that will be added, deleted or discarded and what equipment will be idled, extended or required on the project; c) Delay and disruption in the manner and sequence of performance that has been or will be caused; d) Estimated adjustments to contract prices, delivery schedules, staging and contract time; e) Estimate of the time within which the County must respond to the notice to minimize cost, delay, or disruption of performance. 104.4.1 For good cause the Engineer may extend the time for the Contractor to provide any part of the above information. 104.4.2 The failure of the Contractor to provide notice under Section 104.4 constitutes a waiver of any and all claims that may arise as a result of the allegations. 104.5 Response to Notification of Differing Site Conditions and Changes in the Work. Following submission of the Section 104.4 notification to the Engineer, the Contractor shall continue diligent prosecution of the work not affected by the notification, unless directed otherwise in writing by the Engineer. 104.5.1 Within ten (10) calendar days after receipt of notification, the Engineer will respond in writing to the Contractor to: 1) Confirm or deny that a change occurred and specify future action to be performed by the Contractor and the Engineer, or 2) Advise the Contractor that specific additional information is needed and the date it is to be received by the Engineer for further review. For good cause the Engineer may extend the time for the Contractor to provide any of the additional information. The Engineer will respond within ten (10) days of receipt of additional information from the Contractor. Any adjustments made to the contract shall not include increased cost or time extensions for delay if the Contractor fails to provide the information required in the notice or the requested additional information by the date specified. 104.6 Maintenance of Traffic Operations During Construction. 104.6.1 Through traffic is that traffic which has neither its origin nor its destination within the limits of the project. 104.6.2 Local traffic is that traffic which has its origin or its destination at some point within the limits of the project. Local traffic shall also include that traffic on all side roads that lead into the project where such traffic does not have satisfactory outlet over a passable road or street. 7/1/2015
104-3
Scope of Work
104.6.3 Provision for local traffic shall be made by the Contractor, at the Contractor's expense, at all times during construction. 104.6.4 Unless otherwise specified on the plans or in the special provisions, the Contractor will be required to maintain all traffic over the existing portion of the project, at the Contractor’s expense. 104.6.5 If detours for through traffic are to be provided by the County at its expense or designated on the plans to be constructed and maintained by the Contractor around the entire project or any major portion of the work during construction, the Director may open for use by traffic any uncompleted portions of the project and will have the option either to maintain such portions with County forces or to require the Contractor to maintain them. If the Contractor is required to maintain such opened portions, he will be reimbursed for the cost of such maintenance in accordance with Section 104.3. However, if the time set for completion, together with any authorized extension of time, has elapsed, the Contractor shall be responsible for all further costs of maintaining such opened portions, whether they are maintained by the Contractor's forces and equipment or by County forces. 104.6.6 If detours for through traffic are designated on the plans to be constructed and maintained by the Contractor around the entire project or any major portion of the work during construction, the Director may open for use by traffic any uncompleted portions of the project and will have the option either to maintain such portions with County forces or to require the Contractor to maintain them. If the Contractor is required to maintain such opened portions, the Contractor will be reimbursed for the cost of such maintenance in accordance with Section 104.3. However, when opening of such portions to traffic is necessitated by the Contractor failing to properly maintain such construction detours, or if the time set for completion, together with any authorized extension of time, has elapsed, the Contractor shall be responsible for the cost of maintaining such open portions, whether by the Contractor's forces and equipment or by County forces. 104.6.7 When the Contractor is required to maintain traffic whether over the project, on constructed detours, or by bypasses, such maintenance shall be construed to mean the satisfactory handling of all traffic to maintain safe and substantially uninterrupted flow. 104.6.8 When the Contractor is required to maintain traffic, the Contractor shall maintain the roadbed and driveways substantially free of ruts, holes, and detrimental surface deformations. The Contractor shall control the height of vegetation for the traffic safety, and provide and maintain in a safe condition approaches, crossings, and intersections with abutting property to the highway, railroads, trails, roads, and streets. Such maintenance shall be performed as necessary from the day the Contractor starts working any equipment of the project or from the first day which would qualify as a workday in Section 108.6, whichever is earlier, until the acceptance of the work, regardless of whether the contract time for completion is on a working day or calendar day basis. Snow removal will not be required of the Contractor. 104.6.9 Wherever compensation is provided the Contractor for maintenance by reason of the Director's election to open to traffic portions of the project, such compensation shall not include cost for any construction or finishing incurred by such action.
7/1/2015
104-4
Scope of Work
104.7 Opening Sections of Highways, Roads and Streets. Notwithstanding any other requirements of Section 104.4 and when it is to the advantage of the County, projects involving pavement may be opened to traffic as soon as the surface has been sufficiently cured, even though the shoulders and other items of work may not be completed. The Contractor will be required to complete any remaining construction items under traffic prior to final acceptance. When stated in the Director's acceptance, the Contractor will be relieved from any further responsibility, except for required liability insurance coverage, under the contract for the portion accepted. No extra compensation will be allowed the Contractor for any maintenance, inconvenience, or extra work caused by traffic using the roadbed while such shouldering and other finishing work is being done. 104.7.1 The Contractor may be directed by the Director to repair permanent facilities of the County that have been damaged by events which are beyond the control of the Contractor. The Contractor shall immediately give written notice to the Director of any pedestrian or vehicular accident that results in damage to permanent facilities of the County. If directed by the Director, the Contractor shall pursue the recovery of any repair costs from the responsible third person. To the extent the Contractor is unable to recover the repair costs, reimbursement will be provided by the County under Section 104.3 for the actual cost of labor, equipment, and material, exclusive of overhead, indirect, or consequential costs or profit. Prior to reimbursement, the Contractor shall furnish documentary evidence of all efforts to recover such repair costs. The County may elect to make such repairs in lieu of the Contractor. 104.8 Rights In and Use of Materials Found on the Work. The Contractor, with the written approval of the Engineer, may use in the construction of the project any stone, gravel, or sand found in the excavation that conforms to the requirements of the specifications for materials. It is expressly understood, however, that the County will not pay for damages or for anticipated profits on account of the expected use of any materials shown upon the plans as existing and later found to be nonexistent or unfit for use. Payment will be made to cover the removal of such material at the contract unit price for excavation of the classification under which it properly belongs. If such material is used instead of material that was to have been furnished at the expense of the Contractor under the terms of the contract, the Contractor shall furnish sufficient suitable material, at no additional expense to the County, to complete the roadway. Unless authorized in writing by the Director, the Contractor shall not excavate or remove from within the right-of-way any material that is not within the excavation limits as indicated by the slope and grade lines. 104.9 Mailboxes, Signs and Markers. 104.9.1 Mailboxes. Mailboxes within the construction limits shall be removed by the Contractor before work is begun. They shall be set temporarily on supports that comply with AASHTO "Guide for Erecting Mailboxes on Highways" guidelines and are approved by the Engineer. The temporary mailboxes shall be placed at approved sites for the various phases of construction where they will be accessible to both the mail carrier and the patron. After final grading is completed, the Contractor shall permanently reset the mailboxes at designated locations in accordance with Section 201.2.7 before final acceptance of the work by the County. Permanent mailbox supports shall also comply with AASHTO guidelines and be approved by the Engineer. The Contractor shall be responsible for the maintenance of all temporarily set mailboxes during project construction and shall replace all damaged mailboxes at no cost to the County. No direct payment will be made for the removal,
7/1/2015
104-5
Scope of Work
relocation, or replacement of mailboxes or supports. At no time will a lapse in mail delivery be allowed. 104.9.2 Signs and Markers. Signs and markers within the limits of operations shall be removed by the Contractor before work is begun. All such signs and markers required for safe control and guidance of traffic shall be temporarily reset where they are readily visible to traffic, and shall be maintained in a satisfactory condition. If the nature of the work makes temporary relocation impractical, the signs shall be placed on movable supports and maintained properly. Stop and Yield signs at intersecting roadways shall be maintained where they are readily visible to traffic at all times. Other individual signs may be moved aside only when they interfere with actual operations. All required signs and markers shall be properly located to control traffic at all times. Final removal of signs and markers will be permitted only when permanent signs and markers have been installed. All signs and markers remain the property of the County and shall, after final removal, be delivered without damage to one or more locations within the project limits as directed by the Engineer. No direct payment will be made for removal, relocation, temporary supports, maintenance, or final removal and delivery of signs and markers. Traffic and regulatory signs and devices will be re-set by County forces. 104.10 Final Clean Up. 104.10.1 Before final acceptance, the Contractor shall restore the highway, all borrow areas, and all ground on or adjacent to the highway right-of-way occupied by the Contractor, in connection with the work, in an acceptable manner. All property, both public and private, which may have been damaged on account of the prosecution of work, shall be cleaned of all rubbish, excess materials, temporary structures, and equipment. All areas beyond the limits of construction that have been damaged by the Contractor's operations shall be restored by the Contractor at the Contractor's expense as directed by the Engineer. All parts of the work shall be left in an acceptable condition. 104.10.2 The Contractor shall cut all brush, grain, grass, and weeds from the entire right-ofway, except for improved or selected areas shown on the plans or designated by the Engineer, and shall clean and remove from the right-of-way all abandoned fences, telephone and power line facilities, surplus and discarded material, any perishable matter, rubbish, and temporary structures. The vegetation on the right-of-way outside of the construction limits shall not be removed by blading. All guardrail materials within the rightof-way shall remain the property of the County and shall be stored on the right-of-way as directed by the Engineer. The Contractor shall restore in an acceptable manner all property, both public and private, which may have been damaged on account of the prosecution of the work, and shall leave the right-of-way neat and presentable. All areas outside the rounding of fill slopes and back slopes, on which the existing turf is damaged by the Contractor's operations, shall be restored by the Contractor, at his expense, by seeding and mulching such areas at the rates designated in the contract, or as directed by the Engineer.
7/1/2015
104-6
Scope of Work
104.10.3 In contracts involving grading other than incidental work in connection with resurfacing, the Contractor shall open and clean all existing channels and culverts leaving them free from all excess mud or silt, drift, brush or debris of any kind. Any material excavated in cleaning existing channels will be paid for as roadway excavation, of like classification. Any material excavated in cleaning out culverts that are to be used in place will be paid for at the contract unit price per each structure. Only the initial excavation will be paid for, and any subsequent cleaning required prior to final acceptance shall be done by the Contractor at his expense. 104.10.4 Final cleaning up in accordance with the provisions of Section 104.10.2 will not be required when the principal part of the contract consists of traffic signals, lighting, signing, fencing, plantings, surfacing, or resurfacing work. When the principal part of the contract consists of these items, the Contractor shall remove all excess excavation and all rejected or unused materials and debris from the right-of-way or as directed by the Engineer, and shall restore to a satisfactory condition all shoulders and slopes defaced by the Contractor's operations. 104.11 Requirements for Projects Involving Work Upon Railroad Right-of-Way. 104.11.1 All work upon, over, or under railroad right-of-way shall be performed by the Contractor without damage to the facilities and property of the railroad or its lessees, and in strict observance of requirements of the Director and railroad for the safety of railroad property and operations. The Contractor shall be responsible for maintaining the existing or proposed depth and section of the ditches along the tracks of railroads through the limits of construction. Any sediment resulting from the new construction shall be promptly removed to avoid the possibility of filling the ditches, obstructing drainage, or fouling the ballast. 104.11.2 The work performed upon, over, or under railroad right-of-way shall be subject to the inspection of railroad's representatives. 104.11.3 The County will make provisions for any temporary removal of railroad or railroad lessees' facilities that are to be moved. 104.11.4 The Contractor will in no way hold the County liable for delay caused by securing railroad company's approval of construction features involved in placing any grade separation structure or any changes from the design plans which appear necessary or desirable during construction. 104.11.4.1 The Contractor shall furnish the County with a Release from Liability for all work performed on railroad right-of-way before this item will be considered complete and the project acceptable. Under no circumstance will the County be held as liable for work performed on railroad right-of-way by the Contractor. 104.11.5 The cost of complying with any and all of the requirements in this section shall be considered as completely covered by the contract unit price for the various items of work involved in the contract.
7/1/2015
104-7
Scope of Work
104.12 Warranty. 104.12.1 On all contracts requiring the Contractor to furnish and install electronic, electrical, or mechanical equipment, the Contractor shall obtain, assign, and furnish to the County written manufacturer's warranties for all such equipment consistent with those provided as customary trade practice. Additionally, a Contractor's warranty providing for satisfactory inservice operation shall be provided for a minimum period of six months from the date of project acceptance. 104.12.2 If the equipment fails to perform satisfactorily for the specified length of time, the manufacturer or the Contractor shall replace or repair the equipment as necessary to restore required performance. Department labor costs resulting from equipment replacement will not be charged to the manufacturer or the Contractor. 104.12.3 section.
7/1/2015
No direct payment will be made for complying with the requirements of this
104-8
Scope of Work
Section 105
Control of Work
105.1 Authority of the Engineer. 105.1.1 The Engineer will decide: all questions which may arise as to the quality and acceptability of materials furnished and work performed and as to the rate of progress of the work; all questions which may arise as to the interpretation of the plans and specifications; all questions as to the acceptable fulfillment of the contract on the part of the Contractor; all questions of classification; the proper compensation for the performance or breach of contract; and all claims of any character whatsoever in connection with or growing out of the construction whether claimed under the contract, under force account, under quantum merit or otherwise. The estimates and decisions shall be final, binding, and conclusive upon all parties to the contract. 105.1.2 The Suspension of Work. The Director will have the authority to suspend the work wholly or in part in accordance with the provisions of Section 108.5.7. The suspension will be given verbally, but will be followed in writing immediately. 105.1.2.1 The Director may suspend the work wholly or in part for the contractor's failure to: 1) Correct conditions unsafe for the project personnel or general public; 2) Carry out provisions of the contract; 3) Carry out orders of the Engineer. 105.1.2.2 Suspensions in accordance with Section 105.1.2.1 will be non-excusable and non-compensable. 105.1.2.3 Work may also be wholly or partially suspended for: 1) Periods necessary due to unsuitable weather; 2) Conditions considered unsuitable for the prosecution of the work; 3) Any condition or reason determined to be in the public interest. 105.1.2.4 Suspensions in accordance with Section 105.1.2.3 may be excusable and may be compensable as determined by the Director in accordance with Section 108. 105.2 Plans and Working Drawings. Plans will show details of all structures, lines, grades, typical cross sections of the roadway, location, and design of all structures, and a summary of items appearing on the bid. 105.2.1 The plans will be supplemented by such working drawings as are necessary to adequately control the work. Working drawings for structures shall be prepared, sealed, and signed by a Professional Engineer registered in the State of Missouri. The drawings shall be furnished by the Contractor and shall consist of such detailed plans as may be required
7/1/2015
105-1
Control of Work
to adequately control the work and which are not included in the plans furnished by the County. Required working drawings shall be approved by the Engineer and such approval shall not relieve the Contractor of his responsibility under the contract for the successful completion of the work. 105.2.2 The contract price will include the cost of furnishing all working drawings. 105.3 Conformity with Contract Documents. All work performed and all materials furnished shall be in conformity with the lines, grades, cross section, dimensions, and material requirements, including tolerances, shown in the contract documents. 105.3.1 If the Engineer finds the materials or the finished product in which the materials are used not in conformity with the plans and specifications, but that reasonably acceptable work has been produced, he will then make a determination if the work will be accepted and remain in place. In this event, the Engineer will document the basis of acceptance by contract modifications that may provide for an appropriate adjustment in the contract price for such work or materials as he deems necessary to conform to his determination based on engineering judgment. 105.3.2 If the Engineer finds the materials or the finished product in which the materials are used or the work performed have resulted in an unacceptable product, the work or materials shall be removed and replaced or otherwise corrected by and at the expense of the Contractor. 105.4 Coordination of Contract Documents. The contract documents are essential parts of the contract, and a requirement occurring in one is as binding as though occurring in all. They are intended to be complementary and to describe and provide for a complete work. In case of discrepancy among contract documents, the governing ranking will be: 1) Addendums to Job Special Provisions; 2) Job Special Provisions; 3) Plans; 4) Standard Drawings; 5) Standard Specifications; 6) Bid Items or Quantities. In case of discrepancy, calculated dimensions will govern over scaled dimensions. 105.4.1 The specifications have been published with dual standards of measurement. Projects should be constructed to the unit of measure that has been established on the plans. 105.4.2 The Contractor shall take no advantage of any apparent error or omission in the contract documents. If the Contractor discovers such an error or omission, the Contractor shall promptly notify the Engineer. The Engineer will then make such corrections and interpretations as may be deemed necessary for fulfilling the intent of the plans and 7/1/2015
105-2
Control of Work
specifications. A failure to give notice shall render the effects of any error or omission noncompensable and any delay non-excusable. This shall apply to all bidders. 105.5 Cooperation by Contractor. The Contractor will be supplied with a minimum of two sets of contract documents, one set of which the Contractor shall keep available on the work site at all times. 105.5.1 The Contractor shall give the work the constant attention necessary to facilitate the progress thereof, and shall cooperate with the Engineer and other Contractors in every way possible. 105.5.2 The Contractor shall have on the work at all times, as the Contractor's agent, a competent individual capable of reading and thoroughly understanding the plans and specifications and thoroughly experienced in the type of work being performed, who shall receive instructions from the Engineer or his authorized representatives. That individual shall have full authority to execute orders or directions of the Engineer without delay, and to promptly supply such materials, equipment, tools, labor, and incidentals as may be required. Such superintendence shall be furnished regardless of the amount of work sublet. 105.6 Cooperation with County Forces and Other Contractors. The County reserves the right at any time to contract for and/or self-perform other additional work on or near the project limits covered by the contract. Coordination of work may be necessary with St. Louis County forces and other contractors performing work in the area of the project sites in order to avoid delays and maintain traffic during construction. 105.6.1 If separate contracts are let within the limits of any one project, each Contractor shall conduct work so as not to interfere with or hinder the progress or completion of the work being performed by other contractors. Contractors working on the same project shall cooperate with each other as directed. 105.6.2 If St. Louis County forces are working within the limits of any project site, the Contractor shall conduct work so as not to interfere with or hinder the progress or completion of the work being performed by St. Louis County forces. 105.6.3 Each Contractor involved shall assume all liability, financial or otherwise, in connection with his contract and shall indemnify and save harmless the County, its agents, employees and assigns from any and all damages or claims that may arise because of inconvenience, delay, or loss experienced, caused or contributed to the Contractor because of the presence and operations of other contractors working within the limits of the same project. 105.6.4 The Contractor shall arrange his work and shall place and dispose of the materials being used so as not to interfere with or cause unnecessary inconvenience or delay to the operations of the other contractors within the limits of the same project. The Contractor shall join work with that of the other contractors within the limits of the same project in a manner acceptable to the Engineer and shall perform it in proper sequence to that of the other contractors. When necessary for proper prosecution of work, each contractor shall permit the other contractors access through overlapping construction areas and the use of any access or haul roads. 105.6.5 No direct payment will be made for compliance with Section 105.6 7/1/2015
105-3
Control of Work
105.7 Cooperation with Utilities. All utility facilities and appurtenances within the project limits shall be located or relocated by the utility owner, unless otherwise specified. The Contractor shall notify the Engineer who will in turn notify all railroad and utility owners, all pipe line owners, or other parties affected, and endeavor to have all necessary adjustments of the public or private utility fixtures, pipe lines and other appurtenances within or adjacent to the limits of construction, made as soon as practicable. 105.7.1 The Contractor shall cooperate with utility owners and the Engineer in the location and relocation of utility facilities to minimize effects upon contractor's work, interruption to utility service and duplication of work by the utility owners. Facilities or appurtenances that are to remain in place during construction shall be accounted for and protected by the Contractor's work procedures. Utility location and relocation shall be made in accordance with 7 CSR Division 10, Chapter 3, Utility Location, and Relocation. 105.7.2 In the event utility services are interrupted as a result of breakage within the project limits, the Contractor is to notify the appropriate utility authorities and cooperate with them until service has been restored. Work shall not commence around fire hydrants until provisions for continued service have been made and approved by the local fire authority. 105.7.3 When the failure of the owners of utility facilities to cooperate and coordinate their work with that of the Contractor results in actual delay to the Contractor in the overall completion of the Contractor's work, such delay will be considered in the count of working days or date specified for completion as contractor's sole compensation from the County, provided the Contractor notified the Engineer in writing of the delay at the time it occurs. 105.7.4 The Contractor shall use every precaution to prevent damage to all public and private utilities. Repairs to damaged utilities caused by negligent or wrongful acts or omissions on the part of the Contractor shall be corrected at the Contractor's expense. The damaged facilities shall be restored to a condition similar or equal to that existing before the damage occurred. 105.7.5 Should there be located within the right of way any public or private utility facilities which are to remain in place and which will interfere with the Contractor's proposed methods of operation, the Contractor, in cooperation with the Engineer, shall make all necessary arrangements with the owner for any temporary or permanent removal or relocation of such facilities desired for the Contractor's convenience. Any cost involved shall be borne by the Contractor. 105.7.6 If utility facilities or appurtenances are found that are not noted in the contract documents, and could not be discovered in accordance with Section 102.3.5, the Engineer will determine whether relocation of the utility is necessary to accommodate construction. If relocation is necessary, the Engineer will proceed to make necessary arrangements with the utility owner and the Contractor. Compensability and excusability will be determined under Sections 104 and 108. 105.8 Construction Stakes, Lines, and Grades. The Contractor shall be responsible for giving the Engineer reasonable notice of intent to perform work in a particular area of the project in order to afford the Engineer sufficient time to set construction stakes establishing lines, slopes, and profile grade. For roadway work, the Engineer will set construction stakes establishing lines, slopes, and profile grade and will furnish the Contractor with all necessary 7/1/2015
105-4
Control of Work
information relating to these lines, slopes, and grades. These stakes and marks will constitute the field control by and in accordance with which the Contractor shall establish other necessary controls and perform the work. For structures, the Engineer will stake and reference those centerlines and layout lines used as dimensional references on the plans and provide a benchmark at each structure location. The Engineer will also provide and mark haunching information for the Contractor's use in forming of all bridge decks. The Contractor shall be responsible for providing all other lines, locations, alignment, grade elevations, and any other necessary controls by use of engineering instruments or other tools or methods as required to build the structure. 105.8.1 The Contractor shall be responsible for the preservation of all stakes and marks, and if any of the construction stakes or marks are carelessly or willfully destroyed or disturbed by the Contractor, the cost of replacing them may be charged against him and deducted from the payment for the work. 105.8.2 The Contractor shall furnish and deliver at his expense the size, quality, quantity of stakes and marking paint required by the Engineer. If the stakes and marking paint have not been delivered at the time and place required for use, the Engineer may purchase the stakes and marking paint and deduct the entire cost from any compensation due the Contractor. 105.8.3 Upon written request of the Director, the Contractor shall furnish such assistance as may be necessary for the purpose of making measurements and for driving stakes. The County will reimburse the Contractor by regular payment estimate for assistance by contractor's employees who have been requested in writing by the Director prior to its actual performance. 105.9 Authority of the Director. To prevent all misunderstandings, disputes, and litigation, it is agreed by and between the Surety and all of the parties to this contract that the Director shall, in all cases: determine any and all questions which may arise concerning the quality, quantity, and acceptability of all materials furnished and work performed; the manner and rate of progress of the performance of all work; the acceptable fulfillment of the contract in all respects; the proper compensation for the performance or breach of the contract; and all claims of any character whatsoever connected with or growing out of the construction whether claimed under the contract (including any supplementary agreement or change order), under force account, or otherwise. The Director’s estimates and decisions shall be final, binding, and conclusive upon all parties hereto. For the purpose of this section, the authority vested in the Director shall be exercised solely by the Director, St. Louis County Department of Transportation. 105.9.1 Authority and Duties of Resident Engineer. As the immediate representative of the Director, the resident Engineer has direct charge of the engineering details of each construction project. He is delegated commensurate authority for the administration of the project. The resident Engineer has the authority to reject defective material and to suspend and reject any work that is being improperly performed. 105.10 Inspection of Work. All materials and each part or detail of the work shall be subject to inspection by the Engineer. The Engineer shall be allowed access to all parts of the work and shall be furnished with such information and assistance by the Contractor as is required to make a complete and detailed inspection. 7/1/2015
105-5
Control of Work
105.10.1 If requested by the Engineer, the Contractor, at any time before acceptance of the work, shall remove or uncover such portions of the finished work as may be directed. After examination, the Contractor shall restore said portions of the work to the standards required by the specifications. Should the work thus exposed or examined prove acceptable, the uncovering, or removing, and the replacing of the covering or making good of the parts removed will be paid for as determined by Section 109.3 or 109.4; but should the work so exposed or examined prove unacceptable, the uncovering, or removing and replacing of the covering, or making good of the parts removed shall be at the Contractor's expense. No work shall be done and no materials shall be used without suitable inspection by the Engineer. 105.10.2 Any work done or materials used without supervision and inspection by an authorized County representative may be ordered removed and replaced at the Contractor's expense. 105.10.3 If any unit of government or political subdivision pays all or a portion of the cost of the work covered by the contract, its respective representatives shall have the right to inspect the work. 105.10.4 When any work is being done on, over, or under railroad right-of-way or adjustments are being made to any public or privately owned utility facility, the respective representatives shall have the right to inspect the work. 105.10.5 Inspections authorized in Sections 105.10.3 and 105.10.4 shall in no sense make any unit of government or political subdivision or railroad or public or privately owned utility a party to the contract, and shall in no way interfere with the rights of either party thereunder. 105.10.6 Adequate provision for lighting meeting the prior approval of the Engineer shall be provided by the Contractor to permit satisfactory construction and inspection of all work done and material produced. 105.10.7 Final Inspection. Upon presumptive completion of the entire project, the Engineer will make an inspection. If all construction contemplated by the contract has been completed to the Engineer's satisfaction, that inspection will constitute the final inspection. The Engineer will make the acceptance for maintenance upon completion of the final inspection. The Engineer will notify the Contractor in writing of acceptance for maintenance as of the date of the final inspection. 105.10.7.1 Following the final inspection, the Contractor, subcontractors, and suppliers are relieved of any new or additional liability to third parties for personal injury, death, or property damages which may be alleged to result from the design or construction of the work, unless additional work on the right of way is required by the Engineer. 105.10.7.2 Nothing in Section 105.10.7 shall be deemed to excuse the Contractor of liability or responsibility for any personal injury, death, or property damages that may have occurred prior to the final inspection of the work.
7/1/2015
105-6
Control of Work
105.11 Unauthorized and Defective Work. 105.11.1 Work done without lines and grades being given, or work done beyond the lines and grade shown on the plans or as given, except as otherwise provided in the contract, will be considered unauthorized and done at the expense of the Contractor. 105.11.2 All changes in the work or departures from the plans, except contingent items or those due to reclassification of excavation materials, will be considered unauthorized and at the expense of the Contractor unless, before proceeding with the work, he has obtained a Change Order signed by all parties whose signatures are provided for, except the Federal Engineer. These forms will contain complete detailed instructions regarding the proposed changes. Any departure from the instruction contained in such written order shall be considered unauthorized. 105.11.3 The Engineer may order unauthorized work removed and replaced at the Contractor's expense. 105.11.4 All construction and materials that have been rejected or declared unsatisfactory shall be remedied or removed and replaced in an acceptable manner by the Contractor at his expense. Upon failure of the Contractor to remedy or remove and properly dispose of rejected materials or work, or to replace them immediately after receiving written notice from the Director, the Director may employ labor to rectify the work, and the cost of rectification shall be deducted from any payment due or which may become due the Contractor. 105.12 Load Restrictions. 105.12.1 The Contractor's movement of equipment and vehicles over bridges and pavements within the limits of the project is subject to the load limit regulations for highways as prescribed by County Ordinance in existence when the movement occurs and special permits from the Department will be required prior to the movement of any such equipment or vehicles with a gross weight in excess of the load limits permitted by Ordinance. All costs of obtaining special permits shall be borne by the Contractor. Width, length, and weight regulations as prescribed by State Statutes and County Ordinances shall be adhered to by the Contractor in the movement of equipment and vehicles over any part of the State or County highway system outside the project limits, and the Contractor shall not move or operate any such equipment or vehicles which exceed the prescribed width, length, or weight limits without special permit. Material which cannot be transported by truck without exceeding an overall length of 120 feet shall be shipped by means of other transportation to the destination or the nearest shipping terminal. Permits may be granted for extra length loads for short hauls where there will be no undue interference with normal traffic movements. Materials receipts issued by the Engineer will not indicate compliance with any weight (mass) restriction regulations. All permits required by ordinance for movements on the streets of any municipality shall be obtained by the Contractor from the municipal authority. 105.12.1.1 Special permits will not be required for the movement of construction equipment over any part of a bridge or pavement that is constructed or rehabilitated in the contract.
7/1/2015
105-7
Control of Work
105.12.1.2 All movement will be subject to the same conditions and regulations established by the County for movements under special permits with the following additional requirements: 1) Bridge deck shall be protected by planking of uniform thickness not less than the full tread width of track; 2) All concrete in the bridge shall have achieved design strength and shall not be less than 28 days old; 3) Not more than one unit at a time may be moved over the structure; 4) Equipment shall be centered on centerline of structure during the movement; 5) Adequate provision shall be made to prevent marring of the pavement surface or the loss of surface texture; 6) Portland cement concrete pavement shall have achieved the specified age and strength required for opening to all traffic; 7) Adequate provision shall be made to assure uniform load distribution at the edges of the pavement; 8) All movements shall be made under the supervision of the resident Engineer. 105.12.1.3 Movement of equipment over bridges or pavement not constructed under the contract, but located within the limits of the contract, is subject to all requirements of this section and a special permit will be required. 105.12.2 Crawler type equipment having a gross weight of 40,000 pounds or less fairly evenly distributed over the treads may be moved over bridges not posted for lesser loads or rigid type pavements without special permits. Such equipment having a gross weight in excess of 40,000 pounds shall have a special permit before moving. Crawler type equipment having a gross weight in excess of 75,000 pounds will not be permitted on bridges or rigid type pavements except in rare instances. 105.12.3 Track or crawler type equipment operating within the project which is subject to unequal distribution of weight, (such as cranes and paving mixers), and which have a gross weight in excess of 18,000 pounds but less than 40,000 pounds may be operated upon bridges not posted for lesser loads and rigid type pavements, provided special precautions satisfactory to the Engineer are taken to distribute the weight evenly over the treads. Such equipment in excess of 40,000 pounds will require a "Special Use Permit" from the Department. 105.12.4 The Contractor shall not move or operate any type of equipment of such weight or so loaded that it will cause damage to highway facilities either being constructed or in existence. Equipment and vehicles with steel lugs will not be permitted to operate directly on bridges or pavements at any time.
7/1/2015
105-8
Control of Work
105.12.5 When it is required that material from roadway or borrow excavation be hauled across existing pavement, the Contractor may move the material across the pavement with equipment that results in overweight loading, provided the following requirements are met at the Contractor's expense: 1) The Contractor and the Engineer shall select the location or locations where the crossing of the existing pavement is to be made. The width of the crossing shall be clearly marked on the pavement by painted lines and the Contractor's equipment will be required to operate within the limits of the marked crossing; 2) The Contractor shall obtain written permission, including description of location of the crossing, from the Director prior to movements of overweight loading across the existing pavement; 3) The existing pavement shall be kept open at all times for highway traffic except for short periods of time when individual pieces of equipment are crossing pavement. The pavement shall be kept reasonably free from earth or other material during hauling operations and shall be cleaned off and kept clean during periods when no hauling across the pavement is in progress; 4) The pavement and shoulders within the crossing area shall be maintained by the Contractor in a condition satisfactory to the Engineer; 5) The Contractor shall provide flagmen to direct traffic when hauling across the pavement; 6) If any hauling across the pavement is done during other than daylight hours, the Contractor shall provide adequate lighting to illuminate the crossing; 7) If the existing pavement at the crossing is intended by the plans to be used in place after the contract is completed, the Contractor shall, upon completion of the hauling operations, remove the existing shoulders, pavement, and base between the limits of the crossing and replace it with the same type, width, and thickness of shoulders, pavement, and base; 8) The Contractor shall construct and maintain all necessary bypasses or temporary connections required for the proper handling of traffic during the removal and replacement of the pavement in the crossing area. 105.12.6 Nothing contained herein or in any special permit will relieve the Contractor of liability for any damage caused to highway facilities from the movement or operation of equipment and vehicles over the highway system. 105.13 Maintenance of the Work. The Contractor shall maintain the work during construction until accepted. This maintenance shall be prosecuted with adequate equipment and forces so that the roadway or structures are kept in satisfactory condition at all times. 105.13.1 In the case of a contract for the placing of a course upon a course or subgrade previously constructed, the Contractor shall maintain the previous course or subgrade during all construction operations.
7/1/2015
105-9
Control of Work
105.13.2 Except as otherwise provided, all cost of maintenance during construction, and before the work is accepted shall be included in the unit prices bid for the various pay items and the Contractor will not be paid an additional amount for such work. 105.13.3 After the fertilizing, seeding, and mulching have been completed or the partial application specified in Section 805.3.2 has been made for an area of not less than one acre of work, and the slopes are completed from the top down as far as practicable, the Contractor may request the Engineer to inspect the completed area. If upon inspection the Engineer finds such items to be satisfactory, he will notify the Contractor in writing of the limits within which the fertilizing, seeding, and mulching will be accepted. Thereafter, the Contractor will be reimbursed for maintenance, if directed by the Engineer, as provided in Section 109.4, and for replacement of fertilizer, seed, and mulch, if directed by the Engineer, at contract unit prices, unless such maintenance or replacement is made necessary by damages attributable to actions or negligence of the Contractor. 105.13.4 After completion of the twenty one (21) day maintenance period for sod specified in Section 803.3.3, the Contractor may request the Engineer to inspect any completed area of sodding of not less than 1,500 yd2 or of completed isolated areas which total 1,500 yd2. If upon inspection the Engineer finds the sodding to be satisfactory, he will notify the Contractor in writing of the limits within which the sodding will be accepted. Thereafter, the Contractor will be reimbursed for maintenance, if directed by the Engineer, as provided in Section 109.4, and for replacement of sodding, if directed by the Engineer, at contract unit prices, unless such maintenance or replacement is made necessary by damages attributable to actions or negligence of the Contractor. 105.14 In accordance with Section 105.13, the Contractor is responsible for the maintenance of all items completed by him and his subcontractors until acceptance by St. Louis County, either partial or final, as provided for in Sections 105.15.1 and 105.15.2, respectively. Maintenance shall include removal and replacement of damaged items, either existing or newly constructed, or portions of items to the extent necessary for the work to fully comply with the specifications. Damages to improvements by the Contractor's subcontractors and material suppliers are included and covered. No direct or additional payment will be made for the cost of repair or replacement of damaged items. No adjustment in final quantities will be made. 105.14.1 Failure to Maintain Roadway or Structure. If the Contractor at any time fails to comply with the provisions of Section 105.13, the Engineer will notify the Contractor verbally, to be followed with written notice by fax or mail, of such non-compliance. If the Contractor fails to remedy unsatisfactory maintenance within twenty four (24) hours after receipt of such verbal notice, the Engineer may immediately proceed to maintain the project, and the entire cost of this maintenance will be deducted from monies due or to become due the Contractor. 105.15 Acceptance. 105.15.1 Partial Acceptance. If at any time during the prosecution of the work, the Contractor completes any section of work one mile or more in length, the Contractor may request the Director to make final inspection of that section. If the Director finds upon inspection that the section has been completed in substantial compliance with the contract, 7/1/2015
105-10
Control of Work
he will recommend acceptance of that section by the Council as being completed, and upon acceptance by the Council, the Contractor will be relieved of further responsibility for that section except as set out in Section 105.15.1.2. 105.15.1.1 When the contract contains multiple sites or seasonal items such as seeding, sodding, painting, or such items as might delay the final completion of the whole project, a partial acceptance of the completed portion may be made prior to completion of the entire project. If the Director finds upon inspection that the completed work is in acceptable condition, he will so notify the Contractor in writing and after such notice has been given, the Contractor will be relieved of the duty of maintaining and protecting that work to the extent provided in the notice. 105.15.1.2 Nothing in this provision shall be construed to relieve the Contractor of any responsibility with respect to required liability insurance coverage, of full responsibility for making good any defective work or material found on the section prior to final acceptance of the entire project, to alter in any manner the method of payment prescribed in the contract, or to constitute a waiver of any claim the County might have against the Contractor on the entire project. 105.15.2 Final Acceptance. Upon presumptive completion of the entire project, the Director will make an inspection. If all construction contemplated by the contract has been completed to the Director's satisfaction and the satisfaction of the parties in Sections 105.10.3 and 105.10.4, with receipt by the Engineer of all project documentation required by the contract and authorities accepting maintenance of constructed facilities, that inspection will constitute the final inspection. The Director will make final acceptance and notify the Contractor in writing of this acceptance as of the date of the final inspection. 105.15.2.1 When required by the contract, project documentation shall consist of Form C-242 (Contractor's Affidavit Regarding Settlement of Claims), Final Change Order, DBE Participation List and Final Verification, Structural Steel Certification and FHWA-47 (Statement of Materials and Labor Used By Contractors on Highway Construction Involving Federal Funds). 105.15.2.2 Final acceptance does not excuse the Contractor's liability or responsibility to the County for any latent defects in the work or material incorporated into the work or for claims relating to any work or material incorporated into the work. 105.16 Claims for Adjustment. If either party has a claim against the other which in any way arises out of the provisions of the contract or the performance or non-performance thereunder, written notice of such claim shall be made in triplicate prior to the expiration of sixty (60) days after delivery by the County to the Contractor of a check or draft for the retained percentage. If the claim is against the County, the notice of claim shall be personally delivered or sent by Certified Mail to the office of the Director, St. Louis County Department of Transportation, 1050 North Lindbergh Boulevard, St. Louis, Missouri 63132. If this claim is against the Contractor, notice of the claim shall be personally delivered or sent by Certified Mail to the Contractor at the address shown under the signature on the bid. If the claim is against an assignee, notice of the claim shall be personally delivered or sent by Certified Mail to the assignee at the address shown on the accepted notice of assignment. Within sixty (60) days after receipt of notice of any claim, the party against whom the claim is made shall make any claim he has against the other party. All notices of claims shall contain an itemized statement showing completely and fully the items and amounts forming the basis of the claim. 7/1/2015
105-11
Control of Work
105.16.1 Any claim or an item of any claim not included in the notice and statement, or any claim included but not clearly defined and specifically set out and itemized, or any claim not filed within the time and in the manner provided in Section 105.16, shall be forever waived and shall neither constitute the basis of nor be included in any legal action, counterclaim, or set-off, or arbitration between the parties. 105.16.2 Claims for additional time or compensation under Section 104.5 shall be filed within sixty (60) days after completing the work in question. Claims for additional time or compensation under Section 108.12 shall be filed within sixty (60) days after receipt of the Engineer's determination. The procedures for filing and disposition of the claim shall be as described in Sections 105.16.3 through 105.16.9. 105.16.3 If the Contractor has any claim against the County arising out of the provisions of the contract or the performance or non-performance thereunder, and is not within the scope of Section 105.16.2, the claim shall be filed within the earlier of: 1) Sixty (60) days after the date of delivery into the United States mail of the check or draft for the final retained percentage or the date of receipt of funds transferred electronically or otherwise; 2) Ninety (90) days after the date of final inspection under Section 105.15.2; 3) Sixty (60) days after the date of termination of the contract under Section 108.12, or; 4) Sixty (60) days after the written declaration of default under this contract. 105.16.4 If the County has a claim against the Contractor which in any way arises out of the provisions of the contract or the performance or non-performance thereunder, the claim shall be filed within sixty (60) days of delivery into the United States mail of the check or draft for the final retained percentage, or the date of receipt of funds transferred electronically or otherwise, except for claims of a differing site condition or defects in work or material under Section 105.15.2.2. 105.16.5 If the claim is against the County, the written claim shall be personally delivered or sent by certified mail to the office of the County Counselor. If the claim is against the Contractor, the written claim will be personally delivered or sent by certified mail to the Contractor at the address shown under the signature on the contract. If the claim is against an assignee, the written claim will be personally delivered or sent by certified mail to the assignee at the address shown on the accepted notice of assignment. The party against whom a claim is filed shall file any written counter claims within sixty (60) days after receipt of the claim. 105.16.5.1 This provision shall not extend the claim filing time limits of the Contractor or the County in the case of a differing site condition or a suspension of the work under Section 108.12. 105.16.5.2 This provision will not limit the County's claim filing time for defects in work or material not discovered within sixty (60) days of delivery of the final retention or other rights not discovered within sixty (60) days of filing of any claim by the Contractor.
7/1/2015
105-12
Control of Work
105.16.6 Claim submittals shall be in sufficient detail to enable the Engineer to determine the basis for additional time or compensation. The following minimum information shall accompany each claim submitted: 1)
Detailed factual statement of the claim providing all necessary dates, locations and items of work affected by the claim;
2)
The date actions resulting in the claim occurred or conditions resulting in the claim became evident;
3)
A copy of the notice of claim filed by the Contractor for the specific claim;
4)
The name, title and activity of each County employee knowledgeable about facts that gave rise to such claim;
5)
The name, title and activity of each contractor or subcontractor employee knowledgeable about facts that gave rise to such claim;
6)
The specific provisions of the contract that support the claim, and a statement why the provisions support the claim;
7)
The identification of any pertinent documents, and the substance and date of any material oral communication, relating to the claim;
8)
A statement whether the additional compensation or extension of time is based on the provisions of the contract or an alleged breach of contract or other basis in law with detailed support;
9)
If an extension of time is also sought, the specific days for which it is sought, and the basis for such claim as determined by an analysis of the construction schedule;
10) The amount of additional compensation sought and a breakdown of that amount. 105.16.7 Required Certification of Claims. The claim submittal shall include the Contractor's written certification, under oath, attesting to the following: 1) The claim is made in good faith; 2) Supportive data is accurate and complete to the Contractor's best knowledge and belief; 3) The amount of the claim accurately reflects the Contractor's actual cost incurred. To comply with this requirement, the Contractor shall file a notarized statement with the claim, which statement includes at least the following:
7/1/2015
105-13
Control of Work
AFFIDAVIT FOR CLAIM State of
ss.
County of
(Name of the Person Making this Affidavit), the (State Your Title or Position in the Firm) [hereinafter "the Affiant"], of (State the Name of the Firm Submitting the Claim), [hereinafter "the Claimant"], being first duly sworn upon his or her oath, states as follows: 1) This Affidavit is made upon the personal knowledge of the Affiant, and is authorized by the Claimant to be made upon behalf of the Claimant; 2) The Claim being submitted by the Claimant to the County Council at this time on St. Louis County Job Number (Job No.), is made in good faith. The Affiant has the requisite knowledge of the Claim, and the facts and supporting data, to be able to make this Affidavit and accurately attest to the facts herein; 3) All documents, records, charts, schedules, computer programs and printouts, and other data of any nature or description, which are submitted in support of this Claim pursuant to Section 105.16.5 of the St. Louis County Standard Specifications for Road and Bridge Construction, are accurate and complete in all respects, to the best knowledge and belief of the Affiant and the Claimant; 4) Under all applicable penalties of state or federal law for perjury, submitting a false affidavit or statement, fraud, stealing or other falsification, the Affiant hereby certifies that this Claim for extra compensation and time, if any, submitted herewith by the Claimant for work performed on this contract, is a true and accurate statement of the Claimant's actual costs incurred and time sought in performing the contract work, and is fully documented and supported under and pursuant to the contract described above between the Claimant and the County Council; 5) This Affidavit is given in compliance with Section 105.16 of the St. Louis County Standard Specifications for Road and Bridge Construction, which forms a part of that contract. (Type or Print Name of the Claimant) By
(Affiant's Legal Signature)
Subscribed and sworn to before me, a notary public, on this ____ day of ________, (year).
Notary Public My commission expires:
7/1/2015
105-14
Control of Work
105.16.7.1 The person signing the claim and affidavit under oath shall be the owner if the Contractor is a sole proprietorship, shall be a general partner if the Contractor is a partnership, shall be an authorized agent if the Contractor is a limited liability company or joint venture, or shall be an authorized officer or member of the board if the Contractor is a corporation. 105.16.8 Review of Claims. During the review of the claim, the Contractor, subcontractors, and suppliers shall cooperate with the County and shall provide, at a minimum, access to the following documents:
7/1/2015
1)
Daily time sheets and supervisor's daily reports;
2)
Union agreements, if any;
3)
Insurance, welfare and benefits records;
4)
Payroll register;
5)
Earnings records;
6)
Payroll tax returns;
7)
Material invoices, purchase orders, and all material and supply acquisition contracts;
8)
Material cost distribution worksheets;
9)
Equipment records (list of company equipment, rates, etc.);
10)
Vendor rental agreements and contracts with subcontractors and suppliers;
11)
Subcontractor payment records and invoices;
12)
Canceled checks (payroll and vendors);
13)
Job cost report;
14)
Job payroll ledger;
15)
General ledger, general journal (if used), and all subsidiary ledgers and journals together with all supporting documentation pertinent to entries made in these ledgers and journals;
16)
Cash disbursements journal;
105-15
Control of Work
17)
Financial statements for all years reflecting the operations on this project;
18)
Income tax returns whether such records are maintained by the company involved, its accountant, or others;
19)
Depreciation records on all company equipment;
20)
All other documents used to develop costs for the Contractor's internal purposes in establishing the actual cost of owning and operating equipment;
21)
All documents that reflect the Contractor's actual profit and overhead during the time the project was being performed and for each of the five years prior to the commencement of this project;
22)
All bid records related to the preparation of the Contractor's bid including the final calculations on which the bid was based, unless the documents are placed in escrow;
23)
Worksheets used to prepare the claim, establishing the cost components for items of the claim including, but not limited to, labor, benefits and insurance, material, equipment, and subcontractors, all documents that establish the time periods, individuals involved, the hours and the rates for the individuals, schedule analyses, and all data input used or developed for computer analysis or generation of the claim;
24)
Projected and actual work force and equipment schedules and plans;
25)
Any internal budget for the project.
105.16.9 On any claim for additional compensation for work on the project, whether claimed under the contract, for a differing site condition, as a change in the work, for breach of the contract, for a positive representation by which the contract was induced or otherwise, the following items shall never be allowable or claimed directly or indirectly: 1) Attorney fees, consultant or claims preparation costs, or costs related to litigation; 2) Any item that would not be eligible for federal-aid participation under the provisions of 23 CFR 635.124, regardless of whether the project is one approved by the FHWA; 3) Any item that would be an expressly unallowable cost under the provisions of 48 CFR part 31, subparts 31.1 and 31.2, or as it may be amended, superseded or replaced during the life of the contract.
7/1/2015
105-16
Control of Work
105.16.10 Any claim or item of any claim not included in the writings required to be filed in Section 105.16, or any claim included but not clearly defined and specifically set out, itemized and supported, or any notice or claim not filed within the time and in the manner provided in Section 105.16, shall be forever waived, and shall neither constitute the basis of nor be included in any legal action, counterclaim, defense, set-off, arbitration or other alternative dispute resolution procedure mutually agreed upon between the parties. 105.16.10.1 The omission of any claim or item of a claim or the detail required by Section 105.16.6 may not be cured by information provided during review of the claim. 105.16.10.2 The County has established a written procedure for handling contractor claims that provides the process for resolution of all claims and the Engineer's final decision. The completion of that process and the Engineer's final decision shall be a condition precedent to any legal action, counterclaim, defense, set-off or arbitration concerning the matters claimed. 105.16.11 The County's review of a claim pursuant to Section 105.16.8 shall be in addition to the right or duty of the County or County Council to conduct audits or other reviews of a claim or contractor's books of account or operations otherwise provided by federal or state laws or the rules of civil procedure. 105.17 Venue. Any action concerning any matter, thing or dispute arising out of or relating to the terms, performance, non-performance or otherwise of the agreement, shall be brought in the Circuit Court of St. Louis County, Missouri. The parties agree that the contract is entered into at St. Louis County, Missouri, and substantial elements of its performance will take place or be delivered at St. Louis County, Missouri, by reason of which the Contractor consents to venue of any action by or against it in St. Louis County, Missouri. The Contractor shall cause this provision to be incorporated in all of its agreements with, and to be binding upon, all subcontractors in the performance of this agreement. 105.18 Equipment/Vehicle Parking on Public and Private Property. 105.18.1 The Contractor's equipment and vehicles may be parked on the St. Louis County maintained road or adjacent right-of-way at the close of each day and at the termination of operations for each job site unless other arrangements have been made by the Contractor. If the Contractor elects to park equipment and vehicles on private property, he shall produce and submit a letter of authorization from the affected property owner at least one (1) working day prior to the time he intends to use the property for that purpose. Private roads and public streets not maintained by St. Louis County may not be utilized for parking as part of the contract. 105.18.2 Prior to the parking of equipment or storing of material on public and/or private property, the Contractor shall also receive approval from the Engineer. The location of the parked equipment or stored materials shall not restrict sight distance or cause lane restrictions at any street or driveway intersection. Any parked equipment or stored material shall be properly protected as directed by the Engineer.
7/1/2015
105-17
Control of Work
105.19 Logo on Equipment. Each Contractor and subcontractor engaged in any construction on this project shall have its name, acceptable abbreviation or recognizable logo, and the name of the city and state of the mailing address of the principal office of the company, on each motor vehicle and motorized self-propelled piece of equipment which is used in connection with such project during the time the Contractor or subcontractor is engaged on such project. The sign shall be legible from a distance of twenty feet, but the size of the lettering need not be larger than two inches. In cases where equipment is leased or where affixing a legible sign to the equipment is impractical, the Contractor may place a temporary stationary sign, with the information required pursuant to this provision, at the main entrance of the construction project in place of affixing the required information on the equipment, so long as such sign is not in violation of any State or Federal statute, rule or regulation. Motor vehicles which are required to have similar information affixed thereto pursuant to requirements of a regulatory agency of the State or Federal government are exempt from the requirements of this provision. The requirements of this provision shall not apply to projects for which the Contract awarded is in the amount of $250,000 or less.
7/1/2015
105-18
Control of Work
Section 106
Control of Material
106.1 Source of Supply and Quality Requirements. 106.1.1 All material needed in the work shall be furnished by the Contractor unless otherwise stated in the contract. The Contractor shall assume full responsibility for ordering materials of the quality and quantity required. The Contractor shall be responsible for the delivered costs of all material ordered. 106.1.2 The material used on the work shall meet all quality requirements of the contract. They shall be obtained from sources of supply that meet the approval of the Engineer. If it is found that a uniform product is not being furnished from a source of supply or if, for any reason, the product from any source at any time proves to be unsatisfactory, the Contractor may be required to furnish approved material from other sources. The Engineer shall have the right to reject the entire output of any source where it is impracticable to secure a continuous flow of uniformly satisfactory material. 106.1.3 Any work incorporating materials which have not had prior approval of the Engineer shall be performed at the Contractor's risk and may be considered as unacceptable and unauthorized and, if so considered, will not be paid for. If change in source will affect the control or appearance of the work, the use of any one kind of class of material for a specific project from more than one source is prohibited, except by permission of the Engineer. Such permission, if granted, will set forth the conditions under which the change may be made. 106.1.4 Material is subject to inspection or test at any time during production or manufacture or at any subsequent time prior to or after incorporation into the work. The points of inspection will be determined by the Engineer. Initial inspection, testing, and approval or rejection will be made as early as practicable. The Engineer may waive any of the requirements regarding determination of quality and accept material on certifications or visual inspection if, in his judgment, the quantity involved is too small or its use not sufficiently important to warrant tests. 106.1.5 To expedite the inspection and testing of material, the Contractor shall notify the Engineer in writing of his proposed sources of materials prior to delivery. At the option of the Engineer, materials may be approved at the source of supply before delivery is started. 106.1.6 Every St. Louis County contract or any subcontract thereto in excess of $10,000 for construction, alteration, repair or maintenance of County public works shall require the Contractor or subcontractor to use and/or supply American products, in accordance with Section 106.9, in the performance of the contract on any subcontract thereto provided that the quality and price of the items specified are comparable with other products.
7/1/2015
106-1
Control of Material
106.2 Local Material Sources. 106.2.1 Designated Sources. The County may acquire and make available to the Contractor the right to take materials from sources designated on the plans or described in the contract together with the right to use designated property if so specified, for plant site, stockpiles, and hauling roads. In general, the quality of material contained in such sources is considered to be acceptable, but the Contractor shall determine the method of operation, equipment, and work required to produce a material meeting the specifications. Designation of a source for material is not a representation of the quantity of acceptable material obtainable or the method, equipment, or work required to obtain the material from the source. It shall be understood that it is not feasible to ascertain from samples the limits for an entire deposit, and that variations shall be considered as usual and are to be expected. The Engineer may order procurement of material from any portion of a deposit and may reject portions of the deposit as unacceptable. 106.2.2 Contractor Furnished Sources. If sources of material are not designated on the plans or described in the contract, or if the Contractor desires to use material from sources other than those designated, he shall acquire the necessary rights to take materials from the sources and shall pay all costs related thereto, including any which may result from an increase in length of haul. All costs of exploring, meeting environmental requirements, and developing such other sources shall be at the contractor’s expense. Environmental compliance documentation shall follow St. Louis County guidance for contractor furnished borrow and shall be submitted to Design for review and approval. The use of material from other than designated sources will not be permitted until representative samples taken by the Contractor in the presence of the Engineer have been approved and written authority is issued for the use thereof. If sources of material or material deposits are provided by the Contractor, the Engineer will test the samples and determine the suitability of the material. Where practicable, borrow areas, gravel pits, and quarry sites shall be located so that they will not be plainly visible from the highway. 106.2.3 Operation of Sources. Whether sources of materials are acquired and made available by the County or are furnished by the Contractor, activities shall be in compliance with all federal and state laws and the areas shall be excavated or worked in such manner to avoid or minimize siltation of streams, lakes, ponds, and reservoirs. 106.2.4 Final Condition of Sources. Unless otherwise permitted, pits and quarries shall be so excavated that water will not collect and stand therein. Sites from which material has been removed shall be left in such condition to avoid or minimize siltation of streams, lakes, ponds, and reservoirs, and, if plainly visible from the completed highway, shall be left in a neat and presentable condition upon completion of the work.
7/1/2015
106-2
Control of Material
106.3 Samples, Tests, and Cited Specifications. Samples for tests will be taken by the Engineer. There shall be no direct charge to the County for material taken as samples, either for field tests or for laboratory tests. When a specification of a recognized national standard agency (ASTM, AASHTO, AWWA, AWS, etc.) is designated, the material may, unless otherwise specified, meet either the designated specification of the latest revisions thereof in effect at the time of bid opening. Tests of samples of material will be made by the Engineer in accordance with the methods specified in the contract or in accordance with the latest methods in effect at the time of bid opening, as prescribed by specified national standard agency. Such national standard specifications and methods of tests shall include those designated as tentative, interim, or amended and officially approved and published by the sponsoring agency. If appropriate methods have not been so prescribed, tests shall be performed in a manner determined by the Engineer. 106.3.1 Contractors and subcontractors will be required to produce letters of certification or certified test reports from material producers and suppliers in order to determine compliance with specifications for designated materials prior to the incorporation thereof into the work. No payment will be made to the Contractor by the Engineer for pay items, either in whole or in part, until certifications related to that pay item are received by the Engineer. No direct payment will be made for this work. 106.3.2 The Engineer will determine which materials are to be tested. The form and content of these reports shall be in accordance with recognized standards and practices for this work or as otherwise determined by the Engineer. No direct payment will be made for this work. 106.4 Plant Inspection. The Engineer may inspect material at the source. If plant inspection is undertaken, the following conditions shall be met. 106.4.1 The Engineer shall have the cooperation and assistance of the Contractor and the producer of the materials. 106.4.2 The Engineer shall be permitted free access to all parts of the plant as required for adequate inspection and selection of samples. Every reasonable facility shall be furnished for the procurement of samples, performance of the tests, and for the protection of testing equipment and supplies when tests are made at the source of production. 106.4.3 If bituminous shipments are considered by the Engineer to be frequent enough to justify testing at the source, laboratory facilities and testing equipment meeting requirements of the prescribed methods shall be provided by the supplier. The space and equipment shall be adequate for the order and proper testing of materials without interference to or by the refinery personnel. 106.4.4 When requested, a Type 1 field laboratory shall be furnished at the aggregate source in accordance with Section 601.
7/1/2015
106-3
Control of Material
106.4.5 The County will refuse to provide plant inspection at sources where adequate safety measures are not provided and maintained. 106.4.6 The County reserves the right to retest all materials prior to or after incorporation into the work and to reject all materials, which, when retested, do not meet the requirements of the specifications. 106.5 Storage of Materials. The Contractor shall be responsible for proper storage and handling of all materials to insure preservation of required quality. The Engineer may direct that materials be placed on wood platforms, or other hard, clean surfaces, or that they be protected from the weather. Materials in storage shall be so arranged as to facilitate inspection. 106.6 Handling Material. All material shall be handled in such manner as to preserve their quality and fitness for the work. Aggregates shall be transported from the storage site to the work in tight vehicles so constructed as to prevent loss or segregation of materials after loading and measuring, in order that there may be no inconsistencies in the quantities of materials intended for incorporation in the work as loaded and the quantities as actually received at the place of operations. 106.7 Unacceptable Material. All materials not conforming to the requirements of the specification when initially inspected and tested will be considered as defective, and all such materials, whether in place or not, will be rejected and, unless remedied, shall be removed from the site of the work. Any material having once been inspected and approved that is subsequently found to deviate from the specification requirements to a degree which, in the judgment of the Engineer, renders it unsuitable for use will be rejected even though it has previously been approved. Defective materials, including any material furnished by the County that has been damaged by the Contractor after delivery, shall be replaced or reconditioned by the Contractor and at the Contractor's expense. Rejected material, which has been reconditioned or corrected so that it satisfactorily meets the specification, shall not be used without the Engineer's written approval. 106.8 Material Furnished by the County. When any material is to be furnished by the County, special provisions designating such materials and their locations will be included in the bid. The cost of handling and placing such material after delivery to the Contractor is included in the appropriate contract price. The Contractor is responsible for all material delivered to him, and deductions will be made from any monies due him to make good any shortages and deficiencies, from any cause whatsoever, for any damage which may occur after such delivery and for any demurrage charges.
7/1/2015
106-4
Control of Material
106.9 Buy America Requirement. On all federal-aid projects, the Contractor's attention is directed to Title 23, CFR entitled "Buy America Requirements". Where steel or iron products are to be permanently incorporated in the contract work, steel or iron material shall be manufactured in the USA, except for "minor usage" as described herein. Furthermore, any coating process of the steel or iron shall be performed in the USA. The use of pig iron and processed, palletized, and reduced iron ore manufactured outside of the USA will be permitted in the domestic manufacturing process for steel or iron material. 106.9.1 Any sources other than the USA as defined, are to be considered as foreign. The required domestic manufacturing process includes formation of ingots and any subsequent process. Coatings include any that protect or add value to the product. 106.9.2 "Minor usage" of foreign steel, iron or coating processes will be permitted, provided the cost of such products does not exceed 1/10 of one percent of the total contract cost or $2,500, whichever is greater. If foreign steel, iron, or coating processes are used, invoices to document the cost of the foreign portion, as delivered to the project, shall be provided. The Engineer's written approval shall be given prior to placing the material in any work. 106.9.3 For each domestic permanent steel or iron item, the Contractor shall furnish to the Engineer, for approval, a manufacturer's certification identifying the item and certifying that the manufacturing processes for the product occurred in the USA, including coating process if applicable. For foreign items, a statement of the specific foreign manufacturing location(s) shall be provided. 106.9.4 Upon completion of the project, the Contractor shall certify to the Engineer that all steel, iron and coating processes for steel or iron incorporated into the contract work were in accordance with this specification, except as noted. All exceptions and their costs shall be listed in the same document. 106.9.5 When permitted in the contract, alternate bids may be submitted for foreign structural steel. The award of the contract, when alternate bids are permitted, will be based on the lowest total bid of the contract based on furnishing domestic structural steel or 125% of the lowest bid based on furnishing foreign structural steel. If foreign steel is awarded the contract, domestic structural steel may be used. However, payment will be at the contract unit price for foreign structural steel. 106.10 Measurement of Quantities Weight. The Contractor shall furnish the County with weight invoices for all materials supplied by the Contractor's material supplier that are incorporated into the project for which payment is based on weight. Scales used to measure material weight shall be tagged with a valid State Department of Agriculture approval label. Weights shall be calibrated by the governing state body of weights and measures in accordance to the requirements established by the U.S. Department of Agriculture. All equipment shall be calibrated by the Contractor in the presence of and subject to the approval of the Engineer. Manufacturing Plants shall be calibrated at least once each year, or as directed. Plant certification for calibration and verification will not be required, provided that this certification has been furnished to the State within a twelve (12) month period prior to the time certification is required by the County. A letter of certification to verify this will be required. This does not preclude interim checks by County forces.
7/1/2015
106-5
Control of Material
106.11 Project Documentation. All project tickets, paperwork for measurement, certifications, or reporting of material shall be in the unit measure specified in the contract. Delivery tickets shall contain the following information: Aggregate 1) 2) 3) 4) 5) 6) 7) 8)
Gross, tare and net weights; Identification of the vehicle; Current date and time; Source; Material type or class designation; Formation(s) & Ledge(s); Unique ticket number. (May be preprinted on the ticket); St. Louis County Project No. and Federal Job No. if applicable. Asphalt
1) 2) 3) 4) 5) 6) 7)
Gross, tare and net weights; Identification of the vehicle; Current date and time; St. Louis County job mix designation; Job mix percent asphalt; Unique ticket number. (May be preprinted on the ticket); St. Louis County Project No. and Federal Job No. if applicable. Concrete
1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12)
Name of concrete plant; Serial number of ticket; Date; Truck number; Name of contractor; Specific project, Street name, and County/Federal designation; Specific class of concrete; Volume quantity of concrete; Time when batch was loaded, or of first mixing of cement and aggregates; Arrival time on project; Time when truck has finished discharging load; Any additional water added at jobsite to attain pouring consistency, initialed by the Contractor.
106.11.1 units.
Equipment requiring calibration will be calibrated using its "as manufactured"
106.11.2 Any cost of re-design due to use of material with units of measure other than as specified by the contract shall be borne by the Contractor.
7/1/2015
106-6
Control of Material
Section 107
Legal Relations and Responsibility to the Public
107.1 Laws to be Observed. The Contractor shall at all times observe and comply with all Federal and State laws, County Ordinances, local laws, orders, decrees, and regulations existing at the time of or enacted subsequent to the execution of the contract which in any manner affect the prosecution of the work. The Contractor and his surety shall indemnify and save harmless the County and all of its officers, engineers, representatives, agents, and employees against any claim or liability arising from or based on the violation of any such law, ordinance, regulation, order, codes or decree, which the contract or the Engineer has specifically directed that the Contractor not obey. 107.1.1 Federal Aid Provisions. When the United States Government pays all or any portion of the cost of a project, the Federal laws, and the rules and regulations made pursuant to such laws, shall be observed by the Federal agency as provided in Section 105.10. The Missouri Highway and Transportation Commission acts as a coordinating agent between the County and the Federal agency and, therefore, the work and project records shall also be subject to inspection by agents of the Missouri Highway and Transportation Commission. 107.1.2 Local Building and Zoning Codes or Ordinances. If any questions arise concerning whether the Contractor shall comply with a local code, ordinance, decree, or order of any type, the Contractor shall advise the Engineer of the problem immediately, for resolution by the Engineer. This provision does not exempt the Contractor from the requirement of thoroughly researching, determining, and complying with, before submitting a bid on the contract, all federal, state or local laws, regulations, codes, ordinances, decrees, or orders which may apply to the contract work. The County is not responsible for the Contractor's failure to be informed before bidding as to the federal, state, and local laws, regulations, codes, ordinances, decrees, or orders which may govern the contract work, or for the Contractor's failure to determine before bidding which of these do not govern the contract work. 107.1.3 Authentication of Certain Documents. When plans, plats, detailed drawings, or specifications for falsework, cofferdams, or any other work are required to be submitted to the Director, they shall be signed, sealed, and stamped in accordance with the laws relating to architects and professional engineers (Chapter 327, RSMo). 107.2 Permits and Licenses. The Contractor shall procure all permits and licenses, shall pay all charges and fees, and shall give all notices necessary and incidental to the due and lawful prosecution of the work. No direct payment will be made for the cost of complying with this requirement. 107.2.1 The Contractor is required to secure and pay for all permits and licenses from all agencies having jurisdiction over the work, including the Metropolitan St. Louis Sewer District (MSD), St. Louis County Department of Public Works (Plumbing Section), as well as any other cities, towns, villages, etc. in which such work will take place. Permit requirements shall include, but not be limited to, all connections, adjustments, or relocations of sanitary sewer laterals or water services.
10/1/2018
107-1
Legal Relations and Responsibility to the Public
107.2.2 In addition, the Contractor will be required to procure from the proper municipal authorities all permits which may be required to haul over city streets and any hauling operations of the Contractor shall be subject to the requirements of such permits and other applicable city regulations and ordinances. 107.2.2.1 All streets and roads over, which the Contractor is hauling, shall be kept in a neat, clean condition at all times. Refuse, trash, earth, and other droppings deposited on the street and roads as a result of the Contractor’s operations shall be promptly and completely removed; also, all newly paved sections of streets shall be cleaned and swept prior to reopening to traffic. 107.3 Patented Devices, Materials, and Processes. If the Contractor is required or desires to use any design, device, material, or process covered letters, patent, copyright, service, or trademark, he shall arrange and provide for such use by suitable agreement with the patentee or owner. A copy of the agreement may be required by the Director. The Contractor and surety shall indemnify and save harmless the County from any suits, claims, or damages arising from the infringement upon or use of any patented, copyrighted or registered design, device, material, process or mark. 107.4 Safety and Sanitary Provisions. In order to provide safety controls for protection to the life and health of employees and other persons, for prevention of damage to property, materials, supplies and equipment, and for avoidance of work interruptions in the performance of this contract, the Contractor will comply with all pertinent provisions of the manual "Manual of Accident Prevention in Construction", as revised by the Associated General Contractors of America, Inc., Washington, D.C., for construction superintendents and foremen, and will also take or cause to be taken such additional measures as the Director may determine to be reasonably necessary for the purpose. The Contractor shall be familiar with the latest accepted accident prevention methods and provide necessary safety devices and safeguards in accordance therewith. The Contractor will maintain an accurate record of, and will report to the Director in the manner and on the forms prescribed by the Director, exposure data and all accidents resulting in death, traumatic injury, occupational disease, and/or damage to property, materials, supplies and equipment incidental to work performed under this contract. The Director will notify the Contractor of any non-compliance with the foregoing provisions and the action to be taken. The Contractor shall, after receipt of such notice, immediately correct the conditions. Such notice, when delivered to the Contractor or his representative at the site of the work, shall be deemed sufficient for the purpose. If the Contractor fails or refuses to comply promptly, the Director may issue an order stopping all or part of the work until satisfactory corrective action has been taken. No part of the item lost due to any such stop order shall be made the subject of claim for extension of time or for excess costs or damages by the Contractor. Compliance with the provisions of these Safety Provisions by subcontractors will be the responsibility of the Contractor. 107.4.1 Accident Prevention. In addition to full compliance with the requirements of the clause of the contract entitled "Accident Prevention", the Contractor will comply with the following provision: During the performance of work under the contract, the Contractor shall comply with all procedures prescribed by the Director for the control and safety of persons visiting the job site and will comply with such requirements to prevent accidents as may be issued by the Director.
10/1/2018
107-2
Legal Relations and Responsibility to the Public
107.4.2 Employee Accommodations. The Contractor shall provide and maintain in a neat and sanitary condition such accommodations for the use of his employees as may be necessary to comply with the requirements and regulations of the St. Louis County Department of Community Health, State Division of Health or of other bodies or tribunals having jurisdiction over public health and sanitation. He shall permit no public or private nuisance. 107.4.3 All sanitary facilities and safety devices shall be furnished free to employees and no direct payment will be made for such facilities or devices. 107.5 Public Convenience and Safety. The Contractor shall conduct the work in a manner that will insure, as far as practicable, the least obstruction to traffic and shall provide for the convenience and safety of the general public and residents along and adjacent to the highway in an adequate and satisfactory manner. 107.5.1 Work Schedule. To insure that the work and payment therefore will proceed continuously through the succeeding operations to its completion with the least possible interference and inconvenience to the public, the Contractor shall submit for approval a complete schedule of his intended operations, listing by street names stating the sequence in which are to be performed. The schedule shall also include monthly payment estimates based on the materials anticipated to be in place and the work performed during each monthly interval covered by the schedule. Such payment estimates shall be expressed either as a percentage of the total contract amount for each month or as the cost of work and materials to be completed during each month. The work schedule and cost estimates required by this provision shall be submitted for approval at the pre-construction conference. 107.5.2 Temporary Ways and Structures. The Contractor shall provide and maintain at his expense such temporary roads, pedestrian walkways and other items as may be necessary to provide access to residential properties and commercial establishments abutting the highway under construction, as well as temporary approaches to and crossings of intersecting roads and railroads, unless otherwise provided in the contract. To accommodate traffic on the roadway under construction, the Contractor shall at his expense provide and maintain in a passable condition all necessary bypasses around culverts. Temporary bridges will be required only where specified in the contract. On paving projects, if the Director orders the construction of a temporary bridge for the handling of traffic across new pavements, which bridge is not provided for in the contract, the cost of such crossing will be paid for in accordance with Section 104.3. 107.5.3 Obstructions Prohibited. Materials stored upon the highway shall be placed so as to cause no unnecessary obstruction to public travel. Fire hydrants on and adjacent to the highway shall be kept accessible to firefighting apparatus at all times and no obstruction shall be placed within 15 feet of any such hydrant. Footways, gutters, sewers, outlets, inlets, and portions of highways adjoining the work under construction shall not be obstructed. Pavements over which hauling is performed shall be kept reasonably clean of spilled or tracked-on materials at all times and shall be thoroughly cleaned daily within one hour after the suspension of hauling operations if in use by traffic.
10/1/2018
107-3
Legal Relations and Responsibility to the Public
107.5.4 Material and Equipment. During construction hours, equipment, material, and vehicles utilized in construction of the project will only be allowed on shoulders, medians, or pavements where the locations are closed to traffic, properly signed, and occupied by ongoing construction operations, unless otherwise approved by the Engineer. Except in cases of emergency, construction equipment, material and vehicles will not be allowed on pavements or shoulders being utilized by traffic. If the contract specifies time periods that the Contractor will not be permitted to perform work, construction equipment or vehicles shall not enter or leave the construction area via the pavements handling traffic nor be operated on the pavements handling traffic within the construction area. During nonconstruction hours, construction equipment, material, and vehicles will not be allowed within 30 feet of the edge of the pavement or shoulders carrying traffic unless the equipment, material, and vehicles are located in a properly protected area, an off-site storage area, or as otherwise directed by the Engineer. 107.6 Bridges over Navigable Waters. All work on navigable waters shall be so conducted that free navigation of the waterways will not be interfered with and that the existing navigable depths will not be impaired, except as allowed by permit issued by the United States Coast Guard or the United Sates Army Corps of Engineers. 107.7 Barricades and Warning Devices. The Contractor shall build and maintain standard barricades conforming to Section 612 at locations designated by written order of the Director. Payment will be made for such barricades at the contract unit price. At all times until final acceptance of the work on either a road which is closed to all through traffic or on a road over which traffic is to be handled, the Contractor shall provide and maintain at his expense such signs, lights, watchmen, and barriers other than barricades, as may be necessary to properly protect the work and provide for safe and convenient public travel in accordance with the current Manual on Uniform Traffic Control Devices (MUTCD). 107.8 Use of Explosives. All blasting operations shall be conducted under the direct supervision of a licensed St. Louis County Blaster. When explosives are used in the prosecution of the work, the Contractor shall use the utmost care to prevent personal injury and property damage. All explosives shall be handled, loaded, transported, stored and used in a safe manner and in compliance with all existing statutes and in accordance with the provisions of the Explosives Code, Chapter 711, St. Louis County Ordinances, 1964, as amended. All places used for explosive storage shall receive a permit from the St. Louis County Department of Public Works in accordance with the provisions of the Explosives Code, Chapter 711, St. Louis County Ordinances, 1964, as amended. The Contractor shall warn all persons in the vicinity of the danger area when explosives are being used. 107.8.1 Before beginning work, the Contractor shall furnish the Engineer letters of approval for the proposed operation from the appropriate regulating agencies. The Contractor shall notify in writing the appropriate fire protection jurisdiction of the intent to store, transport or use explosives and shall provide proof of notice to the Engineer. The Contractor shall provide the Engineer with copies of all permits, blasting logs and seismic monitoring data. 107.8.2 The Contractor shall notify in advance each property owner, tenant, and public utility company having structures or facilities close to the work of any intention to use explosives.
10/1/2018
107-4
Legal Relations and Responsibility to the Public
107.8.3 Removal of any item or material of any nature by blasting shall be done in such a manner and at such time as to avoid damage affecting the integrity of the design and to avoid damage to any new or existing structure whether on County right of way or private property included in or adjacent to the work. Unless the contract documents or the Engineer restricts such operation, it shall be the Contractor's responsibility to determine a method of operation to insure the desired results and the integrity of the completed work. See Section 107.14.2 for liability insurance requirements. 107.8.4 The Contractor and surety shall indemnify and save harmless the County, its agents, employees and assigns from any claim related to the possession, transportation, storage, or use of explosives. 107.9 Preservation of Monuments and Artifacts. 107.9.1 Monuments. The Contractor shall not disturb or damage any land monument or property landmark until authorized by the Director. 107.9.2 Human and Archaeological Remains. The Contractor shall be responsible for reporting to the Engineer the discovery of human remains, artifacts, fossils, and other items of historical, archaeological, or geological significance discovered within the right of way during construction. Such items shall remain in the County's custody and shall not be removed from the site unless directed by the Engineer. The preservation and handling of such items shall be in conformity with Section 203.2.9. 107.10 Forest and Park Protection. Environmental and sanitary laws and regulations regarding the performance of work within or adjacent to county, state, or national forests or parks shall be obeyed. The Contractor shall keep the project site in an orderly condition, dispose of all refuse, and obtain permits for the construction and maintenance of all construction camps, stores, warehouses, residences, latrines, cesspools, septic tanks and other structures in accordance with the regulations and instructions issued by the forest or park supervisor. Forest fires shall be prevented and suppressed. The Contractor shall require employees and subcontractors independently and at the request of forest officials to prevent and suppress forest fires and to notify a forest official of the location and extent of any fire. 107.11 Environmental Protection. The Contractor shall comply with all federal, state, and local laws and regulations controlling pollution of the environment. The Contractor shall take sufficient precautions to prevent pollution of streams, lakes, ponds, and reservoirs, with fuels, oils, bitumens, calcium chloride, or other harmful materials. He shall schedule and conduct his operations so as to avoid or minimize siltation of streams, lakes, ponds, and reservoirs. In areas particularly subject to erosion, the Contractor shall, subject to the approval of the Engineer, conduct his operations in such manner as to reduce exposure of the uncompleted portions of the project to the shortest time practicable. 107.11.1 Fording of streams is not permitted unless the plan for such operation meets the approval of the Engineer and results in minimum siltation to the stream. 107.11.2 When work areas or pits are located in or adjacent to streams, they shall be separated from the main stream by a dike or barrier to keep sediment from entering the stream. Care shall be taken during the construction and removal of such barriers to minimize siltation of the stream.
10/1/2018
107-5
Legal Relations and Responsibility to the Public
107.11.3 Disposal of Portland cement concrete residue and wash water, water from aggregate washing, or other operations resulting in sediment shall be treated by filtration, settling basins or other means sufficient to reduce the sediment concentration to applicable limits established by the Department of Natural Resources. 107.12 Responsibility for Claims for Damage or Injury. The Contractor and surety shall indemnify and save harmless the County, its officers, agents, and employees from all claims or suits made or brought for injury to persons or property caused by: 1) The negligence of the Contractor, subcontractors, suppliers or their respective officers, agents or employees; 2) The creation or maintenance of a dangerous condition of or on the County's property or right of way, which condition occurred at least in part due to the acts or omissions of the Contractor, subcontractors, suppliers or their respective officers, agents or employees; or 3) The failure of the Contractor, subcontractors, suppliers or their respective officers, agents or employees, to perform the work in accordance with the plans and specifications. The County may retain from any payment due or to become due the Contractor such sums as are deemed necessary to protect its interests until all such claims or suits have been settled or disposed of and suitable evidence to that effect furnished to the County. 107.13 Contractor's Responsibility for Work. Until work is accepted by the Director, it shall be in the custody and under the charge and care of the Contractor. The Contractor shall rebuild, repair, restore, or make good, at the Contractor’s expense, any lost or stolen Countyowned material, and all injuries or damages to any portion of the work before its completion and acceptance, caused by the action of the elements or from any other reason. Issuance of a payment estimate on any part of the work done will not be considered as final acceptance of any work completed up to that time. The Director may, at his discretion, make such adjustment as he considers to be proper for damage to the work due to unforeseeable causes beyond the control of, and without fault or negligence on the part of the Contractor. 107.14 Liability Insurance Requirements. The Contractor shall procure and maintain at its own expense, until acceptance of the project by the Engineer, liability insurance for all damages and losses imposed by law and assumed under the contract, of the kinds and in the amounts specified in Sections 107.14.1 through 107.14.2. Before the Contractor commences the work, the Contractor shall require the insurance company or companies to furnish to the Engineer evidence of such insurance showing compliance with these specifications. All insurance required in Section 107.14 shall be occurrence policies in a form acceptable to the Engineer, and shall remain in force until all work required to be performed under the terms of the contract is satisfactorily completed as evidenced by its formal acceptance by the Engineer. Each policy or its declaration pages shall provide that the policy shall not be materially changed or canceled until the Engineer has been given at least thirty (30) days advance notice in writing. If any policy is canceled before the contract work is complete, a satisfactory replacement policy shall be in force, with notice and evidence of insurance submitted to the Engineer, prior to the effective date of cancellation of the former policy. All evidence of insurance and notices shall be submitted to: Director, St. Louis County Department of Transportation, 1050 North Lindbergh Boulevard, Creve Coeur, Missouri 63132. Upon request, the Contractor shall promptly furnish the Engineer with a complete copy of the policy. Failure to furnish evidence of proper 10/1/2018
107-6
Legal Relations and Responsibility to the Public
insurance, or complete insurance policies when requested, will result in the temporary suspension of work as provided in Section 108.5.7, and may result in other claims or actions for breach of contract or otherwise, as may be recognized at law or in equity. 107.14.1 Workmen's Compensation Liability Insurance. The Contractor shall furnish evidence to the Engineer that, with respect to the operations it performs, it carries workers' compensation insurance, or is qualified as self-insured, sufficient to comply with all its obligations under state laws relating to workers' compensation. The Contractor shall also require each subcontractor on the project to furnish the same evidence to the Engineer. This evidence shall be furnished to and approved by the Engineer prior to the time the Contractor or subcontractor commences work on the site of the project. 107.14.2 Contractor's Liability Insurance with Additional Insured Parties. 107.14.2.1 Commercial General, Umbrella Liability and Excess Liability Insurance. The Contractor shall obtain one or more occurrence-based policies of commercial general liability (CGL) insurance (on ISO occurrence Form CG 00 01 07 98 or the equivalent) and, if necessary, commercial umbrella or excess which provide coverage for the contract work. The minimum limits of liability for commercial general liability insurance shall be: $2,000,000 each bodily injury or property damage occurrence, combined single limit, $2,000,000 general aggregate with a per project endorsement and $2,000,000 products/completed operations aggregate. Each such policy shall be endorsed so as to cover liability arising from premises, operations, independent contractor, product-completed operations, personal injury, advertising injury, blasting, if applicable, other inherently dangerous activities, underground property damage, and liability assumed under an insured contract (including the tort liability of another assumed in a business contract). Each such policy of commercial general liability insurance shall name St. Louis County as additional insured. Contractor may be required to raise the limits of liability on occurrence bases to match the revised statutory limit of liability for public entities during the contract term. Each such policy shall be endorsed to include broad form general liability, contractual liability, and completed operations coverage. 107.14.2.2 Commercial Auto Liability Insurance. The Contractor shall obtain one or more occurrence-based policies of auto liability insurance to include bodily injury and property damage that provide coverage for its owned, non-owned, and hired vehicles of every type and description which are used in the contract work. The minimum limits of liability for such insurance shall be $2,000,000 per occurrence, Combined Single Limit (CSL). Contractor may be required to raise the limits of liability on occurrence bases to match the revised statutory limit of liability for public entities during the contract term. The Contractor shall include a "Certificate of Liability Insurance" with each contract. One original certificate shall be submitted with the executed contract books. The comment/description shall include the following: 1) Project Name; 2) St. Louis County Project Number; 3) Federal Job Number, if applicable; 4) St. Louis County named as additional insured; 5) Waiver of Subrogation. 10/1/2018
107-7
Legal Relations and Responsibility to the Public
107.14.2.3 Waiver of Subrogation. The Contractor insurer shall agree to waive all rights of subrogation (with the exception of Workmen's Compensation) against the County, it's elected and appointed officials, employees and volunteers for losses arising from work performed by the Contractor for the County. 107.14.2.4 Workers Compensation. The Contractor shall provide proof of Workmen's Compensation Insurance with statutory limits for the duration of the project. Coverage shall extend to employees liability. Contractors shall include a "Certificate of Liability Insurance" with each contract. The comment/descriptions shall include the following: 1) Project Number and Name; 2) St. Louis County named as additional insured; 3) A Waiver of Subrogation. One original certificate shall be submitted with executed contract books. 107.14.2.5 Subcontractor's Coverage. If any part of the contract is subcontracted, each subcontractor, or the Contractor on behalf of that subcontractor, shall obtain the same commercial general liability insurance, commercial automobile liability insurance, and Workmen's Compensation Insurance coverage. The commercial general liability insurance shall name the same entities specified in Section 107.14.2.1 as additional insured's, and shall have the same separation of insured's conditions. 107.14.3 Railroad's Protective Liability Insurance. In addition to other required liability insurance, the Contractor shall provide Railroad's Protective Liability Insurance for and in behalf of the railroads as outlined in special provisions for each project. The insurance policy shall be submitted to the Director in original and duplicate for approval. No work will be permitted on the railroad right-of-way until such approval is granted. 107.14.4 Insurance with Other than Missouri Companies. Any insurance policy required as specified hereinbefore, if written by an insurance company organized in a state other than Missouri, shall be signed by an agent or broker licensed by the State of Missouri. Any certificate or other evidence of insurance, submitted to the County, shall be in a form acceptable to the County. In the case of policies written by companies organized in a state other than Missouri, the evidence of insurance submitted as authorized in the contract shall be signed by an agent or broker licensed by the State of Missouri. Nothing in this provision limits or waives the requirement that each insurance policy shall be issued by a company authorized to issue such insurance in Missouri. 107.14.5 All insurance hereinbefore specified shall be carried until all work required to be performed under the terms of the contract is satisfactorily completed as evidenced by the formal acceptance by the Director.
10/1/2018
107-8
Legal Relations and Responsibility to the Public
107.15 Third Party Liability. Neither St. Louis County nor the Contractor, by execution of the contract including these specifications, intends to create a right of action in a third party beneficiary except as specifically set out in these specifications and the contract. It is not intended by any required contractual liability in the contract or in these specifications that any third party beneficiary has a cause of action arising out of the condition of the project when completed in accordance with the plans and accepted by the Department. 107.16 Personal Liability of Public Officials. The Contractor and its surety shall indemnify and save the County and all of its officers, engineers, representatives, agents, and employees harmless from all suits, actions, including costs of defense, or claims of any character, name and description brought for or on account of any injuries or damages received or sustained by any persons or property, by or from the Contractor, or by or in consequence of any neglect in safeguarding the work, or through the use of unacceptable materials in constructing the roadway, or by or on account of any act or omission, neglect, or misconduct of the Contractor, or by or on account of any claims or amounts recovered for any infringement of patent, trademark or copyright, or from any claims or amounts arising or recovered under the Workmen's Compensation Law or any other law, by-law, ordinance, order, or decree. The County may retain from any monies due or to become due to the Contractor such sum or sums as shall be deemed necessary to protect the County's interest until such suits, action or actions, claim or claims for injuries or damages as aforesaid shall have been settled and suitable evidence to that effect furnished to the County. 107.17 Indemnifying Incorporated Cities, Towns, and Villages. Whenever the work performed lies within the corporate limits of any city, town or village, then and in that event, the Contractor and its surety shall also indemnify and save harmless such municipality or municipalities, and the officers, engineers, representatives, agents and employees thereof from all suits, action or claims of any character, name and description, brought for or on account of any injuries or damages received or sustained by any persons or property by or from said Contractor, or by or in consequence of any neglect in safeguarding the work, or by or on account of any act or omission, neglect, or misconduct of the Contractor. 107.18 Contractors Who Are Not Resident In Missouri. Any Contractor that is not a permanent resident of or domiciled in Missouri shall provide the County with proof of compliance with the Missouri "nonresident employers" financial assurance laws at Sections 285.230 through 285.234, RSMo, before the Contractor performs any work on a project. 107.18.1 A nonresident contractor who is a "transient employer" as that term is defined in Section 285.230.1, RSMo, and 12 CSR 10-2.017(1)(A), shall file with the County a photocopy of its current transient employer's certificate of registration issued by the Missouri Department of Revenue, before performing any work on a project. A nonresident contractor which is not classified by the Missouri Department of Revenue as a "transient employer" because it has properly registered with the Missouri Department of Revenue and the Missouri Division of Employment Security, and has filed and paid its Missouri state income taxes for more than 24 consecutive months, shall file with the County a photocopy of its certificate of registration, issued by the Missouri Department of Revenue, that it is not a "transient employer" before performing any work on a project.
10/1/2018
107-9
Legal Relations and Responsibility to the Public
107.18.2 The Contractor shall require a nonresident subcontractor to file with the County a photocopy of its current transient employer's or alternate certificate of registration, as issued by the Missouri Department of Revenue, before that subcontractor performs any work on a project. 107.18.3 Any nonresident contractor or subcontractor that fails to file the financial assurance forms with the Missouri Department of Revenue as required by Missouri law shall be prohibited from contracting for or performing labor on any project for a period of one year. 107.18.4 No direct payment will be made for compliance with Section 107.18.
10/1/2018
107-10
Legal Relations and Responsibility to the Public
Section 108
Prosecution and Progress
108.1 Subletting of Contract. 108.1.1 The Contractor shall not sublet, sell, transfer, assign, or otherwise dispose of the contract or contracts or any portion thereof, or of his right, title, or interest therein, without written consent of the Director. Requests for permission to sublet, assign, or otherwise dispose of any portion of the contract shall be in writing and accompanied by evidence that the organization which will perform the work is particularly experienced and equipped for such work. In case such consent is given, the Contractor will be permitted to sublet a portion thereof, but shall perform with his own organization, work amounting to not less than 50% of the total contract cost, except that any items designated in the contract as specialty items may be performed by subcontract and the contract value of any such specialty items so performed by subcontract may be deducted from the total contract cost before computing the amount or work required to be performed by the Contractor with his own organization. Consent to a subcontract shall not constitute the County’s endorsement of the qualifications of the subcontractor. 108.1.2 The value of the work sublet will be determined by multiplying the number of units of any contract item sublet by the unit price as set forth in the original contract or by a price agreed to by the Director where no unit price is included in the contract for the work sublet. Approval of a subcontract is not approval of the agreed unit prices in the subcontract. The subcontractor shall perform the work described in the subcontract agreement. No subcontracts, or transfer of contract, shall in any case release the Contractor of his liability under the contract and bonds. Consent to a subcontract shall not create a direct contractual relationship between the subcontractor and the County. 108.1.3 The Contractor shall furnish to the County a complete signed copy of the subcontract and all revisions upon request No second tier subcontracting will be permitted. 108.2 Notice to Proceed. The Notice to Proceed will stipulate the date the Contractor is expected to begin work. The Director will issue the Notice to Proceed by stipulating the date on the Notice of Award sent to all successful bidders, or on a separate form for this purpose. Prior to the stipulated date, the Contractor shall execute and file the prescribed number of copies of the contract and bond and shall furnish satisfactory evidence of having complied with insurance requirements. 108.3 Prosecution of Work. 108.3.1 The Contractor is expected to commence work not later than the date stipulated by the Notice to Proceed. If all contract requirements have been met as specified in Section 108.2 the Contractor may start work before the date stipulated by the Notice to Proceed providing he has notified the Director in writing at least three (3) days in advance of the date on which he expects to begin. 108.3.2 The Contractor shall continuously and diligently prosecute the work in such order and manner as will insure its completion within the specified time and shall be fully responsible for the prosecution and coordination of all work being performed under the contract by subcontractors.
7/1/2015
108-1
Prosecution and Progress
108.3.3 The work in progress shall receive the personal attention either of the Contractor or of a competent and reliable superintendent who shall have full and final authority to act for the Contractor. In case the Contractor delegates authority to a superintendent, he shall notify the Director in writing, stating the name of the person authorized to act as superintendent, and stating the name or names of the persons authorized to sign the various documents such as Weekly Report of Working Days, Change Order, Force Account Statement, Labor Payrolls, and any other documents that may be required during the progress of the work. If progress at any time is not in keeping with the intent of the contract, the Contractor shall take such steps as may be necessary to complete the work in the time and manner specified. 108.3.4 In contracts involving a joint venture, the joint venturers shall, prior to beginning any work on the contract, appoint and maintain a single representative delegated with full and final authority to act for the joint venture. The authority and obligations of this representative shall be those of the Contractor. The Director shall be notified in writing of the name of this representative and of any replacements. 108.4 Progress Schedules. The Contractor shall submit a progress schedule to the Engineer for review at least seven days prior to the pre-construction conference. The progress schedule shall be used to establish the construction operations and to monitor the progress of the work although the Engineer's determination of the then major operation or controlling item of work shall always prevail. The progress schedule shall be in the form specified in Section 108.4.1, unless the contract contains a different requirement. The progress schedule shall be based on the number of working days, calendar days or other increments as set forth in the contract that the Contractor expects to require in completing the project recognizing the capabilities of labor, equipment, arrangements for material, mobilization, shop drawing preparation and approvals, and other relevant items. If an electronic computer software program is used to generate the schedule, a disk containing the schedule files in the native format of the software program used to create the schedule shall accompany the initial and any revised schedules. The disk shall be labeled with the contract ID, county project name and number, date of revision, and the name of the software program used. The contractor will not be required to provide any copies of the software program. 108.4.1 Form and Contents of Progress Schedule. The progress schedule shall contain an activities schedule chart and written narrative which shall break down into detail the time in working days, calendar days or completion date involved in performing all construction activities for the duration of the project, and shall be in a suitable scale as to indicate the percentage of work scheduled for completion at any time. 108.4.1.1 The activities schedule chart shall contain: 1) A bar chart chronologically sequenced and to time scale showing the order, identity and duration of all construction prosecution and preparation activities and the planned starting date of each activity. 2) The durations represented by a bar shall note periods of planned non-work which exceed three consecutive calendar days and work planned during periods of normal seasonal shutdown or when certain activities are prevented by other provisions of the contract.
7/1/2015
108-2
Prosecution and Progress
108.4.1.2 The written narrative shall contain: 1) A description of activities so that work can be measured by working days, calendar days or completion date schedule, and activity dependencies are identified; 2) A description of each activity identifying the item and location of the work; 3) A description of the activities schedule chart indicating planned work days per week, days allowed for weather, holidays, number of shifts per day, number of worker hours per shift and major items of equipment to be used to perform each activity. 108.4.1.3 The activities schedule chart and written narrative shall also clearly outline the intended maintenance of traffic, work phasing provided by the contract and such other information as required by the contract or as deemed appropriate by the Engineer. 108.4.2 Preparation of Initial Schedule. The Contractor shall complete development of the initial activities schedule chart and written narrative and present a copy of each to the Engineer at least seven days prior to the pre-construction conference. 108.4.2.1 The construction time, as indicated by the activities schedule chart and written narrative, for the entire project or any milestone, shall not exceed the specified contract time. If any milestone date or contract completion date is exceeded in the schedule, time estimates on the activities schedule chart shall be revised. The controlling activity shall be clearly shown for each day of the schedule. A controlling activity will be defined as that part of a progress-controlling item or items shall be performed before the next progress-controlling item of work can be started. Following a review of the initial activities schedule chart and written narrative by the Engineer, the Engineer and Contractor shall meet for a joint review, correction, and adjustment of the schedule if required. 108.4.2.2 If necessary this process will be repeated. However, the schedule shall be finalized by the Contractor within seven days after request for correction and adjustment to the schedule. 108.4.3 Intent and Cost of Progress Schedules. The review by the Engineer of any progress schedule does not constitute a determination that it is reasonable, that following it will result in timely completion, or that deviation will result in a delayed completion. The progress schedule and any updates provided are not a part of the contract. If the schedule reflects a completion date different than specified in the contract, that does not void the date or working days specified in the contract. If any schedule reflects a completion time earlier than that specified in the contract, the Contractor specifically understands that no claim for additional contract time or compensation will lie against the County if the work is not completed by the earlier time shown on the schedule. It is the Contractor's responsibility to determine the most feasible order of work consistent with the requirements of the contract.
7/1/2015
108-3
Prosecution and Progress
108.4.3.1 revisions.
No direct payment will be made for furnishing progress schedules or
108.4.3.2 If the Contractor fails to comply with the requirement to supply an initial or any revised progress schedule or if the Engineer determines the original or any revised progress schedule does not provide the information required, the Engineer may withhold progress payments until a schedule complying with this section has been submitted and reviewed. 108.4.4 Revised Progress Schedules. The Contractor shall provide a revised progress schedule, which shall then become the current progress schedule: 1) When requested by the Engineer or required by the contract; 2) When departure from the existing progress schedule makes it apparent that the project will not be completed in the time provided in the contract; 3) When the Contractor determines that the progress schedule requires revision for any reason. 108.5 Labor, Methods, and Equipment. 108.5.1 The Contractor shall at all times employ sufficient labor, methods, and equipment for prosecuting the work to full completion in the manner and time required by the contract. 108.5.2 All workmen shall have sufficient skill and experience to properly perform the work assigned to them. The Director may demand the dismissal of any person employed by the Contractor in, about, or upon the work who engages in misconduct or is incompetent or negligent in the due-and-proper performance of assigned duties, or who neglects or refuses to comply with any proper directions given. Such person shall not again be employed thereon without the written consent of the Director. Should the Contractor continue to employ or re-employ any such person, the Director may suspend the work until the Contractor complies with such orders. 108.5.3 All equipment used on the work shall be of sufficient size and in such mechanical condition as to meet requirements of the work and to produce a satisfactory quality of work. The condition or use of equipment on any portion of the project shall not cause damage to the roadway, adjacent property, other highways, or injury to any person. 108.5.4 If the methods and equipment to be used by the Contractor in accomplishing the construction are not prescribed in the contract, the Contractor is free to use any methods or equipment that he demonstrates to the satisfaction of the Director that will accomplish the contract work in conformity with the requirements of the contract. The failure of the Engineer to object to contractor's equipment or methods shall never constitute agreement that the equipment or methods used are appropriate. 108.5.5 If the contract specifies that the construction be performed by the use of certain methods and equipment, such methods and equipment shall be used unless others are authorized by the Director. If the Contractor desires to use a method or type of equipment other than that specified in the contract, he may request authority from the Director to do so. The request shall be in writing and shall include a full description of the methods and 7/1/2015
108-4
Prosecution and Progress
equipment proposed to be used and an explanation of the reasons for desiring to make the change. If approval is given, it will be on the condition that the Contractor will be fully responsible for producing construction work in conformity with contract requirements. If, after trial use of the substituted methods or equipment, the Engineer determines that the work produced does not meet contract requirements, the Contractor shall discontinue the use of the substitute method or equipment and shall complete the remaining construction with the specified methods and equipment. The Contractor shall remove the deficient work and replace it with work of specified quality, or take such other corrective action as direct by the Engineer. Except as provided in Section 104, no change will be made in the basis of payment for the construction items involved or in contract time as a result of approving any method or equipment change. 108.5.6 Licensed Personnel. The Contractor and all subcontractors shall furnish evidence to the County that, with respect to the operations to be performed under this contract, they will employ licensed personnel (Licensed Master Plumber, Licensed Master Drainlayer, Licensed Electrician, etc.) in accordance with the provisions of the latest revision of County Ordinances providing for the registration of tradesmen for the various types of work involved. The Contractor and all subcontractors shall cause all workmen, for whom licensing is a requirement of work within St. Louis County, to have their respective licenses continued and extended throughout the life of the contract and until all claims thereunder have been settled. The Contractor and subcontractors may contact the St. Louis County Department of Public Works to determine the extent and type of registration and licensing required under each contract. No direct payment will be made for the cost of complying with this requirement. 108.5.7 Temporary Suspension of Work. The Director has authority to suspend work wholly or in part for such a period as he may deem necessary due to: the failure of the Contractor to correct conditions unsafe for the workmen or general public; when weather or other conditions are such that in the judgment of the Director the work may be done at a later time with advantage to the County; for failure to carry out orders; for conditions considered unsuitable for the prosecution of the work; for failure on the part of the Contractor to comply with any of the provisions of the contract; or for any other condition or reason deemed to be in the public interest. If it is necessary to stop work for an indefinite period, the Contractor shall store all materials in a manner that will protect them from damage and shall not unnecessarily obstruct traffic, shall take every precaution to prevent damage to or deterioration of work performed, and shall provide suitable erosion control and drainage of the roadway by opening ditches, shoulder drains, etc., and by placing temporary seeding and by erecting temporary structures where necessary. The Contractor may suspend work for reasonable cause upon the written approval of the Director. When all work except overseeding is completed, the Engineer may approve the Contractor's written request for a temporary suspension of work during the months June, July, October, or November. The workday count or liquidated damages shall not accrue during the period in which work is suspended by approval of the Director unless such suspension is due to the failure of the Contractor to comply with provisions of the contract. If work has been suspended, the Contractor shall notify the Director in writing at least 48 hours before resuming operations.
7/1/2015
108-5
Prosecution and Progress
108.6 Contract Time for Completion of the Work. 108.6.1 The time for the completion of the work is specified by calendar days, calendar date, or working days, and it is an essential part of the contract. The Contractor will not be entitled to any extension of contract time because of unsuitable weather conditions or contract plan changes unless suspension of the work for such conditions or contract plan changes were approved in writing by the Director. Time is an essential element of the contract, and is therefore important that the work be pursued vigorously to completion. 108.6.2 The Director may make allowance for time lost due to causes that he deems justification for extension of contract time. If the Contractor claims an extension of contract time on the grounds that he is unable to work due to causes beyond his control, written notice of intention to claim an extension of contract time on the above grounds shall be filed with the Director at the time the cause or causes occur. The claim shall be filed in writing within thirty (30) days after the claimed cause for the delay has ceased to exist and shall include a statement of the reasons for the delay, proof to establish the claim, and a statement of the number of days the Contractor was delayed. 108.6.3 Completion by Calendar Days or Calendar Date. Any computation of time by calendar days or calendar date will be based on the seasonal importance of days on the basis of a working day table on file in the office of the Division Manager, Construction. When extra or additional work is ordered by the Director, the Contractor will be allowed an extension of contract time based upon the working days tables and the ratio which the cost of such additional work bears to the contract price, unless it can definitely be established that the extra work was of such character that it required more time than is indicated by the money value. In such cases, the actual time required, as determined by the Director, may be allowed. 108.6.3.1 If the Notice to Proceed form is not issued within thirty-five (35) days after the award or the later date specified in the contract, due to any failure of the County, the Contractor will be given an extension of contract time equal to the number of calendar days after the thirty-fifth (35th) day or the later date specified in the contract, until the Notice to Proceed is effective. Such a delay in the effective date of the Notice to Proceed shall be an excusable, noncompensable delay. 108.6.4 Completion by Working Days. If the time for completion of the work is based upon working days, this time will be specified in the contract. A working day is defined as any day when, in the opinion of the Director, soil and weather conditions are such as would permit any then productive operation of the project for at least six (6) hours. If conditions are such as to stop work in less than six (6) hours, the day will not be counted as a working day. 108.6.4.1 December 15 to March 15, both dates inclusive, Saturdays, Sundays, and holidays recognized by the A.G.C. Highway Construction Building Trades will not be counted as working days. No more than one (1) working day will be charged on any one (1) calendar day.
7/1/2015
108-6
Prosecution and Progress
108.6.4.2 Working days to be charged under the contract will normally be taken from the standard forty (40) hour workweek, utilizing daylight hours, eight (8) hours per day, Monday through Friday. Work on Saturdays, Sundays, Holidays, during nighttime hours, or in excess of eight (8) hours per day, will only be permitted if specifically set out in the contract specifications or if approved by the Engineer. If approved, a working day will be charged. 108.6.4.2.1 The Contractor (including their subcontractors) shall submit a request for approval to the Engineer in writing at least four (4) days in advance of any nighttime work that they propose. A verbal request for approval to work shall be submitted to the Engineer at least forty-eight (48) hours in advance of any Saturday, Sunday, holiday work, or any work in excess of the standard eight (8) hour day that is proposed. The Engineer shall be free to reject the Contractors' request for the above work if, in his opinion, it does not benefit the traveling public. 108.6.4.3 The count of working days will start on the date the Contractor starts construction operations, or the authorization date in the Notice to Proceed, whichever is earlier. The Director will be the judge of the number of working days to be charged under the contract. In computing the working days charged against the Contractor in the execution of the work, allowance will be made for days that are not working days and for days during which work is suspended with the written approval of the Director. The Director may make allowance for working days lost due to causes he deems justifiable for the elimination of the count of working days. Utilities working within the project limits will not necessarily be considered a reason to not charge a workday. No allowance will be made for delay or suspension of the prosecution of the work due to fault of the Contractor. Each week the Director will give the Contractor written notice of the number of working days charged to the contract for the preceding week. Any objection by the Contractor to the number of working days so charged shall be made by letter or endorsement on the notice, within ten (10) days, setting forth his objections and specifying the reasons therefore, or those objections shall be forever waived and may not constitute the basis for an excusable or compensable delay. In the event the Contractor considers the utility work a hindrance to accomplishing at least six (6) hours of productive work, the Contractor shall submit in writing, to the Engineer, the effects the utility work has on the Contractor's current operations. 108.6.4.4 If it can be definitely established that Change Order work is of such character that it requires more time than provided by the contract, the appropriate number of working days will be added by the Change Order. 108.7 Liquidated Damages for Failure or Delay in Completing Work on Time. 108.7.1 If the Contractor or, in the case of default, the surety fail to complete the work within the time specified in the contract, or within such extra time as may be allowed in the manner set out in the preceding sections, a deduction of an amount as set out in the bid form will be made for each and every calendar or working day, as specified in the contract, that such contract remains uncompleted after the time allowed for the completion, except as modified in Section 108.7.1.1. The said amount set out in the bid is hereby agreed upon, not as a penalty, but as liquidated damages for loss to the County and the public, after the expiration of the time stipulated in the contract, and will be deducted from any money due the Contractor under the contract, and the Contractor and his surety shall be liable for any and all liquidated damages. Permitting the Contractor to continue and finish the work or any part 7/1/2015
108-7
Prosecution and Progress
of it after the expiration of the specified time, or after any extension of the time, shall in no way operate as a waiver on the part of the County or any of its rights under the contract. 108.7.1.1 When any project awarded separately or when all projects in a combination awarded as a single contract reach a stage of completion where they could be opened to uninterrupted traffic, liquidated damages will be charged against the Contractor only for those days which would qualify as working days. 108.7.1.2 A combination of one or more projects awarded as a single contract will be considered as one unit for the determination of liquidated damages. 108.7.1.3 Regardless of the method used to specify contract time for completion of the work, liquidated damages will not be charged as follows: 1) From December 15 through March 15, both dates inclusive; 2) For Saturdays, Sundays, and holidays recognized by the A.G.C. Highway Construction Building Trades; 3) During any twenty-one (21) day period of the sod maintenance period specified in Section 803.3.3, if such maintenance is the only work remaining and the Contractor can perform the maintenance without inconvenience to the traveling public; 4) During the final fifteen (15) consecutive day test period for traffic signal systems, provided all other work has been completed. 108.7.2 The Contractor shall be liable for liquidated damages chargeable under the contract when the work is being completed by the County by reason of default of the contract unless the delay is due to the negligence of the County. A delay in any part of the work or in the final completion of the project caused by the County or its agents shall not void the provisions of the contract as to liquidated damages. Any such delay by the County or its agents will be compensated for only by the extension of contract time. The County will not be required to file a claim or counterclaim under any other provision, to assess or retain liquidated damages. 108.7.3 The Contractor and surety shall be liable for liquidated damages chargeable under the contract when the work is completed after default of the contract unless the delay is caused by the County. A delay in the work or the final completion of the project caused by the County shall not void the provisions of the contract as to liquidated damages and will be considered an excusable, noncompensable delay. 108.7.4 Signal and Lighting Malfunctions. If the Engineer invokes the option for repair of items under Division 900 to have County personnel or a third party correct a lighting, signal or sign lighting-malfunction, the Contractor will be charged for the service. If County personnel make the correction, the charge will be computed as 5 times the cost for all replacement parts, equipment rental, salaries, and fringe benefits. If a third party makes the correction the Contractor will be charged 1.2 times the charges billed the County by the third party. However, in no case will the charge be less than $100.
7/1/2015
108-8
Prosecution and Progress
108.8 Default and Termination of Contract. The Director may give the Contractor and surety written notice specifying the delay, neglect, or default and the action to be taken by them if the Contractor: 1)
Fails to begin the work by the authorization dated in the Notice to Proceed;
2)
Fails to perform the work with sufficient workmen and equipment or with sufficient materials to insure the prompt completion of work;
3)
Fails to perform the work in accordance with the contract requirements, or neglects or refuses to remove and replace rejected material or unacceptable work;
4)
Discontinues the prosecution of the work;
5)
Fails to resume work that has been discontinued within a reasonable time after notice to do so;
6)
Becomes insolvent, is declared bankrupt, or commits any act of bankruptcy or insolvency;
7)
Allows any final judgment to remain unsatisfied;
8)
Makes an assignment for the benefit of creditors;
9)
Fails to comply with contract requirements regarding prevailing wage payments, DBE or EEO requirements;
10)
Is a party to fraud.
108.8.1 Completion of Work. The Engineer will give notice in writing to the Contractor and surety of the condition described in Section 108.8, and advise them of the actions required for remedy. If the Contractor does not proceed to remedy the condition within ten (10) calendar days of receipt of this notice, the Engineer may declare the Contractor in default. The declaration of default will be made in writing to the Contractor and the surety. If within ten (10) days after receipt of the declaration of default, the Contractor does not proceed to remedy, to the satisfaction of the Director, the fault specified in said notice, or the surety does not proceed to take over the work for completion under the direction of the Engineer, the Director has full power and authority, without impairing the obligation of the contract or the bond, to: 1) Take over the completion of the work; 2) To appropriate or use any or all material and equipment on ground that is suitable and acceptable; 3) To enter into agreements with others; 4) To use other methods as in his judgment may be required for the completion of the contract in an acceptable manner.
7/1/2015
108-9
Prosecution and Progress
108.8.2 Liability for Costs. The Contractor and his surety shall be liable for all costs and expenses incurred by the County in completing the work, and also for all liquidated damages in conformity with the contract. The Contractor and surety are obligated to comply with all change orders and directives of the Engineer to the same extent, and for the same compensation (if any), as the Contractor would have been in the absence of default. If the sum of such liquidated damages and the expense so incurred by the County is less than the sum that would have been payable under the contract if it had been completed by the Contractor, the Contractor or his surety shall be entitled to receive the difference. If the sum of such expense and such liquidated damages exceeds the sum which would have been payable under the contract, the Contractor and his surety shall be liable and shall pay to the County the amount of such excess. This provision shall apply regardless of whether the surety or the County completes the contract work. The Contractor and surety shall solely be liable for the costs and expenses of a completing contractor, laborers, and suppliers with which either has contracted. 108.8.3 If it is determined after termination of the Contractor's right to proceed that the Contractor was not in default, the rights and obligations of the parties will be the same as if the termination had been issued for the convenience of the County under Section 108.9. Sums to which a contractor may be entitled as a result of the contract termination will be limited to amounts determined under Section 108.9. 108.8.4 Sureties' Continued Acceptability. A surety failing to proceed within ten (10) days after the written declaration of default by the Engineer under Section 108.8 may be required to show cause to the County why it should continue to be accepted for future bonds. 108.9 Cancellation of Contract. The Director shall have the right to cancel the contract upon giving thirty (30) days' notice in writing to the Contractor if: 1) Available funds are insufficient for the completion of the work; 2) The Director finds a national emergency exists which creates a shortage of materials, labor, or equipment, and that such emergency will probably continue for an unreasonable length of time, by reason of which the Contractor will be unable to proceed with the contract; 3) The Director determines that a termination is in the County's best interest. 108.9.1 Submittals and Procedures. After receipt of a notice of termination, the Contractor shall immediately proceed with the following obligations: 1) Stop work as specified in the notice; 2) Place no further subcontracts or orders for material, supplies, services or facilities, except as necessary to complete the portion of the contract that has not been terminated; 3) Terminate all subcontracts to the extent they relate to the work terminated; 4) Settle with subcontractors and suppliers all outstanding liabilities arising from the termination; 7/1/2015
108-10
Prosecution and Progress
5) Transfer title and deliver to the County, work in progress, completed work, supplies and other material produced or acquired for the work terminated, and completed or partially completed plans, drawings, information and other property that, if the contract had been completed, would be required to be furnished to the County; 6) Complete performance of the work not terminated; 7) Take any action that the Engineer directs to protect and preserve contract related property that is in the possession of the Contractor in which the County has or may acquire an interest. 108.9.1.1 Payment for Completed Work. If the contract, or any portion thereof, is canceled and the Contractor released before all items of work included in the contract have been completed, payment will be made at contract unit bid prices for the actual work performed, including any retained percentage. The Contractor will be reimbursed by the County for such expenditures as, in the judgment of the Director, are not otherwise compensated. Claims for loss of anticipated profits will not be considered. 108.9.2 Payment for Materials. If the contract, or any portion thereof, is canceled, materials obtained by the Contractor for authorized work, which have been inspected, tested, and accepted by the Engineer, but not incorporated in the work, and which have been properly stored and maintained, will be purchased from the Contractor at actual cost as shown by receipted bills or other proper evidence of actual cost at such points of delivery as may be designated by the Director. 108.9.2.1 Settlement Provisions. When the County orders termination of all or a part of the contract effective on a certain date, completed items of work as of that date will be paid for at the contract price. Payment for partially completed work will be made either at agreed prices or under the provisions below. When items are eliminated in their entirety by such termination, the Contractor will be paid for actual work done and actual costs incurred before notification, including mobilization of equipment or material. 108.9.2.2 Additional Costs. Within sixty (60) days of the effective termination date, the Contractor shall submit any request for additional damages or costs not covered in Section 108.9.2.1 or elsewhere in the contract. Such request may include only such cost items as: mobilization; overhead expenses proven to be attributable to the project or the part terminated and not paid for under work not terminated; subcontractor costs not otherwise paid for; actual idle equipment and idle labor cost only for any time the work is stopped in advance of termination date; guaranteed payments for private land usage as part of the original contract; and any other actual cost for which the Contractor feels reimbursement should be made. 108.9.2.3 Anticipated profits, including anticipated earnings on usage of owned equipment, and impact, delay or other direct or indirect costs resulting from this termination which are not expressly authorized, will not be compensable as part of any settlement.
7/1/2015
108-11
Prosecution and Progress
108.9.2.4 The Contractor and the Engineer may agree upon the whole or any part of the amount to be paid because of the termination. The amount may include a reasonable allowance for profit on work done. The agreed amount may not exceed the total contract price as reduced by the amount of payments previously made and the contract price of work not terminated. The contract will be amended and the Contractor paid the agreed amount. 108.9.2.5 Additional Cost Review. If the Contractor and the Engineer fail to agree on the whole amount to be paid the Contractor because of the termination of work, the County will pay the amounts determined as follows, but without duplication of any amounts agreed upon in Section 108.9.2.1: 1) For contract work performed before the effective date of termination, the total (without duplication of any items) of: a) The actual cost of work performed; b) The cost of settling and paying termination settlements under terminated subcontracts that are properly chargeable to the terminated portion of the contract if not included in Section 108.9.2.1; c) A sum for profit on the actual cost of work performed as determined by the Engineer to be fair and reasonable. The Engineer will allow no profit under this section if the Contractor's costs incurred on work performed exceed the contract prices paid; 2) The reasonable costs to settle the work terminated, including: a) Internal accounting and clerical expenses reasonably necessary for the preparation of termination settlement proposals and support data, including expenses for termination and settlement of subcontracts; b) Storage, transportation, and other costs incurred, reasonably necessary, for the preservation, protection or disposition of the termination inventory; 3) For normal spoilage and to the extent that the Engineer expressly accepts the risk of loss. The Engineer will exclude the fair value of property that is destroyed, lost, stolen, or damaged so as to become undeliverable to the County or to the buyer. 108.9.2.6 In arriving at the amount due the Contractor under this clause, there will be deducted: 1) All advanced payments for mobilization, services or facilities, or other payments to the Contractor under the terminated portion of the contract; 2) Any claim that the County has against the Contractor under the contract;
7/1/2015
108-12
Prosecution and Progress
3) The agreed price for or the proceeds from the sale of material, supplies, or other items acquired and sold by the Contractor, and not recovered by or credited to the County; 4) Any costs saved as a result of the termination. 108.9.2.7 If the termination is partial, the Contractor may file a proposal with the Engineer for an equitable adjustment of the price(s) of the continued portion of the contract. The Engineer will make any equitable adjustment agreed upon. Any proposal for an equitable adjustment under this clause shall be requested within sixty (60) days from the effective date of termination unless extended in writing by the Engineer. 108.9.2.8 The Contractor shall maintain and make available all project cost records to the Engineer for audit to the extent necessary to determine the validity and amount for each item requested. This includes, but is not limited to, all items described in Section 105.16.8. These records and documents shall be made available to the Engineer at the Contractor's office, at all reasonable times, without any direct charge. If approved by the Engineer, photographs, microphotographs, or other authentic reproductions may be maintained instead of original records and documents. 108.9.3 Effect of Termination. Termination of the contract or portion thereof shall not relieve the Contractor of contractual responsibilities for the work completed, nor shall it relieve the surety of its obligation for and concerning that part of the contract not terminated or any just claim arising out of the work performed. 108.10 Notice to Contractor and Surety. Notice to the Contractor, in case of default or cancellation of the contract, shall be deemed to be served when delivered to the person in charge of any office used by the Contractor, his representative at or near the work, or by certified mail addressed to the Contractor at his last known place of business. Notice to the surety shall be deemed served when mailed to the surety's address as shown in the contract by certified mail. 108.11 Termination of Contract for Misconduct. For the purposes of the following provision, "state" includes the State of Missouri and any other state, commonwealth, or territory of the United States. The County may declare the Contractor to be in default on the contract at any time after the contract is awarded and prior to final acceptance of the project, for any one or more of the acts set forth below, if it occurred during the life of the project or within the seven (7) year period immediately preceding the date the contract was awarded, on any County or other federal, state, or local government or private contract: 1) Receiving or giving any currency or item of value in order to influence the competitive bidding process or the award of a competitively-bid contract; bid-rigging, collusion or any similar act or communication with any person or firm in restraint of competitive bidding on a contract; or to obtain or grant an advantage in obtaining the award of such a contract; 2) Fraud, dishonesty, or a material misrepresentation or omission of fact in any request for proposal or bid submitted to a private firm or governmental agency, or in any contract documents submitted to such a firm or agency;
7/1/2015
108-13
Prosecution and Progress
3) Making or receiving kickbacks or payments of currency or any item of value in order to obtain or retain any contract or payment thereunder, or in return for an agreement to make or for the making of any false statements or material misrepresentations or omissions of fact to any federal, state, or local governmental agency or private firm relevant to contract compliance; 4) Suspension, debarment, or other disqualification of the Contractor, or determination that the Contractor is not a responsible bidder for public contracting purposes, by any federal, state, or local governmental agency, regardless of whether the sanction is still in effect at the time of the bid or contract award by the County; 5) Conviction or adjudication of guilt in any criminal proceeding in a federal or state court, regardless of whether sentence was suspended or executed, for any act an element of which is fraud, dishonesty, or moral turpitude, which conduct is relevant to a determination of the responsibility of the Contractor; 6) Commission of any act or failure to act, such that the Contractor is subject to the determination that it is not a responsible bidder under the contract or under applicable Missouri or federal law. 108.11.1 The acts, omissions, and liabilities of persons or firms affiliated with the Contractor or of persons who are principals of the Contractor are those of the Contractor, unless the circumstances clearly negate that conclusion. Persons or firms are "affiliates" of each other if, directly or indirectly, either one controls or has the power to control the other or a third person controls or has the power to control both. Examples of control include, but are not limited to: interlocking management or ownership identity of interests among family members; shared facilities and equipment; common use of employees on projects; or a new business entity organized following the determination of ineligibility or non-responsibility of a person or firm which has the same or similar management, ownership, or principal employees as the ineligible person. A "principal" is an officer, director, owner, partner, or other natural person within a firm with primary management, supervisory, or contracting responsibilities. 108.11.2 The County will not declare the Contractor to be in default of the contract pursuant to this section if the Contractor made a full and complete disclosure of the facts and circumstances described in Section 108.11 to the County in the bid or in writings submitted with the bid and the County did not determine the Contractor to be non-responsible prior to making the award of the contract. The County is not precluded from declaring the Contractor in default under this section if the information provided by the Contractor did not constitute a full and complete disclosure of all facts and circumstances pertinent to the issue of the responsibility and integrity of the Contractor. 108.11.3 The County, upon a finding of default pursuant to this section, may terminate the contract immediately or at the occurrence of some specific date or event in the future, prior to project completion, upon delivery of a written notice to the Contractor by actual service or by certified mail (return receipt requested), sent to the address of record of the Contractor. Effective with the contract termination date, the Contractor shall discontinue further work on the project and shall instruct subcontractors and suppliers to do the same, other than to remove promptly their personnel, equipment, and supplies from the project site. The Contractor shall be paid for all completed work to that date at the contract price. At the option of the Engineer, the County may assume the possession and cost of any specially 7/1/2015
108-14
Prosecution and Progress
fabricated material or supplies for the project that have been ordered prior to notice of termination but have not been installed on the date of termination. The Contractor and surety shall be liable to the County for all costs and expenses incurred by the County in completing the project (including but not limited to the County's costs to redraft and rebid the project), which costs and expenses exceed the total of the Contractor's bid price plus additional expenses allowed by the Engineer during the Contractor's work on the project, less the amount paid the Contractor by the County. The County shall not be liable for damages for breach of contract or in any other action or respect for declaring a default if one exists under this section and for terminating the contract prior to completion by the Contractor. 108.11.4 The County may only exercise its right to declare a default of and terminate the contract under this section when it determines that the act of default described in this provision made the Contractor non-responsible or ineligible for the award of this or other current or future County contracts. The satisfactory prosecution and progress toward project completion by the Contractor is no justification or defense to a County declaration of default on and termination of the contract under this section. 108.11.5 The Contractor shall file any claim it has against the County within sixty (60) days after the effective date of termination, pursuant to the procedures of Section 105.16. The County will file any claim it has against the Contractor or surety within sixty (60) days of the date of final acceptance of the project, whether or not it is renumbered or redesigned, and whether completed by the surety, by a successor Contractor retained by the County, or by the County itself. Any County claim will be filed pursuant to the procedures of Section 105.16. 108.12 Determination of Compensation and Contract Time Extension for Excusable, Noncompensable and Compensable Delays. An extension of the contract time may be granted under the following conditions provided documentation has been given to the Engineer under Sections 108.12.3 through 108.12.5. Strict adherence to the provisions of this section is a condition precedent to the Contractor's entitlement to an extension of contract time or compensation because of project delays. 108.12.1 Excusable or Noncompensable Delay. Contract time allowed for the performance of the work may be extended for delays caused by acts of God, acts of the public enemy, fires, floods, earthquakes, epidemics, quarantine restrictions, strikes, freight embargoes, unusually severe weather, or other delays not caused by the Contractor's fault or negligence. 108.12.2 Compensable Delay. Contract time allowed for performance of the work may be extended for delays caused by the County. The Contractor may be granted an extension of time and additional compensation only as provided by Section 109.7. 108.12.3 Notification of Delay. Within seven (7) days of the occurrence of a delay to the prosecution of any phase of the work, the Contractor shall notify the Engineer in writing of such a delay and indicate that a request for delay consideration will be filed. Delay costs incurred prior to notifying the Engineer that operations have been delayed are noncompensable.
7/1/2015
108-15
Prosecution and Progress
108.12.4 Procedures Following a Delay. The Contractor shall keep daily records of all non-salaried labor, material costs, and equipment expenses for all operations that are affected by the delay. 108.12.4.1 The Contractor shall maintain a daily record of each operation affected by the delay and the station location of the operations affected. Daily records of the operations and stations will also be maintained by the Engineer. Each Monday, the Contractor shall compare the previous week's daily records with the records kept by the Engineer. The Contractor shall also prepare and submit written reports to the Engineer each Monday containing the following information: 1) Number of days behind schedule due to the delay; 2) A summary of all operations that have been delayed or will be delayed; 3) In the case of a claimed compensable delay, the Contractor shall explain how the County's act or omission delayed each operation and estimate the amount of time required to complete the project; 4) Itemized all extra costs incurred, including: a) How the extra costs relate to the delay and how they are being calculated and measured; b) The identification of all non-salaried project employees for whom costs are being compiled; c) A summary of time charges for equipment, identified by manufacturer's year and model and the Contractor's number, for which costs are being compiled. 108.12.4.2 The Contractor shall provide written notice to the Engineer within seven (7) days of the results of the comparison of the detailed reports performed each Monday and define any disagreements between specific records. 108.12.4.3 Failure to meet to review the Engineer's records or to report disagreements between the records will be considered conclusive evidence that the Engineer's records are accurate. 108.12.5 Procedures Following Completion of Work Allegedly Delayed. Within the earlier of fifteen (15) days of completion of any phase of work allegedly delayed, or of project completion, the Contractor shall submit a report to the Engineer containing the following information: 1) A description of the operations that were delayed and the documentation and explanation of the reason for the delay, including all reports prepared by or for the Contractor; 2) An as-built chart or other graphic depiction of how the operations were delayed based on the Contractor's most recent progress schedule prior to the delay event;
7/1/2015
108-16
Prosecution and Progress
3) An item-by-item measurement and explanation of extra costs requested for reimbursement due to the delay. 108.12.5.1 All costs shown in the report submitted to the Engineer shall be directly caused by the delay event and reflect the actual costs incurred as shown on the Contractor's project cost records kept in the ordinary course of business. 108.12.5.2 The Engineer will review the Contractor's submission and any reports prepared for the Engineer. A written decision will be provided to the Contractor within sixty (60) days of the receipt of the Contractor's submission. This time may be extended if the Engineer requires additional information. 108.12.5.3 In the case of compensable delays, if the Engineer determines that the County is responsible for delays to the Contractor's operations, the Engineer's written decision will reflect the nature and extent of any resulting, equitable adjustment to the contract as provided in Sections 109.4 and 109.10. 108.13 Suspension of Work Ordered by the Engineer. 108.13.1 If the performance of all or any portion of the work is suspended or delayed by the Engineer for an unreasonable period of time (not originally anticipated, customary or inherent to the construction industry) and the Contractor believes that additional compensation or contract time is due as a result of such suspension or delay, the Contractor shall submit to the Engineer, in writing, a request for adjustment within seven (7) days of receipt of the notice to resume work. The request shall set forth the reasons and support for such adjustment. The procedures of Sections 108.12.4 and 108.12.5 shall apply to requests for additional compensation or time claimed by the Contractor as a result of a suspension of work ordered by the Engineer under this section. 108.13.2 Upon receipt, the Engineer will evaluate the Contractor's request. If the Engineer agrees that the cost or time required for the performance of the contract has increased as a result of such suspension and the suspension was caused by conditions beyond the control of and not the fault of the Contractor, suppliers, or subcontractors, and not caused by weather, the Engineer will make an adjustment (excluding profit) and modify the contract in writing accordingly. The Engineer will notify the Contractor of the Engineer's determination whether or not an adjustment of the contract is warranted. 108.13.3 No contract adjustment will be allowed unless the Contractor has submitted the request for adjustment within the time prescribed. 108.13.4 No contract adjustment will be allowed under this clause to the extent that performance would have been suspended or delayed by any other cause, or an adjustment is provided for or excluded under any other term or condition of the contract.
7/1/2015
108-17
Prosecution and Progress
(This Page Intentionally Left Blank)
7/1/2015
108-18
Prosecution and Progress
Section 109
Measurement and Payment
109.1 Measurement of Quantities. All work completed under the contract will be measured by the Engineer according to United States standard measure or will be paid for on contract quantity basis as set out elsewhere in these specifications. When the quantity of any item that is to be paid for on a contract quantity basis is found to include errors, or when an authorized revision of the plan is made, the quantity will be corrected before making final payment. The method of measurement and computations to be used in determination of quantities of materials furnished and of work performed under the contract will be those methods generally recognized as conforming to good engineering practice. 109.2 Scope of Payment. 109.2.1 Compensation. The Contractor shall receive and accept the compensation provided for in the contract as full payment for: furnishing all materials, labor, tools, and equipment, and for performing all work contemplated and embraced under the contract, in a complete and acceptable manner in accordance with the plans and specifications; for all loss or damage arising out of the nature of the work or from the action of the elements; for all expenses incurred by, or in consequence of, the suspension of discontinuance of the said prosecution of the work as herein specified, or from any unforeseen difficulties or obstructions which may arise or be encountered during the prosecution of the work as herein specified; and for all risks of every description connected with the prosecution of the work until its final acceptance by the Director. 109.2.2 Completed Improvements. The payment of any current or final estimate or the acceptance of any portion of the work, as provided in the specifications, shall, in no way or in no degree, affect the obligation of the Contractor, who, at his own cost and expense, shall repair, correct, renew, or replace any defects or imperfections in the construction, strength, or quality of materials used in or about the construction of the work under the contract, and said payment shall in no way affect the Contractor's responsibility for all damages due or attributable to such defects or imperfections which may be discovered before the final acceptance of the whole work. The Engineer shall be the judge of such defects or imperfections. 109.3 Compensation for Altered Quantities. The Engineer reserves the right to make changes in plan details that may vary the accepted quantities from those shown on the Itemized Bid. Such revisions shall include, but not be limited to, necessary or desirable variations in the extent of commercial entrance, driveway, and parking lot reconstruction in order to properly join the existing improvements to the new work. 109.3.1 The Contractor shall accept, as payment in full, payment at the original unit prices bid for the accepted quantities of work done. No allowance will be made for any increased cost, except as provided in Sections 104.2, 104.3 and 108.9.
9/1/2023
109-1
Measurement and Payment
109.4 Differing Site Conditions and Changes in Work. Differing site conditions and changes in the work performed in accordance with the requirements and provisions of Section 104.3 will be paid for at the unit prices or lump sum stipulated in the order authorizing the work, or the Director may require the Contractor to do such work on a force account basis, to be compensated in the following manner: 109.4.1 Contract Unit Prices. Where contract unit prices exist, they shall always be applied, without deviation, unless the effect of a differing site condition or a significant change in the character of the work requires an equitable adjustment to a contract unit price under the terms of this contract. Equitable adjustments shall exclude any anticipated profits. 109.4.2 Unit Prices or Lump Sum Amount Agreed Upon in the Change Order Authorizing the Work. Where contract unit prices do not exist for the work to be done, the parties may agree to such unit prices or a lump sum price for that work. Where an equitable adjustment to a unit price is required, the parties may agree to the adjustment to be made to the contract unit price, excluding any anticipated profits. Prior to agreeing upon such unit or lump sum prices, the Engineer may demand from the Contractor any information that the Engineer is authorized to require under Sections 104.4 and 104.5.1. 109.4.3 Equitable Adjustment. In all other cases, except work ordered to be performed under force account, the Engineer will make an equitable adjustment to or determination of the affected contract prices for the work, based upon the Contractor's actual costs to perform the work. This determination will be consistent with the Contractor's other proven costs to perform the contract work, as shown in the Contractor's bid computations and project cost records, produced and kept in the ordinary course of business. Prior to making the equitable adjustment, the Engineer may demand from the Contractor any information relevant to that determination including the information authorized under Sections 104.4 and 104.5.1. 109.4.4 Force Account. Force account as computed under Section 109.5 applies only when expressly directed in writing by the Engineer and in no other instance for any determination of additional compensation for any work performed on the project, whether claimed under the contract, for breach of the contract, for representations by which the contract was induced, or upon any other basis. 109.4.5 Fixed Cost Items. The following fixed prices shall be used when referenced in the specifications and authorized by the Engineer: Fixed Price Table Section 203.7.3 203.7.3 206.6.2 206.6.3 206.6.3.2 206.6.3.3 206.6.3.4 508.10.8.2 508.10.8.3 508.10.8.5 9/1/2023
Item No. 203-10.00 204-60.10 206-45.05 206-10.01 206-20.03 206-30.01 201-20.14 502-90.00 604-20.30
Item of Work Class "A" Excavation Embankment in Place Drilling Test Hole Selected Granular Backfill Class 1 Excavation in Rock Class 2 Excavation in Rock Class 4 Excavation in Rock Tree Removal Expansion Joint Filler Strip Adjusting Manhole to Grade
109-2
Unit Cubic Yard Cubic Yard Linear Foot Cubic Yard Cubic Yard Cubic Yard Cubic Yard Inch Linear Foot Each
Fixed Price $75 $50 $25 $90 $240 $320 $250 $60 $5 $500
Measurement and Payment
508.10.8.6 604-90.52 508.10.8.7 604-21.95 508.50.5 412-20.00 604.35.2
726-90.10
608.5.3
608-60.99
Replace Inlet Sill Replace Precast Inlet Top Sidewalk Grinding MSD Class "A" Concrete for Encasement Truncated Domes for Curb Ramps (Retrofit Construction)
Each Each Each
$500 $750 $100
Cubic Yard Square Foot
$475
609.15
609-10.93
Remove and Replace Curb and Gutter (Various Widths), Vertical/Mountable
Linear Foot
$70
609.25
609-20.91
Remove and Replace Integral Curb (Over 6" Height)
Linear Foot
$50
608.5.2
608-60.96
Remove and Replace Concrete Sidewalk (6" Thick)
Square Yard
$125
608.5.2
608-50.07
Remove and Replace Paved Driveway Approach (7")
Square Yard
$150
$65
109.5 Force Account. 109.5.1 Labor. For all lead workers and laborers, the Contractor will receive the rate of wage actually paid for each hour that said lead workers and laborers are engaged in force account work. The Engineer shall approve all lead workers and laborers prior to commencement of the force account work. 109.5.1.1 The Contractor will receive the actual costs paid to, or in behalf of, employees by reason of subsistence and travel allowances, health and welfare benefits, pension fund benefits, or other benefits, if such amounts are required by collective bargaining agreements or other employment contracts generally applicable to the classes of labor employed on the work.
9/1/2023
109-3
Measurement and Payment
109 5.1.2 An amount equal to forty (40) percent (ten (10) percent profit and thirty (30) percent overhead) of the sum of the above items will also be paid the Contractor. 109.5.2 Bond, Insurance, and Tax. No separate payment will be made for property damage, liability, and workmen's compensation insurance premiums, or for unemployment insurance contributions or social security taxes on the force account work. Compensation for these costs shall be considered as fully covered by the payment allowed under Section 109.5.1.2. 109.5.3 Materials. For materials accepted by the Engineer and used, the Contractor will receive the actual cost of such materials delivered on the work, including transportation charges paid by the Contractor (exclusive of machinery rentals as hereinafter set forth), to which cost twenty (20) percent (five (5) percent for profit and fifteen (15) percent for overhead) will be added. For all material used in connection with, but not entering permanently into the work, reasonable depreciation will be allowed. 109.5.4 Equipment. For only that Contractor owned equipment necessary to accomplish the force account work, including all fuel and lubricants, tires, and repairs, the Contractor will be allowed an hourly rate equal to the monthly rental rate divided by 176 hours, as set out in the Rental Rate Blue Book for Construction Equipment on file in the office of the Director at the time the work is begun. The allowed rates will be the rate adjustment factor multiplied by the bare hourly rates multiplied by the regional adjustment factor, plus the estimated operating cost per hour. The allowed time will be the actual operating time on the work. For the time required to move the equipment to and from the site of the work and any authorized standby time, the rate will be fifty (50) percent of the hourly rate after the actual operating costs have been deducted. All allowed time shall fall within the authorized working hours for such extra work. No payment will be allowed for time elapsed while equipment is broken down or being replaced. The hourly rental rates will apply only to equipment that is already on the job. If the actual unit of equipment to be used is not listed in the schedule, the rate listed for similar equipment with the approximate same initial cost shall be used. Equipment to be used and all prices shall be agreed upon in writing before such equipment is used. An amount equal to twenty (20) percent (five (5) percent profit and fifteen (15) percent overhead) of the sum of these items will also be paid the Contractor. 109.5.4.1 Whenever it is necessary for the Contractor to rent equipment, the rental and transportation costs of the equipment plus five (5) percent for overhead will be paid. In no case shall the rental rates exceed those of established distributors or equipment rental agencies in and around St. Louis County. All prices shall be agreed upon in writing before such equipment is used. 109.5.5 Miscellaneous. No additional allowance will be made for general superintendence, the use of small tools, or other costs for which no specific allowance is herein provided. Job site and home office overhead expenses shall be considered fully compensated by the percentage additions to costs provided in Sections 109.5.1 through 109.5.6.
9/1/2023
109-4
Measurement and Payment
109.5.6 Subcontracted Work. For administration and all overhead costs in connection with approved subcontract work, the Contractor will receive an amount equal to five (5) percent of the actual cost of the subcontracted work. 109.5.6.1 The Engineer has authority to require alterations in the equipment and labor force assigned to force account work, to limit authorization of overtime work to that normally used on the project for work of similar nature or to require overtime work when an emergency exists, and to require the cessation of force account work when adverse conditions seriously limit productivity. 109.5.7 Statements. No payment will be made for work performed on a force account basis until the Contractor has furnished the Engineer with duplicate itemized statements of the cost of such force account work detailed as follows: 1) Name, classification, date, daily hours, total hours, rate, and extension for each laborer and foreman; 2) Designation, dates, daily hours, total hours, rental rate, and extension for each unit of machinery and equipment; 3) Quantities of materials, prices, and extensions; 4) Transportation of materials; 5) Cost of property damage, liability and worker's compensation insurance premiums, unemployment insurance contributions and social security. 109.5.7.1 Statements shall be accompanied and supported by receipted invoices for all rental equipment, materials used, and transportation charges. 109.5.7.2 If materials used on the force account work were not specifically purchased for such work but were taken from the Contractor's stock, then, in lieu of the invoices, the Contractor shall furnish an affidavit certifying that such materials were from Contractor's stock, that the quantity claimed was actually used, and that the price and transportation claimed represent the actual cost to the Contractor. 109.5.8 Compensation. Each day the Contractor's representative and the Engineer shall compare records of the cost of work done as ordered on a force account basis. Two copies of these records will be made by the Engineer on forms provided by the Director, and they shall be signed at the end of each day by both the Engineer and the Contractor, one copy to be retained by the Engineer and one given to the Contractor. The total payment made as provided in Section 109.4 shall constitute full compensation for such work.
9/1/2023
109-5
Measurement and Payment
109.6 Partial and Final Payments. 109.6.1 The Engineer will make progress payment estimates in writing for the materials in place and the work performed during the pay interval and the value thereof at the contract unit bid prices. When a total of $25,000 is completed in the first fifteen (15) days of a monthly period, a bi-monthly payment estimate will be prepared. Otherwise, payment estimates will be made on a monthly basis providing a minimum of $500 has been completed. 109.6.2 Material Allowance. The Engineer may, in any payment estimate, include the value of any nonperishable material which will be finally incorporated in the complete work. The material shall be in conformity with the plans and specifications in the contract, and shall not have been used at the time of such estimate. The value of such materials in a single submission from one supplier shall be no less than $10,000. The materials shall be delivered to the project or other location that is approved by the Engineer. No partial payment will be made on living or perishable plant materials until planted. Any storage area not within the right-of-way is to be leased at the Contractor's expense with provision for right of entry by the Engineer during the period of storage. Invoices for material payments shall be submitted to the Director at least four (4) days prior to the estimate date and receipted invoices for all material payments previously allowed on the estimate shall be submitted to the Director within forty-two (42) days of the date of the estimate on which material allowance was made, or such material allowance will be deducted from future payments. The amounts paid for such material shall go to reduce the amount of other partial or final payments due the Contractor for the work performed as the materials are fabricated or incorporated in the completed work. 109.6.3 From the total amount of work items and material allowances of each estimate, there shall be deducted five (5) percent to be retained until after the final completion of the work and after final quantities have been computed. If computations have reached the point where final quantities have been closely estimated, a portion of the retained percentage may be paid to the Contractor providing, however, that at least one (1) percent of the contract price shall be retained until final payment is authorized by the Director. 109.6.4 The Director shall determine whether the retained percentage shall be reduced below five (5) percent, but prior to full release the Contractor shall file with the Director: 1) An affidavit, or form prescribed by the Director, to the effect that all payments have been made and all claims have been released for all materials, labor, and other items covered by the contract bond, and 2) The written consent of the surety to such payment, and 3) Any other documents which may be required by the contract. The net amount will be certified for payment except that no current payments for less than $500 will be made on a single project or on a group of projects awarded on a combination bid, unless the total amount of the contract is less than $500.
9/1/2023
109-6
Measurement and Payment
109.6.5 Payment for non-perishable material shall pass title to same to the County, but the responsibility for loss of same shall be on Contractor. 109.6.6 Assignments of Equipment, Materials, Money Due or to Become Due. It being the primary purpose of this contract and the bond herein to insure the full performance of all of the work herein required to be performed and the payment in full of all claims for labor and materials used in, upon, or in connection with or as a necessary incident to the work herein described, it is expressly agreed that St. Louis County will not recognize as valid any assignment by the Contractor of any materials, equipment, or supplies used or employed in connection with the work; and that all such assignments, whether made before or after the execution of the contract, shall be subordinate to the terms and provisions of this contract. No assignment of money due or to become due under this contract shall be recognized by St. Louis County unless such assignment is in writing executed by the Contractor, approved by the surety, and filed with the Director and then only subject to prior claims and liens of labor, materials, supplies and equipment used in, upon, or in connection with or as necessarily incident to the work herein provided for. 109.6.7 Acceptance and Final Payment. When the Director is satisfied that the entire work has been properly completed in accordance with the terms of the contract, and that all labor, material, and other bills have been paid by the Contractor, the Director shall, in a reasonable time, make a final estimate including all monies previously retained or otherwise due the Contractor and shall certify the same for payment. The Contractor shall, by affidavit, certify to the Director that all bills and claims properly due and chargeable against the work have been satisfied and that the laws relating to the payment of prevailing wage rates have been complied with, and shall release St. Louis County from all further claims, which certificate shall bear the written endorsement of the surety on the bond. The acceptance by the Contractor of the final payment shall constitute a release and waiver of any and all rights and privileges under the terms of the contract; further, the acceptance by the Contractor of final payment shall relieve the County from any and all claims or liabilities for anything done or furnished relative to the work or for any act or neglect on the part of the County relating to or connected with the contract. 109.6.8 If said affidavit that claims have been paid cannot be given because of a dispute as to the amount or legality of a claim and if the Contractor's affidavit clearly sets out the facts as to (1) the name and address of the unpaid claimant or claimants, (2) the amount of the disputed claim, and (3) a brief statement of the cause of the dispute, the Director, with the consent of the surety, then may consent to and make payment of all of the final amounts and percentage due the Contractor if the Director is of the opinion that the claim has not been paid solely because the Contractor is, in good faith, questioning the legality of said claim or its amount and if the Director is further satisfied that there is good and sufficient bond to fully protect said claimant. 109.6.9 Overpayment. In the event the County erroneously overpays the Contractor, whether on current or final estimates, the Contractor shall reimburse the County for the sum overpaid and the Contractor and its surety shall be liable therefore until paid.
9/1/2023
109-7
Measurement and Payment
109.7.3 The parties agree that, in any adjustment for delay costs, the County will have no liability for the following items of damages or expense: 1) Profit in excess of that provided herein; 2) Loss of profit; 3) Labor inefficiencies; 4) Equipment inefficiencies or reduced production; 5) Home office overhead in excess of that provided in the percentage allowance in Section 109.7.1 or herein if none of those percentages applies; 6) Consequential damages including, but not limited to, loss of bonding capacity, loss of bidding opportunities, and insolvency; 7) Indirect costs or expenses of any nature; 8) Attorney's fees, claims preparation expenses, or costs of litigation. 109.8 Change Orders. Except as otherwise provided for in the change order, an adjustment of the contract price or time of contract performance in a change order constitutes compensation in full to the Contractor and its subcontractors and suppliers for all costs and time effects directly or indirectly attributable to the matter described in the change order, for all delays related thereto, for all impact, cumulative impacts and for performance of the change within the time stated.
9/1/2023
109-8
Measurement and Payment
Section 110
State Wage Rate Requirements
110.1 The prevailing rate of wages, overtime, and fringe benefits for the locality of the work, as determined by the Department of Labor and Industrial Relations of Missouri, or by a court decision on appeal, will be contained in the proposal by special provision. The Contractor and all subcontractors shall pay not less than the prevailing rate of wages, overtime, and fringe benefits, as specified or as same may be changed by a court decision on appeal, for all work performed under the contract. 110.2 The Contractor is advised that the prevailing rate of wages, overtime, and fringe benefits are subject to change during the life of the contract by court decision. No such change shall be the basis for adjustment in the contract price. 110.3 The Contractor and each subcontractor shall keep an accurate record showing the names and occupation of all workmen employed by him, together with the actual wages, overtime, and fringe benefits paid to each workman, which record shall be open to inspection at all reasonable hours by the representatives of the Department of Labor and Industrial Relations of Missouri or the County. The Contractor and each subcontractor on all projects are required to submit one certified copy of labor payrolls for each week that work is in progress. 110.4 In the event of a conflict between any prevailing rate of wage, overtime, or fringe benefits, as determined by the Department of Labor and Industrial Relations, and any minimum rate of wage, overtime, or fringe benefits, as determined by the Secretary of Labor, where the latter is applicable, the greater of the two shall apply. In the event that work is temporarily suspended, the last payroll should be marked appropriately to note that it will be the last payroll until work is resumed. A certified copy of each weekly payroll shall be submitted by the prime contractor within seven (7) days of the payment date of the payroll. The certification may be attached to the payroll or may be on the payroll itself. The prime contractor will be considered responsible for the submittal of payrolls and certifications for all subcontractors on the project. Work that requires transportation of material moved within project limits will require payrolls for the required labor classification. Failure to submit payrolls to the Engineer in the above manner may result in the withholding of all or a portion of the progress pay estimate to the Contractor.
7/1/2015
110-1
State Wage Rate Requirements
(This Page Intentionally Left Blank)
7/1/2015
110-2
State Wage Rate Requirements
Division 200
EARTHWORK
9/1/2023
200-1
Earthwork
(This Page Intentionally Left Blank)
9/1/2023
200-2
Earthwork
Standard Specifications for Road and Bridge Construction Division 200 - Earthwork Section
Description
Revision Date
201..... Clearing and Grubbing ...................................................................................... 10/1/2012 202..... Removals ............................................................................................................ 7/1/2015 202.20 ...... Removal of Improvements ................................................................ 202-2 202.30 ...... Removal of Rigid Pavement .............................................................. 202-5 203..... Roadway and Drainage Excavation, Embankment, and Compaction .................. 9/1/2023 204..... Embankment Control ......................................................................................... 10/1/2012 204.10 ...... Settlement Gauges ........................................................................... 204-2 204.20 ...... Pore Pressure Measurement Devices ............................................... 204-4 205..... Modified Subgrade ............................................................................................ 10/1/2012 206..... Excavation for Structures..................................................................................... 9/1/2023 207..... Linear Grading................................................................................................... 10/1/2012 209..... Subgrade Preparation ......................................................................................... 9/1/2023 217..... Ditching ............................................................................................................. 10/1/2012
9/1/2023
200-3
Division 200 - Index
(This Page Intentionally Left Blank)
9/1/2023
200-4
Division 200 - Index
Section 201
Clearing and Grubbing
201.1 Description. This work shall consist of clearing, grubbing, removing, and disposing of vegetation within the limits of right-of-way and easement areas, except such vegetation as is designated to remain or to be selectively treated. Should gravesites be found during clearing or grading, the Contractor will stop all construction work in the immediate area and notify the Director. Parking meters and posts located within the construction limits shall be removed and stored at locations designated by the Engineer. Parking meters damaged by removal will be repaired or replaced by the Contractor at no additional cost to the County. Existing fencing located within the construction limits shall be removed and stored at locations designated by the Engineer. 201.2 Construction Requirements. 201.2.1 The Engineer will establish right-of-way and construction lines and will designate all trees, shrubs, and plants that are to remain. The Engineer will also designate the trees, shrubs, and plants, in developed or undeveloped areas, that are to be removed and are not designated on the plans. No tree shall be removed from developed areas without express approval of the Engineer. The Contractor shall preserve without damage the vegetation designated to remain. All trees, stumps, brush, and hedge not designated to remain shall be cleared, grubbed, or cleared and grubbed as required and shall be disposed of in an acceptable manner. 201.2.2 Stumps and roots in cut areas shall be grubbed to a depth of not less than 12 inches below the finished earth grade. Grubbing of Osage orange or locust hedge shall include removal of roots. In embankment areas, undisturbed stumps and roots extending not more than 6 inches above the ground line may remain provided they are a minimum of 3 feet below the finished earth grade or the slope of the embankment. Except in areas to be excavated, stump holes shall be backfilled with suitable material and compacted to the approximate density of the adjacent area. In lieu of grubbing, stumps outside of the slope stake limits may be cut off not more than 3 inches above the ground. Grubbing of borrow areas, channel changes, and inlet and outlet easements will be required only to the extent necessitated by the proposed construction. 201.2.3 The Contractor shall dispose of combustible materials in accordance with Ordinance No. 4365, 1967, entitled, "An Ordinance amending Title 6, St. Louis County Revised Ordinances, 1964, as amended by repealing there from Chapter 612 of the St. Louis County Air Pollution Control Code and enacting in lieu thereof a new Chapter relating to the same matter". When burning is permissible under controlling air pollution regulations, all burning of products of clearing and grubbing shall be done under the care of a competent watchman at such times and in such manner that neither vegetation on adjacent property nor that designated to remain within the construction limits will be jeopardized. The burial of stumps and debris will not be permitted in the construction limits. Products of clearing and grubbing may be removed from the construction limits and disposed of out of sight from the
10/1/2012
201-1
Clearing and Grubbing
roadway provided an acceptable written agreement with the property owner on whose property the products are placed is submitted by the Contractor. 201.2.4 All timber not designated to remain and that has not been removed from the rightof-way prior to the beginning of construction shall become the property of the Contractor. Low hanging and unsound or unsightly branches on trees or shrubs designated to remain shall be removed as directed and in accordance with good tree surgery practices. 201.2.5 The Contractor shall scalp all areas where excavation or embankment is to be made, except that mowed, burned over sod need not be removed where the embankment to be constructed is 4 feet or more in height. Scalping shall include the removal of material such as sod, grass, residue of agricultural crops, sawdust, and decayed vegetative matter from the surface of the ground without removing more earth than is necessary. The products of scalping shall be deposited at the toe of embankments where such areas are available within the limits of the roadway balance affected. If such areas are not available, the products shall be suitably removed in accordance with Section 201.2.3. 201.2.6 Cemetery headstones to be removed shall be tagged, marked, and stored in a safe location to prevent breakage or vandalism. Care will be taken to adequately identify the grave-site and its headstone for resetting of the headstones after construction has been completed. 201.2.7 After construction has been completed, each mailbox shall be permanently reset at locations as hereinafter specified, see Standard Drawing C608.56, "Mailbox Placement Standards": 1) Reset the mailbox laterally with front face 2 inches from the edge of the pavement, and 42 inches above the elevation of the edge of pavements with no curb; 2) Reset the mailbox laterally with front face 7 feet from the edge of the pavement at mailbox turnouts in the roadway shoulder, and 42 inches above the elevation of the edge of the pavement; 3) At sidewalks and curbs, reset the mailbox laterally with front face 1 foot from the outside edge of the sidewalk or curb, and 42 inches above the elevation of the finished grade; 4) Special locations for mailboxes will be designated on the plans. Curbside mailboxes shall be located so that they may be safely and conveniently served by carriers without leaving their conveyances, and must be on the right side of the road in the direction of travel of the carriers. Mailboxes shall not be located where traffic conditions are such that it would be dangerous for the carriers to drive to the left to reach the mailboxes or where their doing so would constitute a violation of traffic laws or regulations. In accordance with Section 104.9.1, no direct payment will be made for this work;
10/1/2012
201-2
Clearing and Grubbing
5) Box or house numbers must be inscribed with contrasting color in neat letters and numerals not less than 1 inch high on the side of the box visible to the carrier’s regular approach, or on the door if boxes are grouped. If the box is on a different street from the customer’s residence, the street name and house number must be inscribed on the box. In accordance with Section 104.9.1, no direct payment will be made for this work. 201.3 Method of Measurement. 201.3.1 No separate measurement will be made for clearing and for grubbing. Payment will be on a lump sum basis. 201.4 Basis of Payment. 201.4.1 The accepted quantities of clearing and grubbing will be paid for at the unit bid price per lump sum. 201.4.2 Exclusions. When no pay item for clearing or grubbing is included in the contract, clearing and grubbing, including scalping, will be considered incidental to the work and no direct payment will be made. 201.4.3 Payment for cemetery headstones will be made at a lump sum bid price for special item entitled "Tagging, Marking, Removing and Resetting Headstone". 201.4.4 No special payment will be made for removal and storage of salvageable items. 201.10 Temporary Project Water Pollution Control (Soil Erosion). 201.11 Description. This work shall consist of temporary control measures as shown on the plans or ordered by the Engineer during the life of the contract to control water pollution, through use of berms, dikes, dams, sediment, basins, fiber mats, netting, gravel, mulches, grasses, slope drains, and other erosion control devices or methods. The temporary pollution control provisions contained herein shall be coordinated with the permanent erosion control features specified elsewhere in the contract to the extent practical to assure economical, effective, and continuous erosion control throughout the construction and post-construction period. 201.12 Materials. All material shall conform to Division 1000, Materials Details, as specified: 1) Mulches may be hay, straw, fiber mats, netting, wood cellulose, corn or tobacco stalks, bark, corncobs, wood chips, or other suitable material acceptable to the Engineer, and shall be reasonably clean and free of noxious weeds and deleterious materials; 2) Slope drains may be constructed of pipe, fiber mats, rubble, Portland cement concrete, bituminous concrete, plastic sheets, or other material acceptable to the Engineer that will adequately control erosion;
10/1/2012
201-3
Clearing and Grubbing
3) Grass shall be a quick growing species (such as rye grass, Italian rye grass, or cereal grasses) suitable to the area providing a temporary cover, which will not later compete with the grasses sown later for permanent cover; 4) Fertilizer and soil conditioners shall be a standard commercial grade, acceptable to the Engineer; 5) Others as specified by the Engineer. 201.13 Construction Requirements. 201.13.1 The Engineer has the authority to limit the surface area of erodible earth material exposed by clearing and grubbing, the surface area of erodible earth material exposed by excavation, borrow and fill operations and to direct the Contractor to provide immediate, permanent, or temporary pollution control measures to prevent contamination of adjacent streams or other watercourses, lakes, ponds, or other areas of water impoundment. Such work may involve the construction of temporary berms, dikes, dams, sediment basins, slope drains, and use of temporary mulches, mats, seeding, or other control devices or methods as necessary to control erosion. Cut slopes shall be seeded and mulched as the excavation proceeds to the extent considered desirable and practicable. 201.13.2 At the pre-construction conference, or prior to the start of the applicable construction, the Contractor shall submit for acceptance his schedules for accomplishment of temporary and permanent erosion control work, as are applicable for clearing and grubbing, grading, bridges, and other structures at watercourses, construction, and paving. He shall also submit for acceptance his proposed method of erosion control on haul roads and borrow pits and his plan for disposal of waste materials. No work shall be started until the erosion control schedules and methods of operations have been accepted by the Engineer. 201.13.2.1 The Engineer may increase or decrease the amount of surface area of erodible earth material to be exposed at one time by clearing and grubbing, excavation, borrow, and fill operations as determined by his analysis of project conditions. 201.13.3 In the event of conflict between these requirements and pollution control laws, rules, or regulations of other Federal or State or local agencies, the more restrictive laws, rules, or regulations shall apply. 201.13.4 The Contractor will be required to incorporate all permanent erosion control features into the project at the earliest practicable time as outlined in his accepted schedule. Temporary pollution control measures will be used to correct conditions that develop during construction that were not foreseeable during the design stage; that are needed prior to installation of permanent pollution control features; or that is needed temporarily to control erosion that develops during normal construction practices, but are not associated with permanent control features on the project.
10/1/2012
201-4
Clearing and Grubbing
201.13.5 Where erosion is likely to be a problem, clearing and grubbing operations should be so scheduled and performed that grading operations and permanent erosion control features can follow immediately thereafter if the project conditions permit; otherwise, temporary erosion control measures may be required between successive construction stages. Under no conditions shall the surface area of erodible earth material exposed at one time by clearing and grubbing exceed 750,000 square feet without approval by the Engineer. 201.13.6 The Engineer will limit the area of excavation, borrow, and embankment operations in progress to commensurate with the Contractor's capability and progress in keeping the finish grading, mulching, seeding, and other such permanent pollution control measures current in accordance with the accepted schedule. Should seasonal limitations make such coordination unrealistic, temporary erosion control measures shall be taken immediately to the extent feasible and justified. 201.13.7 Under no conditions shall the amount of surface area of erodible earth material exposed at one time by excavation, borrow, or fill within the right-of-way exceed 750,000 square feet without prior approval by the Engineer. 201.14 Method of Measurement and Basis of Payment. 201.14.1 In the event that temporary erosion and pollution control measures are required due to the Contractor's negligence, carelessness, or failure to install permanent controls as a part of the work as scheduled, and are ordered by the Engineer, such work shall be performed by the Contractor at his own expense. Temporary erosion and pollution control work required, which is not attributed to the Contractor's negligence, carelessness or failure to install permanent controls, will be performed as ordered by the Engineer. 201.14.2 Where the work to be performed is not attributed to the Contractor's negligence, carelessness, or failure to install permanent controls and falls within the specifications for a work item that has a contract price, the units of work shall be paid for at the proper contract price. Should the work not be comparable to the project work under the applicable contract items, the Contractor shall be ordered to perform the work on a force account basis, or by agreed unit prices. 201.14.3 In case of repeated failures on the part of the Contractor to control erosion, pollution, and/or siltation, the Engineer reserves the right to employ outside assistance or to use his own forces to provide the necessary corrective measures. Such incurred direct costs, plus project engineering costs, will be charged to the Contractor and appropriate deductions will be made from the Contractor's monthly progress estimate. 201.14.4 The Contractor may be required to establish temporary pollution control measures at his own expense in keeping with the intent of these requirements on work outside the right-of-way where such work is necessary as a result of roadway construction, such as contractor-furnished borrow pits, haul roads, and equipment storage sites. The erosion control features installed by the Contractor shall be acceptably maintained by the Contractor.
10/1/2012
201-5
Clearing and Grubbing
(This Page Intentionally Left Blank)
10/1/2012
201-6
Clearing and Grubbing
Section 202
Removals
202.11 Description. This work shall consist of the removal and disposal of all existing improvements from the right of way and within the limits of any construction area outside the right of way, except improvements designated or permitted to remain in place or to be removed under other items of work. These specifications will apply to all removal work performed by the contractor. 202.12 Construction Requirements. 202.12.1 Unless otherwise indicated on the plans, the entire structure, including all substructure units, shall be removed to a point 2 feet below the finished ground line or streambed. 202.12.2 All guardrail material shall remain the property of the County and shall be stored on the right-of-way as directed by the Engineer. All other removed material not specified in the contract documents to remain the property of the County, should be removed and disposed of by the Contractor. 202.12.3 Existing structures used for handling temporary traffic shall not be removed until the replacement structures are open to traffic. The Contractor may make use of existing structures, or portions of them, during construction, but no material designated to be salvaged shall be removed from the project, cut, bent, broken, or otherwise damaged. 202.12.4 Any portion of an existing structure below the ground line which falls within the limits of excavation for new structures will be removed and paid for as excavation for structures. 202.13 Method of Measurement. The work provided herein will not be measured for payment, but will be considered a lump sum unit. This shall include the removal of all items, whether in view, or hidden underneath the surface of the ground, regardless of whether shown on the plans or encountered during construction. 202.14 Basis of Payment. Payment for the removal and disposal of bridges will be made at the contract unit bid price.
7/1/2015
202-1
Removals
Section 202.20 Removal of Improvements 202.21 Description. 202.21.1 Description. This work shall consist of the removal and disposal of all existing improvements, except those designated or permitted to be left in place or to be removed under other items of work, from the right-of-way and within the limits of any construction area outside the right-of-way. Improvements, to be left in place within construction limits, must be adequately protected and remain in operating condition. All coal chute and window well structures shall be removed and the openings into the buildings closed with brick masonry in accordance with Section 610.20 with flush mortar joints ready to receive damp proofing. Damp proofing shall be in accordance with Section 708. 202.21.2 Removal of improvements shall include removing all buildings, drainage structures, all rigid, reinforced, flexible or combination pavements, surfacing, and base courses of all types, curb, curb and gutter, sidewalk and driveway approaches (residential, commercial and street), house walks, steps, handrails, retaining walls, foundation walls, columns, footings, floors and any other types of building appurtenances, cisterns, catch basins, manholes, drainage and sewer pipes, box culverts, water and gas main pipes, water vault boxes, utility chambers other objects or structures including scattered or piled bricks, stones, broken masonry, rubbish, debris, etc. from building demolition work, and other existing improvements. This item shall also include the salvaging of materials as designated in the contract, and the backfilling of the resulting trenches, holes and pits, and any grading work required to shape, smooth, and finish the disturbed areas. All guardrail materials within the right-of-way shall remain the property of the County and shall be stored on the right-of-way as directed by the Engineer. 202.21.3 The plans may not show a complete list of all items to be removed. There may be an undetermined number of abandoned utilities, basement or foundation walls, columns, footings, other types of building appurtenances, or other improvements encountered. The Contractor shall determine for himself the extent of the work to be performed under this item and shall base his bid accordingly. When portions of existing buildings are to be removed and portions are to remain, the Contractor shall exercise extreme care to protect the portions of the buildings that are to remain. The Contractor shall confine his activities within the construction limits and the slope license line shown on the plans. 202.22 Construction Requirements. 202.22.1 All buildings, disused structures, old pavements, base courses, abandoned sewers or pipe lines, or other obstructions to the construction of the roadway or within the limits of the right-of-way and not designated or permitted to remain, shall be removed or disposed of by the Contractor as required. Existing structures or pavements used for handling temporary traffic shall not be removed until the replacement structures are open to traffic. The Contractor may make use of existing structures, roadways, or portions of them during construction, but no material designated for use elsewhere shall be removed from the project, cut, bent, broken, or otherwise damaged.
7/1/2015
202-2
Removals
202.22.2 Material designated in the contract to be salvaged from existing structures shall be removed without damage, in sections which may be readily handled or transported, and shall be piled neatly at an accessible point. Material not designated for salvage will be considered the property of the Contractor, unless owned and claimed by any political subdivision or utility company. Salvaged materials becoming the property of the Contractor shall not be stored upon the right-of-way, nor shall any portion of the right-of-way be used by the Contractor as a sales yard. All discarded material or debris shall be disposed of at locations furnished by the Contractor, or at locations on the right-of-way approved by the Engineer. Discarded material or debris shall not be deposited on private property unless authorized in advance by the Director. Property owners interested in obtaining waste products shall be instructed to write the Director, St. Louis County Department of Transportation, giving particulars of their request ten (10) calendar days in advance of requested date to receive discarded materials or debris. 202.22.3 In removing pavement, curb, curb and gutter, gutters, sidewalk, and other similar improvements, and where a portion of such improvements are to be left in place, they shall be removed to an existing joint or to a joint sawed to a minimum depth of 1 inch with a true line and vertical face. Sufficient removal shall be made to provide for proper grades and connections in the new work regardless of any limits, which may be indicated on the plans. 202.22.4 Removal of concrete pavement or base course, concrete floors, basement floors, and concrete sidewalk may consist either of breaking up and disposing of the broken concrete in embankments or in disposal areas furnished at the Contractor's expense, or of breaking the slab into pieces not exceeding 4 square feet where new embankment exceeding 24 inches high is to be placed over the slab. At locations designated on the plans where piling is to be driven, existing pavements, sidewalks, footings, foundations, walls, and all other types of removal items shall be completely removed for a sufficient distance to permit piling to be driven. Existing improvements not removed in their entirety shall be removed to a minimum depth of 12 inches below the finished grading section or natural ground. 202.22.5 All sewers and drainage pipes which have been or are to be abandoned in place shall be completely filled with a sand-cement material which shall consist of a mixture of Portland cement and sand combined in the proportions of 402 pounds of cement and 3,215 pounds of sand mixed with sufficient water to form a plastic mortar like mixture of a consistency appropriate for pumping into place with pressure pumping equipment. The sand and cement shall be mixed in a mixer of a type approved by the Director, after which water shall be added and the mixing continued until a consistency of mixture has been attained which can be pumped into the sewer openings under sufficient pressure, to insure the filling of all openings free of voids and air pockets or at the request of the Contractor and with the approval of the Engineer. The existing pipe may be crushed in place or removed. All floor drains shall be sealed by bulkhead in an acceptable manner by concrete meeting the requirements of Section 501.12 or brick masonry as directed by the Engineer. No direct payment will be made for bulkheads. 202.22.6 All trenches, holes, and pits resulting from the removal of improvements shall be filled with earth, or with broken masonry and earth. No broken masonry shall extend closer than 12 inches to the finished surface. The material shall be placed in the same manner and compacted to approximately the same density as that required in adjoining areas.
7/1/2015
202-3
Removals
202.22.7 Removing and disposing of abandoned fences will be considered as included in final cleaning up of the right-of-way and no direct payment will be made for such work. 202.23 Method of Measurement. The work provided herein will not be measured for payment, but will be considered a lump sum unit. This shall include the removal of all items, whether in view or hidden underneath the surface of the ground, regardless of whether shown on the plans or encountered during construction. No deductions will be made from the volumes measured for payment of roadway excavation where existing improvements are removed from within the limits of the sections measured for determining pay volumes of excavation. Sand-cement backfill will be measured by theoretically computed volume rounded to the nearest 0.1 cubic yard. 202.24 Basis of Payment. The accepted removal of improvements will be paid for at the contract lump sum price. If no lump sum unit for the removal of improvements is included in the contract, the removal of improvements required to complete the contract, or as directed by the Engineer, will be considered incidental to the work and no direct payment for the removal will be made. Sand-cement backfill will be paid to the nearest 0.1 cubic yard in place at the unit bid price.
7/1/2015
202-4
Removals
Section 202.30 Removal of Rigid Pavement 202.31 Description. This work shall consist of the removal and disposal of concrete pavement, or concrete base courses, and curb and gutter sections, except those designated or permitted to be left in place, from the right-of-way and within the limits of any construction area outside the right-of-way. 202.31.1 The plans may not show a complete list of all items to be removed, the Contractor shall determine for himself the extent of the work to be performed under this item. 202.31.2 When portions of existing rigid pavements are to be removed and portions are to remain in place, the Contractor shall exercise care to protect the portions of the rigid pavements that are to remain. 202.32 Construction Requirements. 202.32.1 All concrete pavement, concrete base courses, curb and gutter sections, paved approaches and driveways within the limits of the right-of-way and not designated or permitted to remain, shall be removed and disposed of by the Contractor as required. Existing rigid pavements used for handling temporary traffic shall not be removed until the replacement pavements are open to traffic. The Contractor may make use of the existing rigid pavements or portions of them during construction, but no material designated for use elsewhere shall be removed from the project. 202.32.2 In removing concrete pavement, concrete base courses, and curb and gutter sections where a portion of such improvements are to be left in place, they shall be removed to an existing joint or to a joint sawed to a full depth, with a true line and vertical face. Sufficient removal shall be made to provide for proper grades and connections in the new work regardless of any limits that may be indicated on the plans. 202.32.3 Removal of concrete pavement or concrete base courses, and curb and gutter sections shall consist either of breaking up and disposing of the broken concrete in embankments or in disposal areas furnished at the Contractor's expense, or of breaking the slab into pieces not exceeding 4 square feet in area when new embankment exceeding 24 inches in height is to be placed over the slabs. At locations designated on the plans where piling is to be driven, existing rigid pavements shall be completely removed for sufficient distance to permit piling to be driven. 202.33 Method of Measurement. 202.33.1 Measurement of rigid pavement will be made to the nearest square yard for that area of material actually removed from within the limits of the project. 202.34 Basis of Payment. 202.34.1 The accepted removal of rigid pavement will be paid for at the contract unit bid price. Saw cutting will be considered incidental, unless included as a pay item in the contract. Hauling, disposing and placing of removed portions of rigid pavement will be considered incidental to the work and no direct payment will be made.
7/1/2015
202-5
Removals
(This Page Intentionally Left Blank)
7/1/2015
202-6
Removals
Section 203
Roadway and Drainage Excavation, Embankment, and Compaction
203.1 Description. This work shall consist of excavation, disposal, or compaction of all materials encountered within the limits of the work not being removed under some other item. This work shall be performed in accordance with the specifications and in conformance with the lines, grades, thicknesses, and typical cross sections shown on the plans, or established by the Engineer. All excavation will be classified as hereafter described. 203.1.1 Class A Excavation will consist of all roadway and drainage excavation not classified as Class C or Unclassified. Shale, fire clay, chert broken by intermittent clayey partings or clay seams (joint flint rock), stratified chert cemented with clay seams (hardpan), and plain or bituminous-bound bases or surface courses of macadam, gravel, broken stone or similar material will be considered as Class A Excavation, not Class C Excavation. 203.1.2 Class C Excavation will consist of the removal of stone in ledges 6 inches or more in thickness. A ledge will be considered to be a continuous deposit of rock that may or may not include thin, interbedded seams of soft material or shale. The vertical limits of each ledge will be determined by beds of soft material or shale more than 24 inches thick. The beds of soft material or shale will be included in the measurement of Class A Excavation only. Boulders or other detached stones each having a volume of 2½ cubic yards or more will be considered as Class C Excavation. 203.1.3 Sandstone excavation will consist of the removal of material determined to be sandstone in ledge formation. Laboratory analysis will be made, if necessary, to aid in the determination. 203.1.4 Igneous Rock Excavation will consist of the removal of rock of igneous origin (porphyry, granite, rhyolite) occurring in continuous formation, or of detached boulders having a volume of 2½ cubic yards or more. 203.1.5 Unclassified Excavation will consist of the excavation of all materials of whatever character encountered in the work. All material excavated will be considered as Unclassified Excavation unless the contract specifies classified material. 203.1.6 Borrow and Waste. 203.1.6.1 Borrow will consist of approved material required for the construction of embankment or for other portions of the work and shall be obtained either from borrow areas shown on the plans, from areas designated by the Engineer, or from other approved sources. The Contractor shall notify the Engineer sufficiently in advance of opening any borrow areas in order that the necessary soil sampling, cross sections, or measurements may be taken. Borrow will be classified in the same manner as roadway excavation. Borrow areas will be given a final dressing and seeding prior to completion of the contract, to provide a pleasing appearance to the overall area. Payment for seeding only, for dressing of borrow areas shown on the plans, will be included as an item of the contract. Seeding of borrow areas not shown on the plans will be considered incidental to the work, and no direct payment will be made.
9/1/2023
203-1
Roadway and Drainage Excavation, Embankment, and Compaction
203.1.6.2 The use of borrow or waste area other than those shown on the plans or designated by the Engineer may be approved, provided: 1) The material and area is equally satisfactory; 2) The final cost to the County including the cost of easements is not greater than the cost as originally designated; 3) The substitution is to the best interest of the County; 4) Proper environmental clearances have been obtained for use of any alternate borrow sites, with the exception of permitted quarries and other locations that have already obtained environmental clearances in accordance with Section 203.3.2.5; 5) The contractor has obtained appropriate land disturbance permits from MDNR in advance of excavation, unless the site is already under permit by MDNR. 203.1.6.3 When borrow areas are on private property a letter of permission must be obtained from the property owner before any material may be removed. Following final grading and seeding of the borrow area a letter of release from liability must be obtained from the property owner prior to final payment. 203.2 Construction Requirements. 203.2.1 General. Prior to beginning excavation and embankment operations in any area, all necessary clearing, grubbing, and stripping in that area shall have been performed. The excavation and embankment for roadway, intersections, and entrances shall be made to the designated alignment, grade, and cross section. Side slopes, cuts, and fills shall be finished to a reasonably smooth and uniform surface that will merge with the adjacent terrain without variations readily discernible from the road. Finishing by hand methods will not be required, except that all brush, weeds, excess mud and silt, or other debris shall be removed from culverts and channels within the scope of the work in accord with Section 104.8.3 even though such structures are used in place. Areas disturbed by the Contractor outside the limits of construction shall be restored at the Contractor's expense to a condition similar to that prior to construction operations. 203.2.1.1 Field Stone. All loose field stone greater than 4 inches in size within the limits of the right-of-way, field stone necessary to be removed before commencing operations on light grading sections, and small rocks and boulders resulting from the operations of subgrade scarifying and finishing a graded earth roadway shall be disposed of as directed by the Engineer. 203.2.1.2 Shoulders. Earth shoulders shall be constructed of suitable material to the grade and cross section shown on the plans and shall be compacted in accordance with Section 203.3 by use of a steel wheeled roller weighing not less than 5 tons. The construction of shoulders shall start when sufficient surfacing has been completed and attained satisfactory strength to permit continuous shouldering operations. Equipment that will damage the surfacing will be prohibited from operating on the surfacing during shouldering operations. Surfacing and curbs shall be protected where equipment is crossing or turning.
9/1/2023
203-2
Roadway and Drainage Excavation, Embankment, and Compaction
203.2.2 Maintenance. During construction, the roadway shall be maintained by the Contractor in such condition that it will be passable and well drained at all times. Roadway ditches, channel changes, inlet and outlet ditches, and any other ditches in connection with the roadway shall be cut and maintained to the required cross section. All drainage work shall be performed in proper sequence with other operations. All ditches and channels shall be kept free of debris or obstructions. All slides shall be removed, and material disposed of as directed by the Engineer. 203.2.3 Drilled and Dug Wells. The Contractor will notify the Engineer 24 hours in advance of his intent to plug the well. Drilled well casings shall be cut off flush with the existing ground line or 12 inches below the finished grading section, whichever is lower. The well shall then be plugged from the bottom of the well to the top of the casing with a mixture of commercial concrete or 4:1 sand cement grout. If the mixture is to be placed below water, it shall be placed by means of a tremie, where feasible. If the use of a tremie is not considered feasible, the mixture shall be placed in two stages. During the first stage, the mixture may be deposited directly through the water to plug the well from the bottom to an elevation 10 feet below the bottom of the casing, or to an elevation 80 feet below the top of the casing, whichever is lower. After a minimum period of 48 hours, the well shall be dewatered, and the remaining mixture placed in the dry. The mixture used to plug wells less than 80 feet in depth shall be placed by tremie or completely in the dry. 203.2.3.1 Abandonment procedure for wells shall be in accordance with requirements set forth in the Department of Natural Resources regulations, specifically as follows: Type of Well Regulation Monitoring Wells............................................ 10 CSR 23-4.080 Heat Pump Well ............................................ 10 CSR 23-5.080 Test Holes..................................................... 10 CSR 23-6.050 All Other Wells .............................................. 10 CSR 23-3.110 203.2.3.2 Cisterns shall be pumped out and plugged by filling the lower one-half to threefourths of the cistern with clean fill, such as coarse gravel or rock, agricultural lime, or sand. The cistern walls above the fill shall then be pushed in and the remainder of the cistern filled to the ground line or within 12 inches of the finished grading section, whichever is lower, with clay or clay-rich soil compacted in 6 inches layers to the approximate density of the adjacent soil. 203.2.3.3 Direct payment will not be made for the plugging or disposal of wells or cisterns. The Contractor shall be responsible for the costs and fees associated with the registration of these wells. A copy of the completed registration form shall be furnished to the Engineer. 203.2.4 Subgrade Scarifying. The Engineer may order subgrade scarifying performed to remove oversized material if the upper 4 inches of the subgrade as tentatively completed contains material of a dimension greater than 2 inches sufficient in quantity to make subgrade unacceptable as a roadbed for the proposed type of surfacing.
9/1/2023
203-3
Roadway and Drainage Excavation, Embankment, and Compaction
203.2.5 Excavating in Rock. Excavating and undergrading in rock (i.e., material conforming to the description of Class C, whether the contract calls for classified or unclassified excavation) shall be performed in a manner to produce material of such size as to permit being placed in embankments in accordance with the requirements. Rock within the roadbed limits shall be removed to the limits of undergrading insofar as practicable, and in such manner as to leave no undrained pockets in the surface. Unless specifically set forth in the contract, the Contractor will be required to obtain the necessary permission from all governmental entities before considering blasting as a means of rock excavation. Care shall be taken to avoid overshooting when blasting. Any loose or shattered rock, overhanging ledges, and boulders above the roadbed which might dislodge, shall be removed. If the contract provides a specific use for rock from roadway excavation, the work shall be performed in such order and manner as may be necessary to ensure that the desired quantity of such material may be placed as required. 203.2.5.1 Blasting Requirements. accordance with Section 107.8.
Reporting for all blasting shall be made in
203.2.5.1.1 The Contractor shall submit a rock excavation blasting plan to the Engineer at least 14 days before drilling operations begin. The blasting plan shall address all trenching, presplitting and production shots and shall include, but is not limited to the following information: powder factor per cubic yard, hole size, subdrill, stemming depth, drill pattern, type of explosives and detonators, and safety precautions. A pre-blast survey shall be required on all uncontrolled structures within 500 feet of planned blasting operations. A separate blasting plan shall be required on all locations requiring blasting within 50 feet of any roadway structure. Any changes to blasting plans shall be provided to the Engineer for review prior to performing the work. 203.2.5.1.2 The Contractor shall not exceed blasting holes larger than 4 inches in diameter. The powder factor shall be between 0.60 to 1.35 pounds per cubic yard, except for presplitting or trenching. If stemming ejection becomes a problem, crushed stone stemmings shall be used. Subdrill shall be no more than 30 percent of burden. The Contractor shall not drill within a radius equal to the depth of the cut of a loaded borehole. Seismic monitoring shall be required when the scaled distance is less than 65, where scaled distance equals the distance, in feet, divided by the square root of explosive weight, in pounds, per eight (8) millisecond delay. 203.2.5.1.3 The Contractor shall perform the excavating of rock cuts by the technique of presplitting, cushion blasting or air decking to produce a neat line of the proposed excavation, with the results subject to the approval of the Engineer. Holes for presplitting shall be drilled to the full depth of the cut or to a pre-selected bench elevation as shown on the plans, or as determined by the Engineer. Presplit shots shall be made prior to production shots. Production holes shall not be drilled any closer to the presplit line than 12 times the diameter of the production blast hole. Presplitting shall be done according to accepted practice to produce a clean face on the excavated cut.
9/1/2023
203-4
Roadway and Drainage Excavation, Embankment, and Compaction
203.2.5.2 Undergrading. Areas of required undergrading shall be backfilled with one of the following materials with preference in the order given, dependent on availability: 1) The top approximately 2 inches of the rock backfill shall consist of either rock fragments or spalls or a 2 inch granular-type material having a plasticity index not exceeding 10, and a gradation such that at least 50 percent of the material will be retained on the No. 4 sieve.; 2) A 2 inch maximum size granular-type material having a plasticity index not exceeding 10, and a gradation such that at least 50 percent of the material will be retained on the No. 4 sieve.; 3) A material having a low plasticity index and designated by the engineer as suitable. No material shall exceed 2 inches in size. 203.2.5.3 Overbreak. Overbreak resulting from excavating or blasting rock below the required limits of undergrading shall be backfilled with spalls or rock fragments. If spalls are not available and if the Contractor does not elect to use rock fragments, the use of either of the following will be satisfactory. 1) Material meeting the requirements of Section 1007, Aggregate Base Material; 2) A granular type material having a plasticity index not to exceed 10 and a gradation such that at least 50 percent of the material will be retained on the No. 4 sieve. 203.2.6 Removal of Unsuitable Material and Backfill. Where excavation to the finished graded section results in a subgrade or slopes of unsuitable material, the Engineer may require the Contractor to remove the unsuitable material and backfill to the finished graded section with approved material. The Contractor shall conduct his operations in such manner that the Engineer may make the necessary measurements before the backfill is placed. Required backfill shall be provided to furnish a stable foundation for the roadway. The Engineer may order additional excavation beyond the pay limits established for roadway excavation in order to remove material found unsuitable for roadway construction. The gradation of the material will be determined by the Engineer. Measurement for the volume of unsuitable material excavated beyond or outside the limits shown on the plans or established by the specifications for roadway excavation will be made by the Engineer. 203.2.7 Borrow. Borrow material shall not be placed until after material from roadway excavation has been placed in the fill, except as approved otherwise by the Engineer. The Contractor shall not excavate beyond the dimensions and elevations established, and no material shall be removed prior to staking and cross sectioning the site. If the Contractor places more borrow than required and thereby causes a waste of excavation, such waste will be deducted from the borrow volume as measured in the borrow area. All borrow areas shall be bladed and left in such shape as to permit taking the necessary cross sections after excavating has been completed. The finished borrow areas shall be approximately true to line and grade when so specified in the contract, and shall be finished, where practicable, so that no water will collect or stand therein. If necessary to remove fencing in order to obtain borrow material, it shall be replaced in as good condition as it was at the time of removal. The Contractor shall be responsible for confining livestock when a portion of the fence is
9/1/2023
203-5
Roadway and Drainage Excavation, Embankment, and Compaction
removed. No direct payment will be made for removing and replacing such fence nor for the confining of livestock. 203.2.8 Roadway Obliteration. Obliteration of old roads shall be performed in areas shown on the plans and shall include all grading operations necessary to incorporate the old road into the work. The obliteration shall provide a pleasing appearance. Removal of Portland cement concrete pavement and concrete base course will be paid for in accordance with Section 202.30. The earthwork for obliteration, including the obliteration of bituminous surfacing, will be paid for as roadway excavation, unless otherwise provided in the contract. 203.2.9 Human, Criminal, Historical, Archaeological or Geological Remains. If the Contractor encounters any remains, items, sites or artifacts which may be of criminal, historical, archaeological, or geological significance, such as any human remains, historic or prehistoric sites, artifacts, bones or fossils, the Engineer shall be notified immediately. All excavation operations within 50 feet of the finding shall be temporarily suspended and shall not be resumed at that location except as authorized by the Engineer. The Engineer will determine the disposition of the remains or items found. Such remains or items shall not be disturbed or removed, except as directed by the Engineer. If directed by the Engineer, the Contractor shall excavate the site in such manner as to preserve the items encountered. 203.2.9.1 If a temporary suspension of work under this section lasts for an unreasonable period of time and it results in an actual increase in the time or cost of performance of the contract, then this condition shall be deemed a suspension of the work ordered by the Engineer. 203.2.10 Excavated Material Stockpile. During the process of excavating cuts, the Engineer may order specific excavated material placed in stockpiles to have suitable material available to complete the upper portion of embankments and to backfill portions of undergraded cuts. 203.2.11 Embankment Construction. Embankment construction shall consist of constructing roadway embankments, including preparation of the areas upon which they are to be placed, constructing dikes and berms, placing and compacting approved materials within roadway areas where unsuitable material has been removed, and placing and compacting of embankment material in holes, pits, and other depressions within the roadway area. Only approved materials free of trees, stumps, rubbish, and any other deleterious material shall be used in the construction of embankments and backfills. Rocks, broken concrete, or other solid material shall not be placed in embankment areas where piling is to be placed or driven. 203.2.11.1 Embankments requiring surcharges, restricted loading rates, embankment control stakes, or pore pressure measurement devices, shall be constructed to the design template progressively for the full height. Failure of embankments or embankment foundations, or damage to structures which occur when the Contractor fails to observe restricted loading rates, or fails to construct slopes initially to the design template, shall be repaired as directed by the Engineer at the Contractor's expense. 203.2.11.2 Construction of embankments shall not be started on foundation soil or partially completed embankments having more than 2 inches of frost. When such conditions exist the surface must be thoroughly broken and mixed with non-frosted
9/1/2023
203-6
Roadway and Drainage Excavation, Embankment, and Compaction
material to the satisfaction of the Engineer. No frozen material may be incorporated into the embankment. No material shall be placed on frost layers encountered within 12 inches of the top of the proposed grading section. Frozen material on foundation soil or partially completed embankment not meeting the above requirements shall be removed before placing material for the embankment. The removal of frozen material from the foundation of an embankment, or from any layer of the embankment, and the replacement with satisfactory material shall be at the expense of the Contractor. 203.2.12 Embankment on Hillsides or Against Existing Embankment. When embankment is to be placed on hillsides or when new embankment is to be constructed against existing embankments, the existing slopes that are steeper than six horizontal to one vertical when measured at right angle to the roadway shall be continuously benched in not less than 12 inch rises over those areas where it is required as the work is brought up in layers. Benching shall be of sufficient width to permit placing and compacting operations. Each horizontal cut shall begin at the intersection of the ground line and the vertical side of the previous bench. Existing slopes shall also be stepped to prevent any wedging action of the embankment against structures. No direct payment will be made for the material thus cut out, or for its compaction along with the new embankment material. 203.2.13 Scalping. Scalping shall be performed in accordance with Section 201.2.5. Where an embankment less than 4 feet in height is to be made, all sod and vegetative material shall be removed from the surface upon which the embankment is to be placed, and the cleared surface completely broken up by plowing, scarifying, or stepping to a minimum depth of 6 inches. This area shall be compacted in the same manner as that required for the embankment placed on the area. Sod not required to be removed shall be thoroughly disked before construction of embankment. Where an embankment less than 3 feet high is to be made over a compacted road surface containing bituminous or granular material, the old road surface shall be scarified to a depth of at least 6 inches. This scarified material shall be recompacted. 203.2.14 Embankment Against Existing Structures. If embankment is deposited on one side only of abutments, wingwalls, piers, or culvert headwalls, care shall be taken that the area immediately adjacent to the structure is not compacted to the extent that it will cause overturning of or excessive pressure against the structure. Equipment of such weight as may cause damage to culverts or other structures will not be permitted to work over or immediately adjacent to such structures. The embankment adjacent to the end bent of a bridge shall not be placed higher behind than in front of end bents until the superstructure is in place. If embankment is to be placed on both sides of a concrete wall or box type structure, operations shall be so conducted that the embankment is kept at approximately the same elevation on each side. 203.2.15 Surcharged Embankments. Surcharged embankments shall be built in accordance with the plans and shall remain in place for such time as required by the contract. The requirements for placing and compacting will be waived on the surcharge material above the specified compacted area. 203.2.16 Excess or Unsuitable Material. Surplus roadway material shall be removed and stored at the stockpile area indicated. The stockpiled material will be confined within the area shown, and necessary precautions will be taken to ensure that surface drainage or storm culvert drainage is not interrupted. Prior to contract completion, the Contractor shall give the stockpile area a final dressing and seeding so as to provide a pleasing appearance
9/1/2023
203-7
Roadway and Drainage Excavation, Embankment, and Compaction
to the overall area. Payment for seeding only, for stockpile areas shown on the plans, will be included as an item of the contract. Seeding of stockpile areas not shown on the plans will be considered incidental to the work, and no direct payment will be made. 203.2.16.1 Surplus roadway excavation and waste materials resulting from removals shall be disposed of in areas obtained by the Contractor. The Contractor shall comply with the following requirements in securing waste areas and in depositing waste products thereon. 1) The site shall not be in a flood plain; 2) Letters of permission and release are required from the affected property owner or owners; 3) Precautions shall be taken to insure that surface water or storm culvert drainage are not interrupted; 4) The waste disposal area or areas shall be given a final dressing and seeding to provide a presentable appearance and to prevent soil erosion; 5) Other siltation control measures such as straw bales shall be applied during construction as directed by the Engineer. 203.2.16.2 The permit letter provided from the property owner shall be submitted for approval a minimum of five (5) working days prior to the start of operations that will result in waste products or excess excavation. The letter of release will be required before the retained percentage provided for in Section 109.6 will be released. In accordance with the provisions of Section 107.2, the Contractor will be required to haul over city streets and any hauling operations of the Contractor shall be subject to the requirements of such permits and other applicable city regulations and ordinances. No direct payment will be made for complying with the requirements of this specification. All costs incurred as a result thereof, including seeding, will be considered to be completely covered by the unit prices bid for other items included in the contract. When dump sites are located in municipalities, a letter of authorization signed by the Mayor or City Administrator will be required. 203.2.17 Placement of Embankment. Roadway embankment shall be placed in layers not exceeding 8 inches (loose measurement) and shall be compacted as specified before the next layer is placed. The layers shall be placed approximately parallel to both the proposed profile grade and to the finished roadbed. Effective spreading equipment shall be used on each lift to obtain uniform thickness prior to compacting. Continuous leveling and manipulating will be required during compacting operations. Construction equipment shall be routed uniformly over the entire surface of each layer. Occasional rocks and boulders greater than 24 inches shall be dispersed to allow for uniform compaction between them. 203.2.17.1 Occasional stones or rock fragments exceeding the thickness of the 8 inches layer shall be disposed of by being incorporated into the embankment outside the limits of the proposed surfaced traffic lanes. The thickness of the layer in these areas may be increased if necessary to accommodate the stones, but shall not exceed 12 inches in thickness (loose measurement). The stones or rock fragments are to be placed so there will be no nesting.
9/1/2023
203-8
Roadway and Drainage Excavation, Embankment, and Compaction
203.2.17.2 Lifts may be increased to a maximum of 12 inches in thickness (loose measurement) for berms, filling of old channels, waste, or similar areas. These areas shall be compacted by uniformly distributing the hauling over the entire area and specific density control will not be required. No direct payment will be made for compaction performed in these areas. 203.2.18 Rock Embankment. When the excavated material consists predominantly of rock fragments of such size that the material cannot be placed in layers of the thickness prescribed, such material shall be placed in the embankment in layers having a thickness of the approximately average size of the larger rocks, but not to exceed 24 inches. Rocks or boulders too large to permit placing in a 24-inch layer shall be reduced in size as necessary to permit this placement. Rock shall not be dumped in place, but shall be distributed by blading or dozing in a manner to insure proper placement in final position in the embankment. The spalls and smaller stone fragments shall be left on the surface of each layer as formed. The uppermost portion of rock embankments placed in this manner shall be constructed as follows: 1) Where the specified or proposed surfacing consists of a rigid or flexible type pavement, the top consolidated rock layer for the full width between roadbed slopes shall be finished to the same limits as shown on the plans for undergrading in rock cuts; 2) Any embankment necessary outside the limits of the pavement shall be constructed of suitable earth or as otherwise specified in the contract. 203.2.19 Removal of flexible pavements, where designated on the plans or directed by the Engineer, shall be made to a joint sawed to full depth with a true line and vertical face. The Contractor shall exercise care to protect the portions of flexible pavement that are to remain. 203.3 Compaction of Embankment and Treatment of Cut Areas with Moisture and Density Control. AASHTO T 99, Method A shall be used if 20 percent or less by weight of the material is retained on the No. 4 sieve. For material with 20 percent or less retained on the ¾ inch sieve, use Method C. If more than 5 percent is retained on the No. 4 sieve for method A or ¾ inch sieve for method C, a correction for oversize material is required in accordance with AASHTO T224. These methods will be used as the Standard Compaction Test for determining the moisture density relationship of soils. The optimum moisture as determined by the Standard Compaction Test may be used as a guide in determining the proper moisture content at which each soil type should be compacted. Water shall be added or removed as necessary to permit obtaining the required stability, density and moisture control. The field density and moisture of the embankment after compaction will be determined, using AASHTO approved methods. The calculated field density obtained will be compared with the maximum density as established by the Standard Compaction Test to determine the percent compaction attained.
9/1/2023
203-9
Roadway and Drainage Excavation, Embankment, and Compaction
203.3.1 Compaction for embankments and cut areas will be divided into 3 categories. Category A. No compaction test required. These areas are: 1) Stump holes; trenches, holes, and pits resulting from the removal of improvements; plugged cistern walls above the fill will be compacted to approximately the same density as that required in adjoining areas (Sections 201.2.2, 202.22.6, and 203.2.3.2); 2) Compacting will be waived on surcharged material (Section 203.2.15); 3) Berms, filling old channels, waste, or similar areas will be compacted by uniformly distributing the hauling over the entire area and specific density control will not be required (Section 203.2.17.2); 4) Material having more than approximately 20 percent retained on a ¾ inch sieve shall be compacted by making four complete coverages of each layer with a tamping-type roller or two complete coverages of each layer with a vibratory roller (Section 203.3.5). Category B. Density requirement of 90 percent of maximum density as determined by the Standard Compaction Test AASHTO T99. These areas are: 1) All roadway embankments except as otherwise provided in Sections 203.2.15, 203.2.17.2, 203.3.3, 203.3.4, 203.3.5, and 203.3.7; 2) All backfilled undergraded cuts, except as modified by Section 203.3.3. Category C. Density requirement of 95 percent of maximum density as determined by the Standard Compaction Test AASHTO T99. These areas are: 1) Upper 18 inches of earth subgrade extending the full width between roadbed slopes (Section 203.3.3); 2) Roadway Embankments within 100 feet of a structure on which the top slab or deck is to be used as the riding surface, and the spill fill under such a structure (Section 203.3.4); 3) Embankment below an elevation 50 feet below the top of the finished subgrade (Section 203.3.7); 4) Cut compaction for the full width between roadway inslopes (Section 203.3.8.1); 5) Existing ground for the full width between roadway slopes under embankments of less than 18 inches in height (Section 203.3.8.2); 6) Pavement constructed directly on a soil base, the upper 18 inches of the earth subgrade extending the full width between roadbed slopes (Section 203.3.9);
9/1/2023
203-10
Roadway and Drainage Excavation, Embankment, and Compaction
7) The backfill along end bents, walls, or other units, which falls within the upper 18 inches of the roadbed (Section 206.4.9). 203.3.2 The moisture content of the soil should not exceed 120 percent of optimum at the time of compaction except as herein specified. 203.3.2.1 When necessary to eliminate rubbery condition of the embankment, it may be required that some soils have a moisture content below the optimum during compacting work. Clays, heavy clays, and other Class A excavation materials having liquid limits of 40 or more shall not be placed as embankment when the moisture content of the soil surpasses its optimum moisture by three (3) percent. The liquid limit determination will be as set forth in AASHTO T 89. Some Class A material including heavy clays and material commonly known as shales and fireclays will require breaking down so that the moisture can be uniformly distributed. Existing embankments shall be disked, aerated, or reworked to comply with the moisture requirements of this provision subsequent to the resumption of embankment placement operation. 203.3.2.2 Loessial soils shall have moisture controlled so as not to exceed optimum plus three (3) percentage points when placed in embankments of less than 30 feet high. Such soils when placed in embankments of 30 feet or more high shall have moisture controlled so as not to exceed optimum moisture. If wet foundation conditions contribute to the embankment moisture while compacting, the Engineer may waive this specified moisture content for a height not to exceed 3 feet above the embankment foundation. In the event of conflict of provisions of this section with provisions in Section 203.3.2.1, Section 203.3.2.1 shall govern. 203.3.3 Top Lift Thicknesses. At least 95 percent of maximum density will be required for the upper 18 inches of the earth subgrade extending the full width between roadbed slopes. 203.3.4 Structure Approach. Roadway embankment within 100 feet of each end of a structure on which the top slab or deck is to be used as the riding surface, and the spill fill under such a structure, shall be compacted to not less than 95 percent of maximum density. 203.3.5 Rocky Fill. Density requirements will not apply to portions of embankments constructed of material so rocky that they cannot be satisfactorily tested in accordance with AASHTO T 191 or T 205. Material of a gradation having more than approximately 20 percent retained on a ¾ inch sieve will generally be considered too rocky for satisfactory density testing. In lieu thereof, compactive effort on rock and rocky material shall consist of making four complete coverages of each layer with a tamping-type roller or two complete coverages of each layer with a vibratory roller. The tamping-type roller shall have tampers or feet protruding not less than 6 inches from the surface of the drum and have a minimum load on each tamper of 250 psi of tamping area. The vibratory roller shall have a manufacturer's rating of 16 to 20 tons compacting power. During compaction, each layer shall have the moisture content controlled such that, in the judgment of the engineer, any silt and clay fraction is in a plastic state. Simple diagnostic tests to establish such a plastic state include ability to indent with thumb or heel or to roll a short thread of soil between the hands. Material which crumbles under pressure will be considered too dry. 203.3.6 Lift Consistency. Each layer shall be wetted or dried, as necessary, and shall be compacted to the required density. Regardless of the type of equipment used, the roadway shall be compacted uniformly and the surface kept reasonably smooth at all times. If large
9/1/2023
203-11
Roadway and Drainage Excavation, Embankment, and Compaction
pieces of heavy clay are encountered the material shall be broken down by suitable manipulation to permit satisfactory embankment construction. If shale is encountered, it shall be broken down as much as is practicable and compacted at or above optimum moisture. 203.3.7 Deep Fills. Compaction to at least 95 percent of maximum density will be required for that portion of any embankment below an elevation 50 feet below the top of the finished subgrade. If, because of embankment foundation conditions, the 95 percent of maximum density cannot be obtained after reasonable compactive effort has been expended, the Engineer may waive the 95 percent requirement for a height not to exceed 3 feet above the embankment foundation. 203.3.8 Compacting in Cut. 203.3.8.1 Cut compaction shall be performed in all Class A excavation areas designated by the Engineer, after removal of the roadway excavation material to the required section. A surface parallel to the pavement slope, 12 inches below the bottom of the pavement or lowest base course, shall be temporarily exposed for the full width between roadway inslopes. The exposed material, to a depth of 6 inches, shall be manipulated and compacted to the required density of at least 95 percent of maximum density. The material above this compacted plane shall be respread in layers not exceeding 8-inch loose thickness, each layer being wetted or dried as necessary and compacted to at least 95 percent of maximum density. The entire volume of materials so handled and compacted, including the 6-inch layer compacted in place, will be considered as Compacting in Cut. All Class A excavation material having a liquid limit of 40 or more, including the 6-inch layer compacted in place, shall be compacted at not less than optimum moisture content. 203.3.8.2 In areas designated by the Engineer, the existing ground for the full width between roadway slopes under embankments of less than 18 inches in height shall be treated in accordance with Section 203.3.8.1 to only such depth as to insure having 18 inches of material of the required density and moisture below the top of the finished subgrade. 203.3.8.3 The entire volume of materials so handled and compacted as specified in Section 203.3.8.1 and Section 203.3.8.2, including the 6-inch layer compacted in place, will be considered compacting in cut. 203.3.8.4 Cut compaction shall be performed to an additional depth of 12 inches for 50 feet on each side of the intersection of the natural ground and the top of the subgrade, then graded uniformly for 30 feet to meet the depth requirements of Section 203.3.8.1 and, if necessary, Section 203.3.8.4. 203.3.8.5 The existing ground for the full width between roadway slopes under embankments of less than 18 inches high shall be treated in accordance with Section 203.3.8.1 to only such depth as to insure having 18 inches of material of the required density and moisture below the top of the finished subgrade.
9/1/2023
203-12
Roadway and Drainage Excavation, Embankment, and Compaction
203.4 Compaction of Embankments Not Constructed with Density or Moisture and Density Control. The compactive effort on each layer shall consist of distributing all equipment movements over the entire embankment area and of at least three complete coverages with a tamping-type roller over the entire area to be compacted. The tamping-type roller shall have tampers or feet projecting not less than 6 inches from the surface of the drum and shall have a minimum load on each tamper of 250 psi. Compactive effort shall be continued, if necessary, until the tamping feet penetrate not more than 2 inches into the layer of material being compacted. Continuous leveling and manipulating will be required during compacting operations and the moisture content shall be adjusted as is necessary, in the judgment of the Engineer, to permit proper consolidation. 203.4.1 Dumping and rolling areas shall be kept separate, and no lift shall be covered by another until compaction complying with these requirements has been secured. Unstable areas in the embankment shall be removed and replaced with suitable material at the expense of the Contractor. 203.4.2 Each layer of embankment constructed of rock or rocky material shall also be compacted by three complete coverages of the tamping-type roller. A vibratory roller may be used on approval of the Engineer. 203.5 Compaction of Embankments without Specified Compaction Results or Specified Compaction Equipment. If compaction of embankment is not designated by the contract no compaction will be required other than that obtained by distributing equipment movements over the entire embankment area. 203.6 Method of Measurement. 203.6.1 Contract Quantity Payment. The quantities of excavation and compacting embankment for which payment will be made will be those shown in the contract for the various items, provided the project is constructed essentially to the lines and grades shown on the plans. A partial check of existing ground elevations will be made at the time slope stakes are set, and of the finished work for deviations in the grade, width, or slope from the authorized grade or typical section. 203.6.1.1 Final Measurement. Contract quantities will be used for final payment of Class A Excavation, Unclassified Excavation, and Compacting Embankment except when: 1) Appreciable errors are found in the original computations; 2) An original cross section is found to have an average deviation from the true elevation in excess of 1 foot; 3) An authorized change in grade, slope, or typical section is made; 4) Unauthorized deviations decrease the quantities on the plans; 5) Class C Excavation is encountered, unless the contract calls for unclassified excavation. If the above conditions are encountered the corrections or revisions will be computed and added to or deducted from the contract quantity. The Contractor's attention is directed to Section 105.4.2 with regard to obvious errors;
9/1/2023
203-13
Roadway and Drainage Excavation, Embankment, and Compaction
6) Quantities are determined by measurement as specified in Section 203.6.2. 203.6.1.2 If the plans have been altered or when disagreement exists between the Contractor and the Engineer as to the accuracy of the plan quantities of any balance, or the entire project, either party shall have the right to request a recomputation of contract quantities of excavation within any area by written notice to the other party. The written notice shall contain evidence that an error exists in the original ground line elevation or in the original computations, which will materially affect the final payment quantity. If such final measurement is required, it will be made from the latest available ground surface and the design section. 203.6.2 Measured Quantities. If payment of excavation is to be made on a measured quantity basis, volumes of authorized excavation will be computed from cross section measurements by the average end area method. When not attributable to carelessness of the Contractor, slides in Class A Excavation and in Unclassified Excavation will be included in such measurements. Authorized excavation of rock, shale, muck, or other unsuitable material will also be included. 203.6.2.1 Authorized excavation of rock, shale, muck, or other unsuitable material below grade shall consist of that excavation necessary to provide the designated depth of undergrading. If the plane of the designated bottom of excavation falls within a layer or stratum of rock, the below grade excavation to the bottom of the layer, not exceeding 12 inches below the designated limits of undergrading, will be considered as authorized and will be measured for payment, provided the overbreak has been removed sufficiently to permit accurate cross sectioning. Rock excavation more than 12 inches below the designated limits of undergrading will not be paid for. No measurement or payment will be made of any material removed and replaced from below the design limits of undergrading, if the nature of the material, the thickness of the layer or stratum, and the method of operations are such that it is practicable to excavate only to the depth shown on the plans. No measurement will be made for overbreakage or for the disposal of the same if such material is obtained from outside the neat lines of the proposed backslopes in rock excavation except that such overbreakage will be measured as Class A Excavation or Unclassified Excavation, as applicable, when all suitable authorized excavation has been used and the overbreak material is required for completion of the embankment. A maximum tolerance of 1 foot will be permitted for rock protruding or extending within the neat lines of the proposed backslopes. 203.6.2.2 While work involving classified excavation is in progress, the Engineer will fix points of elevation and stationing as required to establish the lines of demarcation between the materials of different classification. These top points will be determined before any Class C Excavation is removed and it shall be the Contractor's responsibility to notify the Engineer before removing any such material. Any excavation removed before the Engineer has been notified and given 24 hours to establish lines of demarcation will be included in the measurement of Class A Excavation only. 203.6.2.3 Excavation may be encountered in which lines of demarcation between material of different classifications are impracticable to establish. The quantity of material classified as other than Class A Excavation may be determined by the Engineer on a percentage basis as the work progresses after the limits of determinate classification material have been established. Where vertical or near vertical excavation limits are
9/1/2023
203-14
Roadway and Drainage Excavation, Embankment, and Compaction
indicated by the plans, all Class A Excavation material encountered within the actual Class C vertical excavation limits will be included with Class C Excavation quantities. 203.6.2.4 Measured quantities of excavation will be used where the ground elevations shown on the plans are found to be erroneous. No revision of contract quantities will be made when the actual ground elevations are considered to agree generally with the ground line shown on the plans. Where the Engineer authorizes a change in grade, slope, or typical section affecting the volume of excavation allowed for payment in that particular balance or area, the revised volume will be determined by the average end area method on the basis of the revised grade, slope, or typical section. Where unauthorized deviations result in a decrease in the contract quantities, the deviations will be measured and deducted from the contract quantity. 203.6.2.5 The quantity of Class C Excavation will be computed on a measured quantity basis. The volume of Class A Excavation allowed for payment in roadway balances involving rock excavation will be determined by one of the following methods, whichever in the judgment of the Engineer is more applicable. 1) Measuring and computing both the Class A Excavation and the Class C, Excavation within the limits affected or as defined by Section 203.6.2.3; 2) Deducting the volume of Class C Excavation from the total adjusted volume of roadway excavation, regardless of classification, within the limits affected or as defined by Section 203.8.2.3. 203.6.2.6 Measurements will be made for unsuitable material actually excavated and removed to permit proper compaction in cut sections and in foundations for embankment sections. No measurement will be made of the suitable material temporarily removed, and replaced, to facilitate compaction in cuts or under shallow embankments. 203.6.2.7 Borrow quantities will be determined by measuring the borrow area before and after excavating. 203.6.2.8 Excavated material stockpiled in accordance with Section 203.2.10 will be measured in the stockpile by the average end area method. 203.6.2.9 Only that material placed in accordance with the requirements of Section 203.3 will be included in the measurement of Compacting Embankment and Embankment in Place. If an error has been found in the original computations or ground elevations, or if there has been an authorized change in grade, slope, or typical section, the plan quantity for Compacting Embankment and Embankment in Place for those areas or balances affected will be adjusted for final payment. All required compaction above the original ground line and all compacting of material placed in undergraded cut sections will be considered as Compacting Embankment and Embankment in Place. 203.6.2.10 Compacting in Cuts will be the measured quantity of material compacted. The volume allowed for payment will be computed for actual areas compacted during construction, to the dimensions shown on the plans, and will include any required compaction of the original ground under shallow fills.
9/1/2023
203-15
Roadway and Drainage Excavation, Embankment, and Compaction
203.6.2.11 Measurement of roadway and drainage excavation, compacting embankments, and compacting in cuts will be made to the nearest cubic yard. 203.7 Basis of Payment. Payment for roadway excavation will be made at the contract unit bid price per cubic yard which price shall be full compensation for the excavating and hauling; placing and forming of embankments; preparation of subgrade; shouldering, rounding slopes, obliterating old roadway, finishing of graded earth roadway, picking up and disposing of pickup rock; and any work noted on the plans to be included in the price bid for excavation. No payment will be made for any material used for purposes other than those designated, except as approved by the Engineer. 203.7.1 Payment will be made at the contract unit bid price per cubic yard for the applicable item of Class A Excavation or Unclassified Excavation for each handling of stockpiled excavation approved by the Engineer. 203.7.2 No payment will be made for rock overbreak or for backfilling overbreak areas below the undergrading limits. Payment for the material for backfilling required undergraded areas would be made under an applicable excavation item. No direct payment will be made for backfilling around structures, the excavation for which has been paid for as roadway excavation. 203.7.3 Removal and Replacement of Unsuitable Material. When removal of unsuitable material is directed by the Engineer, the Contractor will be reimbursed for removal and replacement of the unsuitable material at 1.5 times the contract unit pricing for Class A Excavation. If no pay item exists in the contract, for Class A Excavation, payment will be made per cubic yard at 1.5 times the fixed cost for Class A Excavation specified in section 109.4.5. Payment will cover all excavation, hauling, and disposal of unsuitable material and procurement, placement, and compaction of replacement materials. 203.7.4 Unclassified Excavation. If the contract does not contain a unit price for Unclassified Excavation, payment will be made at two times the unit price bid per cubic yard for Class A Excavation. If no bid item in the contract exists for Class A Excavation the fixed cost price for Class A Excavation will be the fixed cost price specified in section 109.4.5. . 203.7.5 No direct payment will be made for water required in compaction work. Any costs involved in reducing the moisture content in soils will be at the expense of the Contractor. 203.7.6 Payment for finishing a graded earth roadway will be completely covered by the contract unit bid price for the various classes of excavation except as otherwise specifically noted under Section 104.10.3 in regard to material excavated in cleaning channels and culverts used in place. 203.7.7 Payment will be made at the unit bid price for each of the pay items included in the contract. 203.7.8 No direct payment will be made for any required saw cutting. Saw cutting will be considered incidental, unless included as a pay item in the contract.
9/1/2023
203-16
Roadway and Drainage Excavation, Embankment, and Compaction
203.8 Embankment In Place (Contractor Furnished Borrow). 203.8.1 Description. This work shall consist of constructing embankments using contractor furnished material in accordance with the specifications and in conformity with the lines, grades, thicknesses, and typical cross sections shown on the plans, or established by the Engineer. Contractor furnished material shall meet the approval of the Engineer as provided in Section 106. 203.8.2 Material. Bidders and contractors are advised that proposed sites for contractor furnished material may be sampled and tested only after award of the contract and after proof of an agreement, between the property owner, municipality and the Contractor authorizing use of any borrow site, has been provided to the Engineer. 203.8.3 Contractors are advised that a written certification shall be made by the successful bidder that the proposed borrow site is cleared of environmental concerns under all applicable federal and state laws and regulations. These include but are not limited to the following: Clean Water Act, the Endangered Species Act, the National Historic Preservation Act, the Farmland Protection Act, Resource Conservation and Recovery Act, Comprehensive Environmental Response, Compensation, and Liability Act and RSMo Chapter 194, Section 194.400 Unmarked Human Burial Sites. Certification shall be obtained in advance of the proposed use of a borrow site and furnished to the Engineer. Certification shall include clearance letters and other evidence of coordination from the appropriate regulatory agencies, as attachments. 203.8.4 Guidelines for obtaining environmental clearances for contractor’s furnished borrow sites will be included in the contract documents. 203.8.5 Construction Requirements. The material in the embankment shall be placed in accordance with Section 203.8 and in conformity with the lines, grades, and typical cross sections shown on the plans. Compaction of the embankment will be required in accordance with Section 203.3. 203.8.6 Method of Measurement. The quantity of embankment in place for which payment will be made is that shown in the contract, provided the embankment is constructed essentially to the lines and grades shown on the plans. Contract quantities will be used for final payment of embankment in place except as directed in Section 203.6 and when quantities are determined by measurement as specified in Section 203.6.2. 203.8.6.1 When the above conditions are encountered, the corrections or revisions will be computed and added to or deducted from the contract quantity. No measurement will be made of material placed outside the approved section. 203.8.7 Basis of Payment. Payment will be made at the contract unit price for "Embankment in Place," per cubic yard, and will be considered full compensation for: 1) Furnishing, transporting material from stockpile sites or from a contractor provided source; 2) Placing and forming of embankments;
9/1/2023
203-17
Roadway and Drainage Excavation, Embankment, and Compaction
3) Compacting embankment or for adding or reducing the water content of the embankment; 4) Any excavation required to provide the embankment material included under the item of embankment in place, including mulching and seeding of a borrow site; 5) Any work noted on the plans to be included in the contract unit price for embankment in place. 203.8.8 No payment will be made for any work or material other than that designated for use under the item of embankment in place, except as approved by the Engineer.
9/1/2023
203-18
Roadway and Drainage Excavation, Embankment, and Compaction
Section 204
Embankment Control
204.9 Description. This work shall consist of furnishing, setting, and monitoring embankment control stakes for detection of earth movement. 204.9.1 Materials. Embankment control stakes shall conform in type of materials and dimensions to the requirements shown on the plans. The stakes and cross arms shall be painted white and the horizontal arm on each control stake shall have scale graduations in black for measuring movement. 204.9.2 Construction Requirements. 204.9.2.1 The stakes shall be set firmly in a vertical position by placing in predrilled holes and backfilling with a lean concrete mixture. Stakes shall be set at locations shown on the plans or as directed by the Engineer and shall be set in straight lines or straight line segments. A straight line segment shall consist of not less than three vertical stakes aligned so as to form, with the horizontal cross arms, planes of visual reference for detection of earth movement. Cross arms need not be at constant elevation, but shall be aligned along a constant line of sight plane. Adjacent or intersecting straight-line segments may have common stakes. 204.9.2.2 Unless located on an embankment slope or berm, control stakes shall be placed prior to construction of the adjacent embankment except that, with the Engineer's approval, embankment not to exceed 5 feet high may be placed prior to installation of the stakes, if deemed necessary to minimize disturbance from equipment working in close proximity to the stakes. 204.9.2.3 It shall be the Contractor's responsibility to maintain and protect the stakes from damage and to notify the Engineer if movement is detected. Stakes damaged or misaligned by accident due to the Contractor's negligence shall be replaced or realigned at the direction of the Engineer, at the Contractor's expense. 204.9.2.4 If movement is detected in the embankment control stakes, the Engineer may require that embankment construction be discontinued for a period not to exceed ten (10) days until corrective measures can be determined. 204.9.3 Basis of Payment. Accepted embankment control stakes, complete in place, will be paid for at the contract unit price. No direct payment will be made for any devices required to protect the stakes or for any delays resulting as a consequence of their use.
10/1/2012
204-1
Embankment Control
Section 204.10 Settlement Gauges 204.10.1 Description. Settlement gauges shall consist of pipe gauges installed for the purpose of obtaining foundation settlement data during the placing, and following completion of embankment and surcharge construction. An estimated number of settlement gauges will be indicated in the contract; however, the exact number and location will be determined by the Engineer. 204.10.2 Materials. A settlement gauge shall consist of the following: 1) A steel plate with a galvanized riser pipe attached perpendicular to the plate at its center by a continuous weld; 2) Lengths, to be approved by the Engineer, of ¾ inch threaded galvanized riser pipe and couplings; 3) Lengths, to be approved by the Engineer, of galvanized 1½ inch threaded pipe and couplings to act as a cover or guard for the riser pipe. 204.10.3 Construction Requirements. 204.10.3.1 The first section of the ¾ inch pipe shall be welded to the plate. The distance from the top of plate to the top of pipe will be accurately measured and recorded by the Engineer. 204.10.3.2 An excavation, slightly larger than the plate, shall be made to a depth approximately 18 inches below the natural ground surface. Care shall be exercised during excavation to ensure that the bottom of the pit is level, and that the material at this location is undisturbed. The pit bottom shall be covered with a layer of Portland cement mortar, approximately 3 inches thick, and the plate bedded therein in such position that the riser pipe is vertical. After the mortar has set, the cover pipe, cut approximately 6 inches shorter, shall be slipped over and centered around the riser pipe. The backfill shall then be placed in 6 inches layers and thoroughly compacted. The Contractor shall notify the Engineer when the installation is complete. No embankment shall be placed around the gauge until the elevation of the top of the riser has been determined by the Engineer. 204.10.3.3 Embankment material in the immediate vicinity of the settlement gauge pipe shall be placed and compacted in accordance with the requirements of Section 726.6.1. When the elevation of the embankment reaches a level approximately 1 foot below the top of the cover pipe, the Engineer shall be notified and the next section of riser pipe and cover pipe shall be installed in the Engineer’s presence. As the height of the embankment increases, this procedure shall be repeated until the embankment and surcharge is completed, and the pipe sections, both riser and cover, extend approximately 2 feet above the surface of the completed embankment and surcharge.
10/1/2012
204-2
Embankment Control
204.10.3.4 All necessary precautions shall be taken to keep the alignment of the riser pipe and cover pipe maintained in a vertical position at all times. The Contractor shall operate his equipment so that the settlement gauges are not damaged or displaced. Protective barriers shall be erected when so directed by the Engineer. Settlement gauges shall be maintained in a satisfactory operating condition until after placing of the embankment and surcharge, and until, in the judgment of the Engineer, the settlement readings are no longer necessary. Any gauges that are damaged shall be repaired or replaced by the Contractor at the Contractor's expense. 204.10.3.5 The Engineer will obtain and record all measurements and elevations necessary for accurate determination of settlement data during and after completion of embankment and surcharge. 204.10.4 Basis of Payment. Accepted settlement gauges, complete in place, will be paid for at the contract unit bid price. No direct payment will be made for any devices required to protect the gauges.
10/1/2012
204-3
Embankment Control
Section 204.20 Pore Pressure Measurement Devices 204.20.1 Description. This work shall consist of placing and maintaining pore pressure measurement devices as shown on the plans, and obtaining foundation pore pressure measurements during the placement of embankment. Pore pressure measurement devices, locations, elevations, and limits of embankment subject to control by each device will be shown on the plans. 204.20.2 types:
Equipment.
Pore pressure measuring devices shall consist of the following
Type A. - This device consists of a pneumatic transducer sealed within a sand chamber which is set into the foundation to the specified elevations. Type B. - This device consists of a ½ inch PVC standpipe extending to the surface of the embankment from a sand chamber set into the foundation to the specified elevations. 204.20.2.1 The pneumatic transducer, jacketed tubing, and necessary pressurizing and gauging equipment for Type A installations will be furnished by the Commission without cost to the contractor upon two weeks written notice preceding the date of installation. The balance of the material for the Type A installation shall be furnished by the contractor. All material for the Type B installation shall be furnished by the contractor, except for the electrical sounding device. 204.20.3 Construction Requirements. 204.20.3.1 The Contractor shall be responsible for making the installation, for furnishing all incidental materials, for providing all necessary protection of the installation, and for replacement in the event of damage. In the event of damage to the installation, the Engineer may require suspension of embankment construction in the controlled area until the Contractor has restored the installation to satisfactory working order. Installation of the pore pressure measurement device shall precede placement of any embankment by at least two weeks to allow time for testing of the completed installation and replacement in the event of malfunction. No embankment may be placed until the installation is complete and tested to the satisfaction of the Engineer. 204.20.3.2 A hole of not less than 5 inches in diameter, or more than 8 inches, shall be drilled to Elevation B as defined in the plans. If necessary, casing shall be used to prevent sloughing of material from the walls of the hole and contamination of the walls or bottom of the hole by sloughed material. Casing shall be no smaller in its outer diameter than the diameter of the hole and shall have no externally coupled joints in the bottom 10 feet.
10/1/2012
204-4
Embankment Control
204.20.3.3 If casing is required, the hole shall be washed to the bottom with clean water circulated through the bit until the discharge is clear. Clean sand shall then be poured into the hole to the approximate depth shown on the plans. The assembled pore pressure measurement device shall then be lowered to its indicated position with care to avoid contamination with soil from the side of the hole and additional sand shall be placed around it to Elevation "A" as shown on the plans. During these steps, any casing shall be pulled ahead of the backfill in increments of 6 inches to 24 inches as necessary to prevent collapse or sloughing of the hole. The hole shall be maintained full of clean water during these steps to at least the elevation of the top of the sand chamber. The creation of pockets of soil, air, or voids in the sand backfill shall be avoided. 204.20.3.4 After sand is placed to the indicated elevation, the hole shall be backfilled with wetted, plastic bentonite clay as the casing is withdrawn, for not less than 4 feet above the top of the sand filled chamber. If necessary, the clay shall be worked by hand into plastic balls to be dropped into the hole and tamped into a coherent mass. An acceptable alternate is the use of preformed dry bentonite pellets. In dry installation, dry granular bentonite may be tamped in place. The remainder of the hole shall be filled with a thick slurry of bentonite. 204.20.3.5 At natural ground level, or as otherwise directed by the Engineer, four layers of ¾ inch exterior grade plywood, 4 feet x 4 feet, nailed and clinched together with rust proof nails, and a 3 inch diameter hole cut at the center, shall be centered over the installation after the ground is smoothed and leveled with sand. A closet flange, or other suitable receptacle shall be securely fastened to the plywood over the 3 inch diameter hole, so as to securely receive a 5 foot length of 3 inch iron or steel casing. Earth or sand shall be compacted about the casing in 6 inch lifts with care to avoid misalignment after the Engineer has established the elevation of the plywood slab and the top of the casing. 204.20.3.6 Upon completion, each installation shall be tested. Type A installation shall be tested in accordance with recommendations of the transducer manufacturer. Type B installations shall be tested by dropping a weighted line through the standpipe to check for possible obstructions. The standpipe shall then be filled with water and periodic readings made of the water level in the standpipe until the level of natural ground water is reached. If less than a 70 percent drop in head is experienced in the first 24 hours, the standpipe shall be flushed and retested. Records of rate of head loss shall be kept for subsequent evaluation of possible time lags in response of water levels to embankment placement. 204.20.3.7 The Engineer may require the installation of additional pore pressure measurement devices, at the contract unit price, within any area subject to control by such devices, at any time during the construction of the embankment. The Engineer will determine the type of device, location, and elevation of additional installations. Any such additional pore pressure measurement device shall govern the rate of construction in the same manner as the original devices. The reference pressure levels for additional devices shall be either that of the original devices or as determined from boreholes located outside the loaded area, as directed by the Engineer.
10/1/2012
204-5
Embankment Control
204.20.4 Pore Pressure Measurements and Records. 204.20.4.1 The Engineer will make and record all observations and measurements required to determine natural ground water pressures and pore water pressures induced by embankment construction. The pressure of the natural ground water existing at the time of installation and prior to placement of any embankment will be used as a reference to determine pore pressures induced by subsequent embankment placement. However, the Engineer may, at his discretion, subsequently make borings outside the loaded area to facilitate observations to determine if the natural ground water table has lowered due to seasonal or climatic variations. Such observations may be used to lower, but not raise, the initial reference ground water pressure. 204.20.4.2 The Engineer will make all records of ground water and pore water pressures readily available to the Contractor for his guidance in the planning of the Contractor's work. 204.20.4.3 If foundation pore pressure, in excess of pressure from the natural water table, equals or exceeds 35 percent of the unit pressure of the embankment in place over the installation at any time, placement of embankment shall be immediately suspended. Construction shall not resume until such excess pressure declines to 25 percent of embankment pressure, unless otherwise authorized by the Engineer. 204.20.4.4 After the embankment reaches an elevation equal to 60 percent of the maximum height, the Contractor shall control his rate of construction in such a manner that foundation pore pressure, in excess of pressure from the natural water table, will not exceed 35 percent of the unit pressure of the embankment in place over the installation at any time. An example of pressure relationships follows: Soil embankment with an average wet density of 125 pounds per cubic foot is equal to twice the unit weight of water. 1 foot of such embankment thus has a potential to create, at most, 2 feet of water rise in a standpipe, or a 0.87 psi increase in a Type A installation. The Contractor may thus anticipate the maximum possible effect of any load to be added. The Contractor is cautioned that Type B installations are prone to some time lag in rate of response to a pressure increment. Records of pore pressure response during placement of the first 60 percent of embankment height shall be examined for evidence of such lag. The time required for dissipation of head during testing will also be indicative of the rate of response. 204.20.4.5 When embankment has advanced to within approximately 1 foot of the top of the casing, the casing and the ½ inch PVC pipe for the Type B installations, shall be advanced in 5 foot increments. No extension shall be made without the Engineer's approval. PVC pipe extensions shall be made using solvent welded couplings,, exercising care to make smooth, squared cuts with all burrs removed, in accordance with recommendations of the pipe and solvent cement manufacturers. Pneumatic tubing leads used with Type A installations shall be long enough to permit extension, without connections, to the top of the embankment or surcharge. Excess tubing shall be stored in a steel container attached to the last casing extension as shown on the plans.
10/1/2012
204-6
Embankment Control
204.20.5 Settlement Records. The Engineer will make and record all measurements and elevations necessary, including elevations of the plywood plate and all casing extensions, for use in establishing a settlement record at the site of the pore pressure measurement device. The 3 inch outer steel casing will be used for this purpose. Care shall be taken to insure the tightest possible coupling connections, using pipe wrenches, without rotating the bottom pipe. Settlement records obtained in this manner may be used to satisfy such settlement rate requirements as may be outlined in the contract. 204.20.6 Basis of Payment. 204.20.6.1 The contract unit bid price shall include acceptance by the Contractor of the possible restraints inherent in the use of these devices upon the rate of construction. No additional compensation will be made for any costs incurred as a result of compliance with this requirement. 204.20.6.2 Accepted pore pressure measurement devices, complete in place, will be paid for at the contract unit bid price per each.
10/1/2012
204-7
Embankment Control
(This Page Intentionally Left Blank)
10/1/2012
204-8
Embankment Control
Section 205
Modified Subgrade
205.1 Description. This work shall consist of modifying a subgrade to improve stability. This work shall be performed as specified in the contract, at the Contractor's option with concurrence from the Engineer or at the direction of the Engineer. 205.2 Material. All material shall be in accordance with Division 1000, Material Details, and specifically as follows. 205.2.1 The modifying material shall be hydrated lime or other material approved by the Engineer. 205.2.1.1 If hydrated lime is used, the contractor shall furnish or require the supplier to furnish with each load certification that the product is in accordance with AASHTO M 216. 205.2.1.2 If modifying material other than hydrated lime is used, the material and application plan shall be approved by the Engineer prior to use. 205.3 Construction Requirements. 205.3.1 Application. 205.3.1.1 If not directed by the Engineer or specified in the contract, the contractor may determine the locations, amount of modifying material and depth of application, within the limits of this specification and subject to concurrence from the Engineer. 205.3.1.2 Where performed, subgrade modification shall be done to all areas uniformly and laterally between outside shoulder points plus 18 inches on each side. When the modified areas are stopped and started, there shall be a longitudinal transition zone at the rate of 30 feet per 6 inches of modified depth. The transition may be made by reducing modifying material or by mixing depth. 205.3.1.3 The modifying material shall be spread in uniform and regular patterns. No material shall be applied if the material is being blown from the work area. 205.3.1.4 The application rate of the modifying material shall be approved by the Engineer. 205.3.2 Compaction. The subgrade shall be uniformly mixed with the modifying material. Mixing and compaction shall continue until the subgrade is shown to have suitable compaction as demonstrated by the roller equipment. Density and moisture testing will ordinarily be waived for subgrade modified under this specification, except that should compaction not be demonstrated to the Engineer's satisfaction, the Engineer reserves the right to run stability tests, as necessary, in accordance with ASTM D 6951.
10/1/2012
205-1
Modified Subgrade
205.3.3 Stability. The subgrade shall be uniformly mixed with the modifying material. Mixing and compaction shall continue until the subgrade is shown to have a minimum California Bearing Ratio (CBR) value of 5 percent in the upper 3 inches of subgrade. 205.4 Method of Measurement. Measurement of modified subgrade will be made to the nearest square yard, including transition areas. Subgrade meeting all other requirements, suitable for the placing of base material and having modifying material incorporated as specified herein, will be paid for at the contract unit price per square yard except as noted herein. 205.5 Basis of Payment. 205.5.1 If included in the contract, payment for modified subgrade will be made per square yard of modified subgrade at the contract unit price. No direct payment will be made for the required modifying material. 205.5.2 If performed at the option of the Contractor, payment for modified subgrade will be made at the invoiced material cost from the supplier, and no reimbursement will be made for incorporation or for processing. 205.5.3 If modified subgrade is not included in the contract and is directed by the Engineer, payment will be made in accordance with Section 104.3. 205.5.4 Reimbursement for transition areas will be made at the contract unit price per square yard for ½ the area of the transition. 205.5.5 Reimbursement will be limited to modified areas, the width of the pavement and shoulders, plus 18 inches on each side. 205.5.6 Only one payment for modified subgrade will be made for any area, regardless of the depth of stabilized material, number of applications, or other circumstances.
10/1/2012
205-2
Modified Subgrade
Section 206
Excavation for Structures
206.1 Description. 206.1.1 This work shall consist of the necessary excavating for the foundations of all structures, the removing and disposing of all excavated materials, the backfilling around the completed structures, and all related work. 206.1.2 No direct payment will be made for removing existing structures within the limits of excavation for structures. However, existing headwalls or culvert concrete to be removed will be paid for as removal of improvements for roadway culverts or partial removal of culvert concrete for bridge culverts. All removal work that might endanger the new structure, shall be completed before any work on the new structure is started. Partial removals of any structure or adjustments of any utility shall be made with care to preserve the value of the retained portions. Work around any live utility shall be done in such manner that uninterrupted service can be maintained. 206.1.3 Excavated material which is unsuitable for backfill and embankments, and excess material not required for either, shall be disposed of. It shall not be dumped into the channel of a stream. 206.2 Depth of Excavation. The elevation of the bottoms of footings as shown on the plans shall be considered an approximate elevation, and the Engineer by written order, may make such changes in plan elevations and dimensions of footings as may be necessary to secure a satisfactory foundation. 206.2.1 When blasting is approved in accordance with Section 203.2.5, the lower limit of blasting allowed will be 18 inches above the bottom of footing elevation. In the event that over fracturing of the underlying rock below bottom of footing occurs, the removal of loose rock and the backfilling of the resultant void with fill concrete will be at the Contractor's expense. 206.3 Foundation Stabilization and Tests. 206.3.1 The Contractor shall furnish and place sand, rock, gravel, or other suitable backfill material to replace unsuitable material encountered below the foundation elevation of the structures. 206.3.2 The Contractor shall stabilize suitable foundation material or form the bottom of pile footings if necessary to obtain a stable foundation. The Contractor shall furnish assistance in driving sounding rods or drilling test holes to permit an adequate inspection of the foundation. The depth of the excavation, the character of the material, and the condition of the foundation shall be approved by the Engineer before any concrete is placed in the footing.
9/1/2023
206-1
Excavation for Structures
206.4 Construction Requirements. 206.4.1 Foundation Excavation Protection. Methods shall be used in excavating for foundations of structures that will insure maintaining the stability of the material adjacent to the excavation. Sheeting, cribbing, timbering, or bracing shall be placed by the Contractor where indicated on the plans and wherever considered necessary. The Contractor will be held responsible for the adequacy of all sheeting, cribbing, timbering, or bracing used. Shop drawings prepared, sealed and signed by a Professional Engineer registered in the State of Missouri showing bracing or cribbing to be employed by the Contractor must be submitted for approval fourteen (14) calendar days prior to any installation on the project. 206.4.2 Foundation Key. Foundations for structures and retaining walls shall be free of loose, shelly, or disintegrated rock, and the footing shall be placed on undisturbed material. Footings shall be keyed not less than 6 inches into hard, solid rock and not less than 18 inches into soft rock, or shale, or other suitable material specified for spread footings. Excavation in rock or shale for the key shall be made as near as practicable to the size of the footing, or of the key as shown on the plans. When placing the footing, the key portion shall be cast against the vertical, undisturbed face of the rock or shale. If side forms are necessary for footings, they will be adequately braced and they shall be removed approximately 24 hours after placing the concrete, and the excavation shall immediately be backfilled to the top of the footing. All cavities or crevices or low areas below the bottom of footing elevation shall be cleaned out and filled with concrete in accordance with Section 703.3.12.8, or spanned with a reinforced concrete beam, as directed by the Engineer. 206.4.3 Foundation Subgrade. Care shall be taken to avoid disturbing the material below the bottom of the footings when the structure is founded on material other than rock, and final removal of grade shall not be made until just prior to placing concrete. Where foundation piles are required, the excavation of each pit shall be completed before the piles are driven, and after the driving is completed all loose and displaced material shall be removed. 206.4.4 Culverts on Rock. If rock is encountered under a portion of the bottom slab of a concrete box-type structure, the rock shall be removed to at least 6 inches below the bottom of the slab and curtain walls, and backfilled with material similar to that under the remainder of the structure. 206.4.5 Footing Construction. Concrete footings for structures shall be placed on reasonably dry foundation material. The Contractor shall perform all draining, bailing, or pumping operations, drive any sheeting, and construct any cofferdams or cribs necessary to obtain this condition. Pumping from the interior of any foundation enclosure shall be done in a manner to preclude the possibility of the movement of water, or other fluids or semi-fluids, through any fresh concrete. If necessary, the footing form shall be made watertight and shall be sealed around the bottom, and all pumping done between the footing form and the wall of the enclosure. 206.4.6 Footing Drainage. All holes, pits, or sumps resulting from excavating operations shall be kept drained or pumped out until the completion of the work. No ponding of water around footings on other than rock will be permitted.
9/1/2023
206-2
Excavation for Structures
206.4.7 Cofferdams. In accordance with the contract, the contractor shall provide cofferdams, consisting of sheet piling, or the contractor may propose alternate methods for the construction of the bridge foundations. Alternate designs or methods may consist of, but are not limited to: the construction of cofferdams, seal courses, over excavation, well point systems, dewatering and drainage diversion. The method proposed by the contractor shall stay within the right of way limits provided in the contract. Cofferdams shall, in general, be carried well below the bottom of the footings, and shall be well braced and as watertight as practicable. The interior dimensions of cofferdams shall provide sufficient clearance for the construction of forms and ample room for a sump and for pumping outside the footing forms. Cofferdams that have been tilted or moved laterally during the process of sinking shall be corrected to provide the necessary clearance. Cofferdams shall be constructed to protect the work against damage from sudden rising of the stream and to prevent damage to the foundation by erosion. Cofferdams, with all sheeting and bracing, shall be removed after the completion of the substructure unit, unless specific authority is given for them to be left in place. The Contractor shall submit drawings showing his proposed method of cofferdam construction and other details open to his choice or not fully shown on the plans. 206.4.8 Temporary Shoring. When temporary shoring is required by the contract documents, the contractor shall provide temporary shoring as needed, consisting of sheet piling or alternate methods for the construction of roadway fills, mechanically stabilized earth walls or structures. The contractor shall submit the proposed method of temporary shoring construction to the Engineer prior to beginning work. 206.4.9 Seal Courses. Seal courses will be required if indicated on the plans or when conditions are encountered which, in the judgment of the Engineer, render it impracticable to dewater the foundation area. The dimensions of the seal course shall be adequate to seal the foundation area. Pumping will not be permitted while excavating, driving piling, or placing the seal course, and not until, by determination of the Engineer, the seal course has attained sufficient strength to withstand the hydrostatic pressure. If seal courses are shown on the plans, and the Engineer determines that the footings may be satisfactorily placed without sealing, the Contractor will be required to dewater any completed excavation for investigation purposes. Seal courses, other than those on the plans, will not be authorized or permitted except for extreme cases where it is impracticable to unwater the footing area by other means, and then only with the written permission of the Engineer. If the Contractor's proposed alternate method includes cofferdams that are to be constructed with seal courses, the Contractor shall prepare construction plans that are properly designed for the site conditions and water elevations that may be encountered during footing construction. These plans shall be signed and sealed by a professional engineer licensed in the State of Missouri and shall be provided to the Engineer for review a minimum of two weeks prior to the beginning of actual footing construction. The Contractor is responsible for the safety and performance of the Contractor's proposed system. 206.4.10 Backfill. Backfill material shall be of an acceptable quality and shall be free from large or frozen lumps, wood, or other extraneous material. All spaces excavated and not occupied by the new structure, or by porous backfill, shall be refilled with earth to the original ground surface or to the finished ground lines shown on the plans. All backfill shall be thoroughly compacted and its top surface neatly graded. The backfill at end bents, walls, or other units which falls within the limits of the roadbed shall be placed in successive 6 inch layers and compacted to the same density required for the adjacent roadbed. Dry footings at interior bents shall be backfilled and compacted to no less than the density of the adjacent undisturbed material. Large rock, broken concrete, asphalt or other solid material
9/1/2023
206-3
Excavation for Structures
shall not be used as backfill within 18 inches of the fill face of culverts, retaining walls, or end bents. Precaution shall be taken to prevent any wedging action against the masonry. The slope bounding the excavation, if steeper than six horizontal to one vertical, shall be stepped or serrated. Backfill placed around culverts and piers shall be kept at approximately the same elevation on opposing sides. Drains consisting of 5 square feet of coarse aggregate shall be placed at weep holes except where porous backfill is required. Backfill material shall not be placed against end bents or bridges, sides of box culverts, or back of retaining walls until the concrete has attained the strength specified in Section 703.3.10. Backfill material shall not be placed higher behind than in front of end bents until the superstructure is in place. Until the grade is in place, drainage shall be maintained away from the end bent backwall by constructing a 6 horizontal to 1 vertical or steeper slope away from the backwall for a minimum distance of 3 feet and providing a lateral path for all water to flow off of the roadbed section. 206.4.11 Porous Backfill. Porous backfill meeting the requirements of Section 1009.1 shall be placed in back of abutments, wings, and retaining walls where specified and shown on the plans. It shall be 18 inches thick and shall extend from the bottom of weep holes or other drainage devices to within 2 feet of the finished ground line. The remaining 2 feet shall be backfilled with earth. Porous backfill shall be so placed and consolidated in successive 12 inch layers that it will not become mixed with other backfill material. 206.4.12 Flowable Backfill. Flowable backfill will be required when indicated in the contract documents. The Contractor may, with the approval of the Engineer, use flowable backfill as an alternate to compacted backfill for structures, pipes or utility cuts. Flowable backfill intended for any other use by the Contractor shall also be approved by the Engineer. Flowable backfill shall not be used to surround drainage systems such as vertical drains or edge drains. Flowable backfill shall meet the requirements of Section 625, Flowable Fill (Controlled LowStrength Materials). 206.4.13 Excavation Classification. Unless otherwise shown on the plans, excavation for structures will be classified as Class 1 Excavation, Class 1 Excavation in Rock, Class 2 Excavation, Class 2 Excavation in Rock, Class 4 Excavation or Class 4 Excavation in Rock. In general, Class 1 Excavation and Class 2 Excavation will apply to excavation for bridges and large retaining walls. Class 4 Excavation will apply to excavation for culverts, concrete box-type structures classed as bridges, sewers, small retaining walls and other miscellaneous structures. Class 1 Excavation will include all excavation above a specified elevation indicated on the plans while Class 2 Excavation will include all excavation below this specified elevation. The classification of excavation for all structures will be shown on the plans. Any material excavated in cleaning out culverts which are used in place, will be paid for at the contract price per each structure. However, only the initial excavation will be paid for, and any subsequent cleaning required prior to final acceptance shall be done at the Contractor's expense. 206.5 Method of Measurement. 206.5.1 Measurement of Class 1 and Class 2 Excavation will be made to the nearest ½ square yard for each structure of that volume of material actually removed from within the limits herein established. The volume measured will be limited by vertical planes 18 inches outside of and parallel with the neat lines of footings, tie beams, or overhangs of structures classed as bridges or retaining walls. The upper limits of the volume measured will be the existing ground line or the lower limits of the roadway, drainage, or channel excavation,
9/1/2023
206-4
Excavation for Structures
including any allowable overbreak, whichever is lower. Where roadway spill fills are required to be placed and compacted before driving piles for end bents, no measurement of excavation will be made for the end bents. If such roadway spill fills are placed and compacted before constructing an intermediate bent, any required additional excavation for the intermediate bent will be measured from the spill slope. For stream crossings the measured volume will not include water, but will include mud, muck, and other semi-solids. The lower limits of the volume measured will be the bottom of the footings, bottom of seal courses, or 18 inches below the bottom of tie beams and overhangs. For timber bents, the excavation will be measured within the horizontal limits shown on the plans to the bottom of the backing supports for end bents, and to the bottom of the sway bracing for intermediate bents. 206.5.1.1 Excavation for columns above pedestal piles will be Class 1 Excavation with measurement being made of the volume of material actually removed above top of pedestal. The volume measured will not exceed that of a cylinder having a diameter 36 inches greater than that of the column above the pedestal. No measurement will be made of the material excavated for the pedestal below the bottom of the column. 206.5.2 Measurement of Class 4 Excavation will be made to the nearest cubic yard for each structure of that volume of material actually removed from within the area bounded by vertical planes 18 inches outside of the outer walls of box culverts with bottom slabs or the sides of pipe culverts except as modified for vitrified clay pipe culverts in Section 726.8.2(a) and except the volume of headwall and culvert concrete removals included in the contract for direct payment. The upper limits of the volume measured will be the existing ground line, or the lower limits of the roadway excavation, whichever is lower. Class 4 Excavation under embankments and in channel changes will be measured from the original ground surface unless otherwise designated on the plans. For box culverts without bottom slabs, measurement will be made as above, except no material below plan flow line will be included which is outside of the area bounded by vertical planes 18 inches each side of and parallel with the neat lines of the walls or footings. 206.5.2.1 Final measurement of Class 4 Excavation for box culverts with a span of 6 feet or less, pipe culverts, sewers and miscellaneous small structures will not be made unless there is an authorized change from plan location resulting in a different quantity or there is an authorized change averaging more than 6 inches in the foundation elevation. If a revision is made, or an appreciable error is found in the contract quantity, the revision or correction will be computed and added to or deducted from the contract quantity. Excavation classification will not change if a substitution of a drainage structure type is approved. 206.5.2.2 Measurement of Class 4 Excavation will be made for authorized excavation necessary to locate existing utilities requiring reconstruction work. 206.5.3 Where concrete in footings or walls is cast against the vertical faces of the excavation, the neat lines of the concrete footings will be considered the limits of excavation for the depth in which the concrete is in contact with the excavation, and no measurement will be made of any excavation or overbreak beyond the neat footing lines.
9/1/2023
206-5
Excavation for Structures
206.5.4 The volume of porous backfill will be computed to the nearest cubic yard at each structure from dimensions on the plans. Any porous backfill material placed outside the neat lines shown on the plans will be placed at the Contractor's expense. Final measurement of the porous backfill will not be made except for authorized changes during construction, or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. 206.6 Basis of Payment. 206.6.1 Payment for additional Class 1 and Class 2 Excavation required to carry footings a maximum of 8 feet below elevations shown on the plans will be made at 125 percent of the contract unit price for that additional excavation within the limits of Class 1, and at 150 percent of the contract unit price for that additional excavation within the limits of Class 2 Excavation. Additional excavation required to carry footings a depth of more than 8 feet below plan elevations will be considered extra work, and will be paid for as provided in Section 104.3. 206.6.2 Payment for drilling test holes for foundations tests will be made at the fixed cost price specified in section 109.4.5 206.6.3 Payment will not be made for removal or replacement of foundation material which became unsuitable because of improper methods of construction by the Contractor. Payment for removal of inherently unsound material for foundation stabilization will be made at the contract unit price for excavation for structures. No payment will be made for any cost involved in replacing the volume below grade, except that the Contractor will be reimbursed for the delivered material cost if a granular type material is specified by the Engineer. If no Selected Granular Backfill pay item exists in the contract, payment for Selected Granular Backfill, as deemed suitable by the Engineer, will be made per cubic yard at the fixed cost specified in section 109.4.5. 206.6.3.1 If Class C Excavation material, as defined by Section 203, is encountered in Class 1 Excavation, and no pay item for Class 1 Excavation in Rock is included in the contract, payment for Class 1 Excavation in Rock will be made per cubic yard at the fixed cost specified in section 109.4.5.. 206.6.3.2 If Class C Excavation material, as defined by Section 203, is encountered in Class 2 Excavation and no pay item for Class 2 Excavation in Rock is included in the contract, payment for Class 2 Excavation in Rock will be made per cubic yard at the fixed cost specified in section 109.4.5. 206.6.3.3 If Class C Excavation material, as defined by Section 203, is encountered in Class 4 Excavation and no pay item for Class 4 Excavation in Rock is included in the contract, payment for Class 4 Excavation in Rock will be made per cubic yard at the fixed cost specified in section 109.4.5.
9/1/2023
206-6
Excavation for Structures
206.6.4 No direct payment will be made for placing coarse aggregate at weep holes as required by Section 206.4.9. No direct payment will be made for backfilling the structure unless so specified in the contract. 206.6.5 The accepted quantities of excavation for structures will be paid for at the unit price for each of the pay items included in the contract. 206.6.6 All costs for furnishing material, labor or equipment, construction, dewatering, drainage, and any other incidental work necessary to complete cofferdam construction; and subsequent removal of any cofferdams, berms, diversions, and any other features constructed for cofferdams as identified by the Engineer will be considered completely covered in the contract unit price per lump sum per bent, regardless of construction method. Payment for Class 1 Excavation and/or Class 2 Excavation will be limited to the volume defined in Section 206.5. No additional payment for excavation will be made for a contractor proposed method of cofferdam construction. 206.6.7 All costs for furnishing material, labor, equipment, construction, drainage, and other incidental work necessary to complete temporary shoring construction; and subsequent removal of any temporary shoring, berms, diversions, and any other features construction for temporary shoring as identified by the Engineer will be considered completely covered in the contract unit price per lump sum regardless of construction method. 206.6.8 No direct payment will be made for removing existing structures within the limits of excavation for structures. Existing headwalls or culvert concrete to be removed will be paid for as removal of improvements for roadway culverts or partial removal of culvert concrete for bridge culverts. 206.6.9 Payment for seal courses other than those on the plans will be made only with written authorization from the Engineer. 206.6.10 Any material excavated in cleaning out culverts to be used in place will be paid for at the contract unit price per each structure. However, only the initial excavation will be paid for, and any subsequent cleaning required prior to final acceptance shall be done at the Contractor's expense.
9/1/2023
206-7
Excavation for Structures
Section 207
Linear Grading
207.1 Description. This work shall consist of grading work necessary to bring the roadway to the required grade and cross section within reasonable tolerances. It shall also include the following: 1) Construction of all inlet and outlet ditches and ditch blocks within the linear grading limits unless otherwise provided for in the contract; 2) Construction of entrances and approaches; 3) Breaking up and satisfactory removal or incorporation into the roadway of all gravel, macadam, or bituminous surfaces; 4) Compaction of the roadway subgrade within linear grading limits; 5) All linear grading will be classified as hereafter described. 207.1.1 Linear Grading, Class 1, shall consist of grading where the topography is such that the excavation necessary to bring the roadway to the designated cross section will approximately make the nearby fills with a minimum of drifting or hauling, and where it will not be necessary to control the finished grade line for purposes other than to obtain minimum cover over culverts. 207.1.2 Linear Grading, Class 2, shall consist of grading where it is necessary to excavate and haul material approximately 200 feet to bring the roadway to the desired grade and may involve work on high banks and side hills. 207.1.3 The class of linear grading designated on the plans will apply only to those sections which have been specifically indicated as such on the plans and will not be subject to change during construction unless approved by the Engineer. 207.2 Construction Requirements. 207.2.1 The roadway shall be brought to the required grade and cross section within reasonable tolerances by backsloping, ditching, removing stone and boulders from the roadbed surface, or any other work necessary, including drifting and hauling of any excavated material. A reasonable tolerance in alignment means a maximum gradual deviation of 2 feet, free of sharp breaks, to take advantage of favorable topography. Gradual deviation in alignment will also be permitted, if necessary to center an existing drainage structure that is to be used in place. A reasonable tolerance in grade means a final grade that is uniform in appearance, free of sharp breaks or humps, and within 0.5 feet of plan grade.
10/1/2012
207-1
Linear Grading
207.2.2 Stumps, roots, rubbish, or any other deleterious material shall not be placed in embankments. Where an embankment of less than 2 feet high is to be constructed, all vegetative matter shall be cut and removed from the surface upon which the embankment is to be placed. The cut-over surface shall be thoroughly broken. All ditches including inlet and outlet ditches, shall be cut to grades that will properly drain. The required cross section for inlet and outlet ditches leading to or from structures shall be of a width not less than the width of the floor or the diameter of the structure being served. Finishing operations shall continue until the roadbed is free from sharp breaks in alignment and grade, and until it has been shaped to the required cross section. Material considered unsuitable for the subgrade shall be disposed of on nearby slopes or as otherwise directed by the Engineer. 207.2.3 If obliteration of old roads is designated in the contract to be performed on a linear grading basis, such obliteration shall include all grading operations necessary to fill the ditches and blend the old road with the natural ground to provide a pleasing appearance. 207.2.4 Any subgrade upon which a paved surface is to be placed shall be compacted in accordance with Section 203. 207.3 Method of Measurement. Measurement of Linear Grading, Class 1 and Class 2, will be made to the nearest 1/10 station. 207.3.1 Unless otherwise provided in the contract, measurement and payment for entrances and approaches will be made as Linear Grading, Class 1. Entrances and approaches will be measured along the centerline of each facility, regardless of the width to be constructed, beginning at the shoulder line of the road that is being entered and extending to the point of zero cut or fill of the entrance or approach. Measurement will be made to the nearest 10 feet for each facility and totaled to the nearest 100 feet. 207.3.2 If material is encountered that may be classified as other than Class A Excavation as described in Section 203.1, the limits of Linear Grading will not be underrun. Material classified as other than Class A Excavation will be measured and paid for per cubic yard in accordance with Section 203.7. If the contract does not contain a unit price for Class A Excavation and if Class C Excavation is encountered, payment for Class C Excavation will be made at a unit price of $6.50 per cubic yard regardless of quantity, unless the project is let on an unclassified basis. Where undergrading is necessary, backfilling of the undergraded area will be considered as a part of the linear grading operation. 207.4 Basis of Payment. The accepted quantities of linear grading will be paid for at the unit bid price for each of the pay items included in the contract, and will be considered as full compensation for all equipment, labor, material or other construction involved in completing this work.
10/1/2012
207-2
Linear Grading
Section 209
Subgrade Preparation
209.1 Description. This work shall consist of preparing the subgrade upon which a base course is to be constructed or a surfacing placed. After a base course has been constructed, the top of the completed base course will be considered the subgrade for the next operation. 209.2 Equipment. A self-propelled steel wheel roller weighing not less than 10 tons shall be used in preparing any subgrade for flexible type surfacing and weighing not less than 5 tons in preparing any subgrade for Portland cement concrete base course or pavement. 209.3 Construction Requirements. The subgrade shall be substantially uniform in density throughout its entire width. It shall conform to the lines, grades, and typical cross sections shown on the plans, or as established by the Engineer. The subgrade shall be constructed to drain surface water to the side ditches, and all ditches shall be kept open by the Contractor. Where hauling results in ruts or other objectionable irregularities, the Contractor shall reshape and reroll the subgrade before the base or surfacing is placed. If an old, traveled roadway comprises any part of the roadbed, the Contractor shall loosen the compacted portions to a depth of at least 6 inches and shall reshape the roadbed. 209.3.1 All subgrades shall be rolled. The subgrades shall be checked after rolling and, if not at the proper elevation at all points, sufficient material shall be removed or added and compacted to bring all portions of the subgrade to the required elevation and density. The moisture content of the top 6 inches of the finished subgrade at the time the base is placed, or at the time the pavement is placed if no base is provided under the pavement, shall be not less than the minimum specified for compacting in Section 203. If the moisture content has not been maintained, the subgrade shall be scarified, wet to the required moisture content, and compacted. An occasional maximum deviation of plus or minus ½ inch from the required elevation will be permitted on the surface of the finished subgrade. The extent of acceptable areas of deviation will be determined by the Engineer. 209.3.2 Soft Spots and Unsuitable Material. Prior to laying base or setting paving forms, the subgrade shall conform to the moisture and density requirements for compaction. Soft spots and unsuitable material shall be removed to a depth not to exceed 24 inches and backfilled with approved stable material. Unsuitable material shall be removed and backfilled in accordance with Section 203.2.6. The gradation of the material will be determined by the Engineer. 209.3.3 Subgrade Backfill in Trenches. Recycled concrete washout will be allowed as fill material in a trench environment only. If at any time the fill material becomes unstable, the contractor, at the contractor's expense, shall restore with a suitable material to the required grade, cross section, and density. Recycled concrete washout as fill material shall consist of crushed stone, sand, gravel, and cement from reclaimed concrete washout. It shall be placed in six (6) inch lift and compacted to achieve an average dynamic cone penetration CBR index value great than or equal to ten (10), per an approved ASTM method, throughout the lift thickness. The final six (6) inches, brought to grade, will be an approved Type V aggregate base. Recycled concrete washout material specifications located in section 1010. 209.3.3.1 The subgrade shall be compacted and brought to true shape. Any material added shall be satisfactorily incorporated and compacted. After all grading or planing operations have been completed, and immediately before the aggregate base is placed, the subgrade shall be checked with an approved template. Scratch templates with 9/1/2023
209-1
Subgrade Preparation
spikes or teeth will not be permitted. A taut line across the top of side forms and a ruler may be used in lieu of a template for checking the subgrade on irregular areas or variable widths. Extreme care shall be taken in forming the crown and shaping the subgrade to assure that the specified thickness of aggregate base will be attained. The finished subgrade at the time of aggregate base placement shall be moist, but sufficiently firm to resist rutting or deforming under construction traffic. 209.3.3.2 In the event the Contractor elects to use slip forming method for pavement construction, additional subgrade preparation will be in conformance to specifications. No direct payment will be made for such additional subgrade preparation requirements. 209.4 Method of Measurement. Measurement for the volume of unsuitable material excavated beyond or outside the limits shown on the plans or established by the specifications for roadway excavation, will be made by the Engineer to the nearest cubic yard. 209.5
Basis of Payment.
209.5.1 No direct payment will be made for subgrade preparation. No direct payment will be made for water necessary for subgrade preparation.
9/1/2023
209-2
Subgrade Preparation
Section 217
Ditching
217.1 This work shall consist of that grading and excavating required to bring the roadway to the ditch grades shown on the typical sections included with the plans. 217.2 Construction Requirements. 217.2.1 Excavation under this item shall not exceed a maximum of 2 feet measured from the existing ground line to the finished grade of the ditch. Gradual deviation in alignment will be permitted, if necessary to center an existing drainage structure that is to be used in place. 217.2.2 Stumps, roots, rubbish or other deleterious material shall not be left in place in the ditch slopes. All ditches, including inlet and outlet ditches, shall be cut to grades that will properly drain. The required cross section for inlet and outlet ditches leading to or from structures shall be of a width not less than the floor or the diameter of the structure being served. Finishing operations shall continue until the alignment of the ditch and side slopes are smooth and free from sharp breaks in grade. Material considered unsuitable for roadway construction shall be disposed of by the Contractor at his expense. 217.2.3 Method of Measurement. Measurement for ditching will be made to the nearest 1/10 station, along the centerline of the roadway one or both sides as indicated on the plans or as directed by the Engineer. 217.2.4 If material is encountered that may be classified other than Class A Excavation as described in Section 203.1, such excavated material will be excavated in accordance with Section 203. 217.2.5 Basis of Payment. The accepted quantities of ditching will be paid for at the unit bid price. If the contract contains a unit price for excavation classed other than Class A Excavation and such excavation is encountered in the ditching operations, payment will be made at the unit price bid for such classified excavation. If the contract does not contain a unit price for excavation classed other than Class A Excavation, and such excavation is encountered in the ditching operations, payment will be made at four times the unit price bid for Class A Excavation, or Embankment in Place unless the project is let on an unclassified excavation basis. The unit prices established in the above manner will apply regardless of the quantities involved.
10/1/2012
217-1
Ditching
(This Page Intentionally Left Blank)
10/1/2012
217-2
Ditching
Division 300
BASES AND AGGREGATE SURFACES
7/1/2016
300-1
Bases and Aggregate Surfaces
(This Page Intentionally Left Blank)
7/1/2016
300-2
Bases and Aggregate Surfaces
Standard Specifications for Road and Bridge Construction Division 300 - Bases and Aggregate Surfaces Section
Description
Revision Date
301..... Blank ................................................................................................................................. 302..... Blank ................................................................................................................................. 303..... Blank ................................................................................................................................. 304..... Aggregate Base Course ...................................................................................... 7/1/2016 305..... Blank ................................................................................................................................. 306..... Blank ................................................................................................................................. 307..... Blank ................................................................................................................................. 308..... Blank ................................................................................................................................. 309..... Portland Cement Concrete Base (Deleted - Moved to Section 509) .................................. 310..... Blank .................................................................................................................................
7/1/2016
300-3
Division 300 - Index
(This Page Intentionally Left Blank)
7/1/2016
300-4
Division 300 - Index
Section 304
Aggregate Base Course
304.1 Description. This work shall consist of furnishing and placing one or more courses of aggregate on a prepared subgrade in accordance with these specifications and in conformity with the lines, grades, thicknesses, and typical cross sections shown on the plans or established by the Engineer. 304.2 Material. All material shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Aggregate for Base, Type 5
1007
304.2.1 Sampling and Testing. Samples for preliminary testing shall be furnished by the Contractor prior to the start of base construction. All tests for initial aggregate submittals necessary to determine compliance with the specification requirements will be made by the Engineer at no expense to the Contractor. 304.2.1.1 Samples of aggregate base shall be furnished by the Contractor at the start of production and at intervals during production. The sampling points and intervals will be designated by the Engineer. Samples for gradation, deleterious and Plasticity Index (PI) shall be taken at the roadway, behind the placing operation, prior to compaction. The samples will be the basis of approval of specific lots of aggregate base for the quality requirements. 304.2.1.2 When production for a week is anticipated to be 1,000 tons or less, samples of aggregate base to check gradation shall be taken at least once per 250 tons or 1 per week, whichever occurs first. Sampling and testing shall be in accordance with Section 1007. 304.3 Construction Requirements. 304.3.1 Field Laboratory. When authorized by the Engineer, the Contractor shall provide a Type 2 Field Laboratory meeting the requirements of Section 601. Payment for the laboratory will be made as provided in Section 601. 304.3.2 Subgrade. All work on that portion of the subgrade on which the base is to be constructed shall be completed in accordance with the requirements of Section 209.3.1 prior to the placing of any base material on that portion. Aggregate base shall not be placed on a frozen subgrade. 304.3.3 Hauling Equipment. The mixed recycled concrete aggregate base course shall be transported from the plant to the job site in hauling equipment having beds that are smooth, clean, and tight. Trucks that transport aggregate shall be legally licensed, in good working condition, free from hydraulic or transmission oil leaks, have beds that are free from detrimental foreign matter, and are equipped with the safety devices required by the United States Department of Transportation. All loads shall be covered with a tarpaulin in accordance with Section 404.14.
7/1/2016
304-1
Aggregate Base Course
304.3.4 Mixing. Unless otherwise specified, base material, any additional material required, and sufficient water to obtain the desired compaction shall be thoroughly mixed and delivered to the road as a combined product. 304.3.5 Placing. The maximum compacted thickness of any one layer shall not exceed 6 inches. If the specified compacted depth of the base course exceeds 6 inches, the base shall be constructed in two or more layers of approximately equal thickness. The compacted depth of a single layer of the base course may be increased to 8 inches for shoulders and lightly traveled areas. 304.3.5.1 Excess Material. The Contractor shall be responsible for placing the correct quantity of base material on the roadbed to construct a base conforming to the contract. Excess material shall be hauled ahead and reused, or loaded into trucks and measured or weighed (measured or the mass determined) over scales furnished by the Contractor. Only material incorporated in the completed base will be included in the quantity allowed for payment. 304.3.5.2 Slip-Form Construction. If the Contractor elects to construct concrete pavement by slip-form methods in accordance with Section 502.17, the width of the aggregate base shown on the plans shall be increased to provide a 3-foot width outside the edge of the pavement being placed. 304.3.5.3 Spreading and Placement. Type 5 aggregate base used for shoulders adjacent to rigid or flexible type pavement, including pavement resurfacing, shall be simultaneously deposited and spread on the subgrade with an approved spreading machine. Aggregates shall not be deposited on the pavement and bladed or dozed into place. 304.3.5.4 Subdrains and Geotextile Filter Fabric. Reclaimed aggregate base materials shall not be placed around or intersect with pavement subdrains or geotextile fabric to avoid potential leachate from blinding the fabric or clogging the drainage system. 304.3.6 Shaping and Compacting. Immediately before spreading the mixture, the subgrade shall be uniformly dampened with water, as directed by the Engineer. The mixture shall be uniformly spread in successive layers of such depth that when compacted, the base will have the approximate thickness specified. Each layer shall be compacted to the specified density before another layer is placed, with the following exception. If difficulty is encountered in obtaining the specified density after reasonable compactive effort has been expended on the first lift, the Engineer may permit placing another layer. The testing for density will then be made on the combined lifts or layers. 304.3.6.1 Segregation and Contamination. Type 5 aggregate base is intended to provide some drainage and shall not be segregated. Trimmed Type 5 aggregate base may not be reused until it is verified as meeting the required specifications. Base material contaminated to such an extent that it no longer complies with the specifications shall be removed and replaced with satisfactory material at the expense of the Contractor.
7/1/2016
304-2
Aggregate Base Course
304.3.6.2 Shaping and compacting shall be performed until a true, even, and uniform surface of proper grade, cross-section, and density is obtained. 304.3.6.2.1 Density Determination. The Standard Compaction Test will be made in accordance with AASHTO T 99, Method C; a correction for oversize material is required in accordance with AASHTO T224. Field density will be determined in accordance with AASHTO T 191 or T 205, using the total material or AASHTO T 310 Direct Transmission, for wet density. The volume of the test hole may be reduced as necessary to accommodate available testing equipment. If nuclear density test methods are used: 1) Moisture content will be determined in accordance with AASHTO T 310. 2) A moisture correction factor will be determined for each aggregate in accordance with MoDOT Test Method TM 35. 304.3.6.2.2 Compaction Equipment. Aggregate base course compaction shall be accomplished using one or a combination of the following pieces of equipment as specified in Section 404.17. The number, type, and weight of rollers shall be sufficient to compact the material to the required density. 304.3.6.2.3 Roadway and Shoulder Density Requirements. Type 5 aggregate base under both roadway and shoulders shall be compacted to not less than 100 percent of the standard maximum density. 304.3.6.2.4 All Other Area Density Requirements. Type 5 aggregate base used for sidewalks, paved approaches, concrete medians, islands, isolated pavement repair removal and replacement areas, shall be compacted to not less than 95 percent of standard maximum density. 304.3.6.2.5 Moisture Control and Final Rolling. During shaping and compacting operations, the moisture content of the base shall be maintained at the level necessary for compaction, by wetting or drying as required. Final rolling shall be accomplished a by self-propelled, smooth-wheeled roller weighing not less than 5 tons. Rolling shall be continued until there is no visible evidence of further consolidation. 304.3.6.2.6 Isolated Area Compaction Equipment. For isolated pavement repair removal and replacement areas where a Section 404.17 roller is not practical, the Contractor shall utilize a reversible vibratory plate-type compactor with a minimum centrifugal force rating of 6,520 pounds to achieve the aggregate compaction specified. When approved by the Engineer, the aggregate base for the isolated pavement repair removal and replacement areas may be compacted by a minimum of four complete reversible vibratory compactor coverages when not over excavated trenches.
7/1/2016
304-3
Aggregate Base Course
304.3.6.3 Surface Tolerance. 304.3.6.3.1 Hot Mix Asphalt Base. Shaping of the completed surface of the aggregate base for flexible type base shall be continued until the deviation from the required elevation does not exceed a roughly compensating maximum of ½ inch. 304.3.6.3.2 Concrete Pavement or Base. The surface of aggregate base for rigid type pavement or base shall be brought to proper crown and elevation in accordance with the requirements of Section 502. 304.3.6.4 Drainage and Stability. The surface of aggregate base shall be well drained at all times. If at any time the compacted aggregate base or subgrade becomes unstable, the Contractor, at the Contractor's expense, shall restore the earth subgrade and the aggregate base to the required grade, cross section, and density. 304.3.6.5 Substitutions for Aggregate Base (Temporary). If available, the Contractor may substitute bituminous pavement cold millings or crushed recycled concrete in lieu of aggregate base for any temporary surface, regardless of the type or thickness of aggregate shown on the plans. If this option is exercised, the Contractor shall notify the Engineer at least two weeks prior to using the millings or recycled concrete, and shall identify the location from where the millings or concrete will be removed. The millings or recycled concrete shall be installed to the same dimensions shown on the plans for the aggregate base. Millings or recycled concrete shall be placed in maximum loose 5 inch lifts, and each lift shall be compacted by a minimum of three passes with a 10 ton roller. 304.3.6.6 Aggregate Base Thickness Determination. If measurement of aggregate base course by area, complete in place, is specified, thickness of the aggregate base will be determined from measurements through the finished base. When the measurement indicates that the thickness is deficient in excess of ½ inches from the plan thickness, additional measurements will be taken at 100 foot intervals parallel to centerline ahead and back of the affected location until the extent of the deficiency has been determined. It will be assumed that each measurement is representative of the base thickness for a distance extending one-half the distance to the next measurement, measured along centerline, or in the case of a beginning or ending measurement, the distance will extend to the end of the base section. Any deficient areas shall be corrected by reworking and adding material within the limits of the deficiency. 304.3.7 Delivery Ticket. Prior to unloading at the site, the manufacturer of each load of truck shall furnish a delivery ticket to the Engineer, on which is shown information concerning the aggregate as follows: 1) Gross, tare and net weights; 2) Identification of the vehicle; 3) Current date and time; 4) Source; 5) Material type or class designation;
7/1/2016
304-4
Aggregate Base Course
6) Formation(s) and Ledge(s); 7) Unique ticket number. (May be preprinted on the ticket); 8) St. Louis County Project Number and Federal Job Number if applicable. 304.3.8 Maintenance. When the aggregate base is to be constructed in more than one layer, the Contractor shall maintain each layer by wetting or drying, blading, and rolling in a manner satisfactory to the Engineer, until it is covered by the next layer. This maintenance, including necessary water, shall be entirely at the Contractor's expense. 304.3.8.1 Prime Coat. If a prime coat is specified in the contract, the Contractor will be required to apply the prime coat on any completed portion of the aggregate base as soon as practicable, or as otherwise specified. However, the Contractor will not be permitted to apply prime if the moisture in the top 2 inches of the aggregate base exceeds the higher of either: 1) The average of the optimum moisture as determined by the standard compaction test and the absorption of the plus No. 4 fraction; or 2) Two-thirds of the optimum moisture as determined by the standard compaction test. The Contractor shall maintain the required density and surface condition of any portion of the completed aggregate base until either the prime or a succeeding course or pavement is placed. 304.3.8.2 Rework. In addition to the requirements in Section 304.3.7 the Contractor shall maintain any aggregate base material that is not paved over prior to the onset of winter (or for more than 2 months). The aggregate base material left from the winter (or in-place for more than 2 months) shall be retested to verify that it still complies with the requirements of this specification. Aggregate base material that does not conform to the above requirements shall be removed, reshaped, or reworked, watered and thoroughly compacted to conform to the specified requirements at the contractor's expense. 304.3.9 Quality Control. The Contractor shall control operations to ensure the aggregate base in place, meets the specified requirements for density, thickness, gradation, deleterious, and plasticity index. Tests shall be taken at random locations designated by the Engineer. 304.3.9.1 When two consecutive tests for gradation, deleterious material, or plasticity index do not meet specification limits, the material shall be removed beginning at the point where the first test was conducted. 304.3.9.2 Disposal of Unsatisfactory Materials. Any aggregate base material that becomes unsuitable shall be removed and disposed of as directed by the Engineer and at the Contractor's expense.
7/1/2016
304-5
Aggregate Base Course
304.3.10 Construction Traffic. The Engineer may permit equipment used in construction may be routed over completed portions of the base course, provided no damage results and provided that the equipment is distributed evenly over the full width of the base course to avoid rutting or uneven compaction. If the Engineer determines that the aggregate base has been damaged and requires reworking, the Contractor shall rework the base in accordance with Section 304.3.8.2. 304.4 Method of Measurement. 304.4.1 Measurement of Aggregate by Volume. Measurement will be made in the vehicle at the point of unloading. The Contractor shall strike off and level each load for inspection and checking. Measurement will be made to the nearest ¼ cubic yard for each load and to the nearest cubic yard for the total quantity of material accepted. Additional material required by Section 304.3.4.2 will be deducted from the total quantity of material accepted. 304.4.2 Measurement of Aggregate by Weight (Mass). Measurement will be made by weighing each truckload (determining the mass of each truckload) on scales conforming to the requirements of Section 304.4.3. Deductions for excess moisture will be made as follows: 1) Type 5 Aggregate for Base. Deduction will be made for moisture in the total material in excess of one percent over optimum moisture as determined by the standard compaction test. 2) After deduction for excess moisture, measurement will be made to the nearest ton for the total tonnage of material accepted. Additional material required by Section 304.3.4.2 will be deducted from the total quantity accepted. 304.4.3 Vehicle Scales. Vehicle scales shall be approved by the Engineer and shall conform to the requirements specified herein. 304.4.3.1 following:
Basis of Acceptance.
Scale acceptance shall be based on one of the
1) A valid certification or seal of approval by the Missouri Department of Agriculture, Division of Weights and Measures. 2) Certification of calibration from a commercial scale service company showing that the scale meets the requirements of these specifications. The Contractor shall furnish the certification of calibration to the Engineer. 3) Calibration from zero weight through the maximum load to be applied by the application of standard weights in the presence of the engineer by the contractor's personnel. In lieu of starting the calibration at zero weight, the standard weights may be applied to an unloaded truck, the weight of which has been determined on a certified scale and the calibration continued through the maximum load to be applied. Regardless of the form of acceptance, the calibration shall be within the accuracy requirements specified in Section 304.4.3.2 and the scales shall meet all requirements of these specifications.
7/1/2016
304-6
Aggregate Base Course
304.4.3.2 Scale Calibration. Scales shall have been calibrated within the 12-month period immediately prior to any material being delivered or any time the engineer has cause to question the accuracy of the scale. Scales shall be accurate within 0.4 percent of the net load applied regardless of the location of the load on the platform. The value of the smallest unit of graduation on a scale shall be not greater than 20 pounds. Sensitivity requirements of scales not equipped with balance indicators shall be twice the value of the minimum graduated interval on the weigh beam, or 0.2 percent of the nominal capacity of the scale, whichever is less. For scales equipped with balance indicators, the sensitivity requirement shall be the value of the minimum graduated interval on the weigh beam. 304.4.3.3 Scale Verification. Verification of a vehicle scale may be required by the weighing of a hauling unit on another recently calibrated and certified scale. 304.4.3.4 If equipment to be weighed is of such length that all axles cannot be weighed simultaneously, a level area of concrete or bituminous pavement shall be provided permitting those axles not on the scale platform to be on the pavement during the weighing operation. The approach shall be at least as wide as the platform and of sufficient length to insure the level positioning of vehicles during weight determinations. The weighing shall be performed with all brakes released. If equipment to be weighed is equipped with an air bag suspension unit on any axle, the equipment including semitrailers or pup trailers shall be weighed on vehicle scales of sufficient size to weigh all axles of the combination simultaneously. 304.4.3.5 All costs incurred in obtaining a certification of calibration or verification shall be borne by the Contractor. 304.4.4 Measurement of Aggregate Base Course by Area. Measurement of aggregate base course complete in place will be made to the nearest square yard, except that the area of additional material required by Section 304.3.4.2 will not be included. Separate measurement will be made for each type and each thickness of base course. Final measurement of the completed aggregate base course will not be made except for authorized changes during construction or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. Where the aggregate base course extends to the in slope of the shoulder, the pay limit of the aggregate base course will be measured from the mid-point of the sloped portion. 304.5 Basis of Payment. The accepted quantities of aggregate base course of the thickness will be paid for at the contract unit price for each of the pay items included in the contract. Payment will be considered full compensation for furnishing all labor, materials (including water), tools, equipment and incidentals and for performance of all work involved in processing and constructing aggregate base (including reclaimed aggregate base) material, complete in place, as shown in the contract documents, and as directed by the Engineer. 304.5.1 Temporary Aggregate Base. When bituminous pavement cold millings or recycled crushed concrete are substituted for temporary aggregate base, payment will be made for the aggregate base quantity provided in the plans, regardless of whether millings, recycled crushed concrete or the aggregate base is used. Payment will be considered full compensation for hauling of millings, cold milling operations, and all other material or labor necessary to substitute bituminous pavement millings for aggregate base.
7/1/2016
304-7
Aggregate Base Course
(This Page Intentionally Left Blank)
7/1/2016
304-8
Aggregate Base Course
Division 400
FLEXIBLE PAVEMENT
9/1/2023
400-1
Flexible Pavement
(This Page Intentionally Left Blank)
9/1/2023
400-2
Flexible Pavement
Standard Specifications for Road and Bridge Construction Division 400 - Flexible Pavement Section
Description
Revision Date
401..... Blank ................................................................................................................................. 402..... Blank ................................................................................................................................. 403..... Geosynthetic Interlayer for Roadway Applications ............................................... 7/1/2015 404..... Superpave Asphaltic Concrete Pavement and Base............................................ 9/1/2023 405..... Bituminous Pavements and Base ........................................................................ 7/1/2016 406..... Joint and Cracksealing ...................................................................................... 3/15/2022 407..... Tack Coat ............................................................................................................ 2/1/2017 408..... Prime Coat .......................................................................................................... 5/1/2010 409..... Seal Coat ............................................................................................................ 7/1/2015 410..... Micro-Surfacing ................................................................................................... 9/1/2023 411..... Blank ................................................................................................................................. 412..... Pavement Surfacing and Texturing...................................................................... 9/1/2023 413..... Asphaltic Concrete Incorporating Reclaimed Asphaltic Pavement or Shingles (RAP or RAS) ............................................................. 7/1/2015
9/1/2023
400-3
Division 400 - Index
(This Page Intentionally Left Blank)
9/1/2023
400-4
Division 400 - Index
Section 403
Geosynthetic Interlayer for Roadway Applications
403.1 Description. This work shall consist of furnishing and placing a geosynthetic interlayer within the pavement structure as shown on the plans or directed by the Engineer. The geosynthetic interlayer shall provide a moisture barrier/stress relieving membrane and shall be placed beneath a hot-mix asphalt (HMA) overlay. 403.2 Material. 403.2.1 Geosynthetic Interlayer. The geosynthetic interlayer shall consist of geosynthetic material, saturated with asphalt binder. 403.2.1.1 Geosynthetic Material. The geosynthetic interlayer material shall be of the system specified in the contract documents. All geosynthetic interlayer materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
System A Geosynthetic Material
1011.3.7
System B Geosynthetic Material
1011.3.8
System C Geosynthetic Material
1011.3.9
This specification covers geosynthetic material, which is to be saturated with asphalt binder to form a geosynthetic interlayer, for use as a moisture barrier and a stress relieving membrane within the pavement structure. 403.2.2 Tack Coat. The same asphalt binder to be used in the first HMA layer over the geosynthetic interlayer shall be used as the tack coat material for the geosynthetic material, unless the manufacturer of the geosynthetic material recommends a higher performance grade asphalt binder. The asphalt binder shall be in accordance with Section 1015. No emulsions will be allowed. 403.2.3 Clean Sand. Clean sand shall be sand meeting Section 1005.2 or a washed sand meeting the approval of the Engineer. 403.3 Equipment. Equipment used to place the asphalt tack on the geosynthetic material, to install the geosynthetic material or to roll the geosynthetic material into the tack coat shall be in accordance with the manufacturer’s recommendations. 403.4 Construction Requirements. 403.4.1 The geosynthetic material shall be stored as per the manufacturer's recommendations in a dry covered condition free from dust, dirt and moisture.
7/1/2015
403-1
Geosynthetic Interlayer for Roadway Applications
403.4.1.1 The geosynthetic material shall be installed in accordance with the manufacturer's specifications and this specification. Where a conflict exists between the specifications, the more stringent specification will apply. A copy of the manufacturer's specifications shall be provided to the Engineer at the pre-construction meeting or no later than five working days prior to installation. 403.4.1.2 A manufacturer representative shall be present, at minimum, for the first two days of installation of the geosynthetic interlayer and available thereafter upon request by the Engineer. 403.4.1.2.1 This requirement may be waived by the Engineer under the following conditions: 403.4.1.2.1.1 The Contractor has been certified by the manufacturer for installation of the geosynthetic material. 403.4.1.2.1.2 A copy of the written certification is provided to the Engineer and the Contractor certification is approved by the Engineer prior to installation of any material. 403.4.1.2.2 If a manufacturer representative has been waived in accordance with Section 403.4.3.1, the Engineer will still maintain the right to require a representative to be present if the Engineer deems it necessary due to poor installation practices by the Contractor. 403.4.1.3 The surface on which the geosynthetic material is to be placed shall be reasonably free of dirt, water, vegetation or other debris. The geosynthetic interlayer shall be placed on a drainable surface, and any rutting or low spots in the pavement shall be removed by milling or by the use of a leveling course as shown on the plans. Cracks exceeding ⅛ inch in width shall be filled with suitable crack filler. Potholes shall be properly repaired as directed by the Engineer. Fillers shall be allowed to cure prior to placement of the geosynthetic material. 403.4.1.4 Neither the asphalt binder nor the geosynthetic material shall be placed when weather conditions, in the judgment of the Engineer, are not suitable. Air and pavement temperatures shall be sufficient to allow the tack coat to hold the geosynthetic material in place. The air temperature shall be 50°F and rising for placement of the asphalt tack coat. 403.4.1.5 The specified application rate of tack coat shall be sufficient to satisfy the asphalt retention properties of the geosynthetic material and to bond the geosynthetic material and HMA overlay to the existing pavement. 403.4.1.6 Application of the tack coat shall be by a calibrated distributor truck spray bar. Hand spraying, squeegee and brush application will only be allowed where the distributor truck does not have room to operate and shall be kept to a minimum. Temperature of the tack coat shall be sufficiently high enough to permit uniform spray pattern and shall be at minimum 290°F. To avoid damage to the geosynthetic material, distributor tank temperatures shall not exceed 325°F.
7/1/2015
403-2
Geosynthetic Interlayer for Roadway Applications
403.4.1.7 The target width of the tack coat application shall be the geosynthetic material width plus 6 inches. Tack coat application shall be wide enough to cover the entire width of geosynthetic material overlaps. The tack coat shall be applied only as far in advance of the geosynthetic material installation as is appropriate to ensure a tacky surface at the time of the geosynthetic material placement. Traffic shall not be allowed on the tack coat. 403.4.1.8 The geosynthetic material shall be placed onto the tack coat with minimum folds or wrinkles and before the tack coat has cooled and lost tackiness. As directed by the Engineer, wrinkles or folds in excess of 1 inch shall be slit and laid flat or pulled out and replaced. In these repaired areas, additional tack coat shall be applied as needed to achieve a sound bond to the substrate. Damaged geosynthetic material shall be removed and replaced, per the manufacturer's recommendations, at the Contractor's expense with the same type of material. 403.4.1.9 Overlap of geosynthetic material joints shall be sufficient to ensure full closure of the joint, but shall not exceed 6 inches. Transverse joints shall be lapped in the direction of paving to prevent edge pickup by the paver. A second application of tack coat shall be placed beneath the overlapping geosynthetic material to ensure proper bonding of the double material layer. 403.4.1.10 Brooming, squeegee or pneumatic rolling shall be used to remove any air bubbles and to maximize geosynthetic material contact with the pavement surface and shall be done in accordance with the manufacturer’s specifications and to the satisfaction of the Engineer. 403.4.1.11 Excess tack coat that bleeds through the geosynthetic material shall be removed by broadcasting clean sand on the geosynthetic interlayer. Broadcasting of clean sand may also be used to facilitate movement of equipment during construction, to prevent tearing or delamination of the geosynthetic material or to prevent pickup by the paving machine. If sand is applied, any excess sand shall be removed from the interlayer prior to placing the HMA overlay. Scattering loose HMA mix out in front of the paver tires will also be permissible. No other material, such as asphalt release agents or diesel, shall be used for this purpose. 403.4.1.12 No traffic, except necessary construction traffic or emergency vehicles, shall be driven on the geosynthetic interlayer, unless approved by the Engineer. If traffic on the interlayer is approved by the Engineer, clean sand shall be lightly broadcasted over the geosynthetic interlayer, and any loose sand shall be removed prior to paving. 403.4.1.13 Placement of the first lift of the HMA overlay shall closely follow placement of the geosynthetic interlayer. All areas in which the geosynthetic interlayer has been placed shall be paved during the same day, unless approved otherwise by the Engineer. In the event of rainfall on the geosynthetic interlayer prior to the placement of the first HMA overlay lift, the geosynthetic interlayer shall be allowed to dry before the HMA is placed. The compacted thickness of the first lift of the HMA overlay on the geosynthetic interlayer shall not be less than 1.5 inches, and the temperature of the mix at placement shall not exceed the geosynthetic material melting point temperature. Where the total HMA overlay thickness is less than 1.5 inches, geosynthetic material shall not be placed.
7/1/2015
403-3
Geosynthetic Interlayer for Roadway Applications
403.4.2 Method of Measurement. Measurement for furnishing and installing the geosynthetic interlayer will be made to the nearest square yard of pavement System A, B, or C Geosynthetic Interlayer (Non-Woven paving fabric or paving mat specified to be covered.) 403.4.3 Basis of Payment. The accepted quantities of geosynthetic interlayer will be paid for at the unit price for each of the pay items included in the contract.
7/1/2015
403-4
Geosynthetic Interlayer for Roadway Applications
Section 404
Superpave Asphaltic Concrete Pavement and Base
404.1 Description. This work shall consist of providing a Superpave asphaltic concrete mixture to be placed in one or more courses on a prepared base or underlying course in conformance with the lines, grades, thicknesses, and typical cross Sections shown on the plans, or established by the Engineer. 404.1.1 Nomenclature of Superpave (SP) Asphaltic Concrete Mixtures. The nomenclature of Superpave (SP) asphaltic concrete mixture is as follows: The design traffic level of the project is expressed in 18,000-pound Equivalent Single Axle Loads or ESALs. For convenience, the aggregate size is shown, e.g. SP125. The 125 represents the ½ inch nominal maximum aggregate size. The next information shall be the binder performance grade (PG), e.g. SP125 (76-22). The "76" represents the design high and "-22" the design low temperature in degrees Celsius and would be read "PG 76 minus 22". The base Performance Grade binder is a PG 64-22. For slow moving design loads, 12 to 45 Miles per hour, or for design traffic between 10 million and 30 million ESALs, the binder selection shall be one temperature grade higher to a PG 70-22. For standing design loads, less than 12 miles per hour, or for design traffic exceeding 30 million ESALs, the binder selection shall be two temperature grades higher to a PG 76-22. Following the binder grade will be a letter that represents the 20-year Design Traffic ESALs, e.g. SP125 (PG 76-22) E. The E corresponds to a Design Traffic Level of 300,000 to 3,000,000 ESALs. Finally, when designated, a two-letter system is used to indicate special mixtures, e.g. SP125 (PG 76-22) E LP. The LP indicates that the mix is a combination of Limestone and Porphyry and the LS indicates a mix of Limestone and Slag is required. The binder grade for the wedge and wearing courses shall be the same. The standard designs for Arterial Road System roads are SP 125(70-22)C for wedge course, SP 125(70-22)CLP for the wearing course and SP 190(70-22)C for the base course, unless specified otherwise in the contract documents. The standard designs for County Road System roads are SP 125(PG 64-22)E for the wearing course and SP 190(PG 64-22)E for the base course, unless specified otherwise in the contract documents. 404.1.2 The following cumulative ESALs shall be utilized for the specified Superpave mixture design: Design Level F E C B
9/1/2023
Design Traffic (ESALs) ≤ 300,000 ≤ 3,000,000 ≤ 30,000,000 > 30,000,000
404-1
Superpave Asphaltic Concrete Pavement and Base
404.1.3 When Special Asphaltic Concrete Mixture for Surfacing (SP125(PG xx-xx) x LP) or (SP125(PG xx-xx) x LS) is called for in the contract, the work shall consist of a mixture of crushed limestone, crushed porphyry or slag aggregates, natural or manufactured fine aggregate, mineral filler, and asphalt cement prepared in a plant meeting the requirements of Section 404.13, to be used for a surface course of pavement. The aggregate fractions shall be sized, uniformly graded, and combined in such proportions that the resulting mixture meets the grading requirements within specified tolerances of the job-mix formula. This mixture shall be placed in one lift on an underlying course in conformance with lines, grades, and typical cross sections shown on the plans, or established by the Engineer. 404.1.4 Production Notification. Manufacturing plant inspection is typically required for quantities at or above 500 tons. The plant shall certify loads when the quantity produced is less than 500 tons and plant inspection is not performed by the Engineer. Whenever production is made for the Department, the Contractor shall notify the Engineer by 2:30 pm the business day before the day of production with the mix number, amount ordered, and loading time. When night, weekend, or holiday paving is to take place, the Contractor shall notify the Engineer at least two business days in advance of production. 404.1.4.1 Pre-Paving Meeting. This requirement is for projects with total hot mix asphalt (HMA) plan quantity tonnage exceeding 3,000 tons. At least 15 days prior to the start of the paving season, project or operation, all key parties (representative of contractor, paving subcontractor, HMA producer, emulsion applicator and supplier and any other concerned parties) involved in the supply, haul, placement, compaction, inspection and quality control and quality assurance (QC/QA) of the HMA pavement shall attend a prepaving meeting to go over procedures and acceptance of the HMA pavement. The Engineer will send a pre-paving agenda on operations and procedures to representative of concerned parties not less than 10 days before the scheduled date of the meeting. Prepaving meetings should be held prior to beginning paving operations for the project, prior to phase changes in a project, and at the beginning of each construction season for multiyear projects. The meeting may be scheduled by the Engineer. Areas of responsibility and contact names and phone numbers will be shared. The Engineer will distribute the minutes of the pre-paving meeting to representatives of concerned parties within 5 days after the pre-paving meeting. Refer to the Guideline for Pre-Paving Meetings: Pre-Paving Meeting Guidelines 1) Key Personnel and Project safety. 2) Project mixture and testing Special Provisions. 3) Job mix formula and field adjustments. 4) Sampling and Testing Frequencies and procedures. 5) Reporting of test results. 6) Laying out core locations, procedures, and traffic control for coring. 7) Layout and quality control for joint construction. 8) Halting Production. 9) Traffic Control and sequence of operations.
9/1/2023
404-2
Superpave Asphaltic Concrete Pavement and Base
10) Paving widths. 11) Paver, Compaction and Hauling Equipment required. 12) Application rate of materials. 13) Plant production and paver speed. 14) Mixture temperature at the paver. 15) Pavement density control, roller patterns. 16) Weather and air temperature requirements. 17) Project documentation. 18) Testing Procedures, Locations, and Frequencies. 404.1.5 Warm Mix Design. Superpave warm mix asphalt use is allowed as long as the mix is conformance with these specifications. Warm mix technologies can be added to the binder, added to the mix during production, be wet aggregate mixtures, or a plant foaming process. These technologies can be used as coating and compaction aids while lowering the mixture production temperature 50°F or lower. 404.1.6 Reclaimed Asphalt Pavement (RAP) or Shingles (RAS). Superpave manufactured with reclaimed asphalt pavement (RAP) and reclaimed asphalt shingles (RAS) is allowed as long as the mix is in conformance with these specifications. 404.2 Materials. All materials shall conform to Division 1000, Materials specifically as follows:
Details, and
Item
Section
Asphaltic Concrete Incorporating Reclaimed (RAP or RAS) Asphaltic Pavement
413
Asphalt Cement (PG Grade)
1015.4
Superpave Coarse Aggregate
1002.1
Superpave Fine Aggregate
1002.2
Superpave Mineral Filler
1002.4
Superpave Hydrated Lime
1002.5
Anti-Strip Additive
1071
The grade of asphalt binder will be specified in the contract. 404.2.1 When Special Asphaltic Concrete Mixture for Surfacing (SP125(PGxx-xx) x LS) or (SP125(PG xx-xx) x LP) is called for in the contract, all materials shall conform to Division 1000, Materials Details. Slag or Crushed Porphyry aggregate meeting the approval of the Engineer shall be a uniform product, furnished in one or more fractions, and shall comply with Section 1002 except that the percent of wear of the coarse aggregate when tested in accordance with AASHTO T 96 (Los Angeles Abrasion) shall not exceed 20.
9/1/2023
404-3
Superpave Asphaltic Concrete Pavement and Base
404.2.2 Allowance for Testing. The Contractor shall make allowance for sampling of materials for quality control testing purposes. 404.3 Composition of Mixtures. 404.3.1 Prior to mixing with asphalt cement, the total aggregate, including the filler if needed, shall meet the following gradation for the type of mixture specified in the contract. Maximum size is defined as 1 sieve size larger than the nominal size. Nominal size is defined as 1 sieve larger than the first sieve to retain more than 10 percent by weight. 404.3.1.1 A job mix formula may be approved which permits the combined aggregate gradation to be outside the limits of the master range when the full tolerances specified herein are applied.
Percent Passing by Weight
9/1/2023
Mixture Sieve Size
SP190 ¾ inch (Nominal Max. Size)
SP125 ½ inch (Nominal Max. Size)
SP95 ⅜ inch (Nominal Max. Size)
SP48 ¼ inch (Nominal Max. Size)
1 inch
100
---
---
---
¾ inch
90-100
100
---
---
½ inch
90 maximum
90-100
100
100
⅜ inch
---
90 maximum
90-100
95-100
No. 4
---
---
90 maximum
90-100
No. 8
23-49
28-58
32-67
---
No.16
---
---
---
30-55
No. 200
2-8
2-10
2-10
6 – 13
404-4
Superpave Asphaltic Concrete Pavement and Base
404.3.1.2 Restricted Zone. The restricted zone should be used as a guide in designing mixes. The combined aggregate gradation should not pass through the restricted zone as shown in the table below and as plotted on a 0.45 power chart. Mixtures passing through this zone will be considered only if the mixture satisfies all other requirements. Aggregate Restricted Zone (Percent Passing by Weight) Sieve Size
SP190
SP125
SP95
No. 8
34.6
39.1
47.2
No. 16
22.3 - 28.3
25.6 - 31.6
31.6 - 37.6
No. 30
16.7 - 20.7
19.1 - 23.1
23.5 - 27.5
No. 50
13.7
15.5
18.7
404.3.2 Reclaimed Asphaltic Pavement (RAP) and Reclaimed Asphalt Shingles (RAS) will be used in accordance with Section 413. 404.4 Job Mix Formulas. At least 45 days prior to placing any mixture on the project, the Contractor shall submit a mix design for approval to Materials Testing Lab. The mixture shall be designed in accordance with AASHTO R 35 and shall be tested in accordance with AASHTO T 312 except as noted herein. A detailed description of the mix design process shall be included with the job mix formula (JMF). When participating in the AASHTO proficiency sample programs representative samples of each ingredient for the mixture shall be submitted with the mix design. If the Contractor does not participate in an AASHTO proficiency program, then the Contractor shall obtain, in the presence of the Engineer or his representative, samples of asphalt cement and mineral aggregates for tests. The Contractor must give the Engineer 24 hours' notice to arrange sampling. The samples of materials shall be of the size specified by the Engineer and shall be submitted to the Materials Laboratory for mixture verification. Aggregate fractions shall be provided in the same proportions as the proposed job mix formula. A minimum of 60 pounds will be required for any individual fraction. The amount of each ingredient submitted shall be as follows for each mix design to be verified: Ingredient
Minimum Amount
Aggregate
60 pounds
Hydrated Lime, Mineral Filler, and/or Baghouse Fines
20 pounds
Asphalt Binder
2 gallons
Reclaimed Asphalt Pavement (RAP) and /or Reclaimed Asphalt Shingles (RAS)
60 pounds
Additives
To be determined by supplier
Any costs due to delays caused by the submittal of mix designs which do not meet specification requirements will be the responsibility of the Contractor.
9/1/2023
404-5
Superpave Asphaltic Concrete Pavement and Base
404.4.1 Proficiency Sample Program. Laboratories that participate in and achieve a score of three or greater in the AASHTO proficiency sample program for T 11, T 27, T 84, T 85, T 166, T 176, T 209, T 304 (ASTM C 1252), T 308 and T 312 will have the mixture verification process waived. The mix design shall be submitted to the Materials Testing Laboratory for approval at least 10 working days prior to mixture production. 404.4.2 Required Information. When a mix design is designated for a specific project, the Project Name, County Project Number, and Federal Job Number on which the mixture will be used shall be specified. All mix designs shall contain the following information: 1)
Source, grade, and specific gravity of asphalt binder.
2)
Warm mix additive source, trade name, target rate for water and/or additives, acceptable variation for production, and technology description (added to binder, added to mixture during production, wet aggregate mixtures or foaming process), material safety data sheets, and equipment used. a) Asphalt binder performance grade test data over the range of warm mix additive percentages proposed for use. b) Documentation of past warm mix additive technology field applications including project type, project owner, tonnage, location, mix design, mixture volumetrics, field density, and performance. c) Mix design shall incorporate the practices described in AASHTO R 35, Appendix X2 for the warm mix technology selected.
3)
Source, trade name, and target rate of anti-strip used.
4)
Source, type (formation, etc.), ledge number, if applicable, and gradation of the mineral aggregates. The gradation of the component materials shall be representative of the material at the time of use.
5)
Bulk and apparent specific gravities and absorption of each aggregate fraction in accordance with AASHTO T 85 "Specific Gravity and Absorption of Coarse Aggregate" for coarse aggregates and AASHTO T 84 "Specific Gravity and Absorption of Fine Aggregate" for fine aggregates.
6)
Specific gravity of hydrated lime or mineral filler, if used, in accordance with AASHTO T 100 "Specific Gravity of Soils".
7)
Percentage of each aggregate component.
8)
Combined gradation of the job mixture.
9)
Percent asphalt binder (Pb), by mass, based on the total mix intended to be incorporated in the completed mixture, shown to the nearest 0.1 percent.
10)
Bulk specific gravity (Gmb), by AASHTO T 166 "Bulk Specific Gravity of Compacted Hot Mix Asphalt (HMA) Using Saturated Surface-Dry Specimens, Method A", of a laboratory compacted mixture (compacted Ndesign gyrations).
9/1/2023
404-6
Superpave Asphaltic Concrete Pavement and Base
11)
Percent air voids (Va) of the laboratory compacted specimen (compacted to Ndesign gyrations).
12)
Voids in the mineral aggregate (VMA) and voids in the mineral aggregate filled with asphalt binder (VFA) at Ndesign gyrations.
13)
Theoretical maximum specific gravity (Gmm) as determined by AASHTO T 209 "Theoretical Maximum Specific Gravity and Density of Hot-Mix Asphalt Paving Mixtures" after the sample has been short term aged in accordance with AASHTO R 30.
14)
The tensile strength ratio (TSR) as determined by AASHTO T 283 "Resistance of Compacted Hot Mix Asphalt (HMA) to Moisture-Induced Damage" including all raw data. TSR shall be performed with anti-strip or warm mix technologies as submitted.
15)
The gyratory sample mass to produce a 115 mm minimum height specimen.
16)
Mixing temperature range @ discharge and gyratory molding temperature.
17)
Compaction temperature range in accordance with Section 404.5.3.2
18)
The Design Traffic Level and Number of gyrations Ninitial, Ndesign, Nmaximum.
19)
Dust proportion ratio (No. 200 / Effective asphalt binder (Pbe)).
20)
Bulk specific gravity (Gsb) of the combined aggregate.
21)
Percent chert contained in each aggregate fraction.
22)
Percent of Theoretical maximum specific gravity (Gmm) at Ninitial, and Nmaximum.
23)
Blended aggregate properties for clay content and angularity.
24)
For SP48 mix designs, the volume (percent) of effective binder (Vbe)
25)
Baghouse fines added for design. a) Batch and continuous mix plants - Indicate which aggregate fraction to add baghouse percentage during production. b) Drum mix plants - Provide cold feed settings with and without baghouse percentage.
404.4.3 Approval. Exceptions to spreading and compaction temperature limits shall be submitted with the mix design by the material supplier for Engineer review and approval. No mixture will be accepted for use until the job mix formula for the project is approved by the Engineer and signed by the mix design reviewer. If the supplier's test facilities are to be used for mix verifications, the Ignition Furnace calibration factor must be included on a submitted mix design.
9/1/2023
404-7
Superpave Asphaltic Concrete Pavement and Base
404.4.4 The job mix formula shall be within the master range specified for the particular type of asphaltic concrete and shall include the type and sources of all materials, the gradations of the aggregates, the relative quantity of each ingredient, and shall state a definite percentage for each sieve fraction of aggregate for asphalt cement. The Contractor shall comply with the manufacturer's recommendations for incorporation of additives into the mix. 404.4.5 Job Mix Formula Modification. The job mix formula approved for each mixture shall be in effect until modified in writing by the Engineer. When unsatisfactory results or other conditions occur, or a source of material has been changed, a new job mix formula may be required. 404.5 Mixture Testing Procedures. 404.5.1 Superpave asphaltic concrete mixtures shall be tested in accordance with AASHTO T 312, "Standard Method for Preparing and Determining the Density of Hot Mix Asphalt (HMA) Specimens by Means of a Superpave Gyratory Compactor". 404.5.2 SP mix design shall follow the procedures defined in AASHTO R-35 "Superpave Volumetric Design for Hot Mix Asphalt (HMA)", except as follows. 404.5.2.1 Once the optimum asphalt content of the mixture has been determined, a minimum of two specimens shall be prepared at the optimum asphalt content and compacted to the respective Nmaximum values. The average specimen density shall then be calculated, compared against the requirement at Nmaximum and furnished with the job mix data for informational purposes only. 404.5.3 The compaction and mixing temperature range for warm mix and modified binders will be furnished by the supplier. 404.5.3.1 Mixing Temperature. Mixing temperature range for unmodified binders will be determined where the unaged binder has a Viscosity of 0.17 ± 0.02 Pa-s measured in accordance with AASHTO T 316 "Viscosity Determination of Asphalt Binder Using Rotational Viscometer". 404.5.3.2 Compaction Temperature. Compaction temperature range for unmodified binders will be determined where the unaged binder has a Viscosity of 0.28 ± 0.03 Pa-s measured in accordance with AASHTO T 316 "Viscosity Determination of Asphalt Binder Using Rotational Viscometer". 404.5.4 The Contractor is advised that SP mix design will require gradation design, asphalt binder content design, moisture susceptibility testing, and nuclear gauge or ignition oven calibration. It may also require testing of the blended aggregate once the mixture design is completed. 404.5.5 Mix Design Expiration Time Limit. A mix design may be transferred to other projects for a period of 2 years from the original approval date or the last field verification date provided that satisfactory results are obtained during production and placement.
9/1/2023
404-8
Superpave Asphaltic Concrete Pavement and Base
404.6 Compaction Criteria. 404.6.1 The number (N) of gyrations required for gyratory compaction shall be as follows: Gyrations Design Level NInitial
NDesign
NMaximum
F
6
50
75
E
7
75
115
C
8
100
160
B
9
125
205
404.6.2 When compacted in accordance with AASHTO T 312, the SP 48, SP 95, SP 125, and SP 190 mixtures shall meet the following criteria: 404.6.2.1 Air Voids (Va). Design Level
Design Air Voids (Percent)
All levels ...................................................................................................... 4.0
404.6.2.2 Voids in the Mineral Aggregate (VMA). Mixture
VMA Minimum (Percent)
SP 190 ...................................................................................................... 13.0 SP 125 ...................................................................................................... 14.0 SP 95......................................................................................................... 15.0 404.6.2.3 Voids Filled With Asphalt (VFA). Design Level
VFA (Percent)*
F
70-80
E
65-78
B, C
65-75
*SP 48 mixtures shall have a VFA ≥ 75 for Design Levels E, and F
9/1/2023
404-9
Superpave Asphaltic Concrete Pavement and Base
404.6.2.4 Compaction Level.
Required Density (Percent of Theoretical Maximum Specific Gravity) Design Level
Less than Ninitial
F
91.5
E
90.5
B, C
89.0
Equal to Ndesign
Less than Nmaximum
All Levels 96.0
All Levels 98.0
404.6.2.5 SP 48 Volume of Effective Binder (Vbe).
Required Volume of Effective Binder*, (percent) Design Level
Minimum
Maximum
F
12.0
15.0
E
11.5
13.5
* Vbe is the VMA minus the Va
404.7 Other Criteria. 404.7.1 Dust to Binder Ratio. The ratio of the aggregate passing the No. 200 to effective asphalt binder (Pbe) content shall be: 404.7.1.1 For SP 95, SP 125 and SP 190 mixes, between 0.8 and 1.6. 404.7.1.2 For SP 48 mix, between 1.0 and 2.0. 404.7.2 Tensile Strength Ratio. The mixture shall have a tensile strength ratio (TSR) greater than 0.80 when tested in accordance with AASHTO T 283 "Resistance of Compacted Hot Mix Asphalt (HMA) to Moisture-Induced Damage". Specimens for AASHTO T 283 shall be 150 mm in diameter and be compacted to a 95 ± 5 mm height with 7 ± 0.5 percent air voids. If the strength ratio is less than 80 percent, remedial action, such as the use of antistrip agents, is required to improve the moisture susceptibility of the mix. When remedial agents are used to modify the asphalt binder, retest the mix to assure compliance with a minimum TSR greater than 80 percent.
9/1/2023
404-10
Superpave Asphaltic Concrete Pavement and Base
404.7.3 Blended Aggregate. The blended aggregate shall meet the grading for the specified SP mixture. 404.7.3.1 Porphyry Mixtures. For LP Mixtures, at least 50 percent by volume of the retained material shall be from crushed porphyry as retained on the following sieves: No. 30 for SP 48, No. 16 for SP 95, and No. 8 for SP 125. Depending on the actual gradation of porphyry aggregate furnished, the amount of crushed porphyry required will vary; however, at least 40 percent by weight of crushed porphyry will be required. 404.7.3.2 Steel Slag Mixtures. Steel slag may be substituted for porphyry in LP mixes, except at least 45 percent by weight of slag will be required. The Engineer may approve the use of other hard durable aggregates in addition to porphyry and steel slag. 404.7.3.3 Recycled Mixtures. For Superpave mixtures, reclaimed asphaltic pavement (RAP) and reclaimed asphalt shingles (RAS) will be used in accordance with Section 413. 404.7.3.4 Crushed Gravel Limitations. Crushed gravel shall not exceed 20 percent by weight of the plus No. 8 mineral aggregate. 404.7.4 If difficulty is experienced in obtaining a satisfactory mixture with the aggregate combinations submitted, the Contractor will be advised, and new types or sources of materials may be required by the Engineer. Additional aggregate, other than local stone or sand, may be required in order to modify the mixture for compliance. 404.7.5 The total aggregate for Asphaltic Concrete mixtures shall contain not less than 85 percent crushed material. The Contractor will adjust quantities of the various components of the mixture as necessary to obtain the required characteristics of the mixture. 404.7.6 Mixture Quality Testing. All field inspection, sampling and testing will be performed by a qualified technician. The Engineer shall have free access to any and all testing equipment used by the mixture producer and any workbooks, records or control charts maintained by the mixture producer for the quality testing process. The Engineer shall also have sufficient access to the plant grounds to assure compliance with the standards and specifications. 404.7.6.1 Mixture Testing. The Engineer will sample and test the mixture from the roadway at least once per day of production exceeding 250 tons. The sample will be of sufficient size to retain half for possible disputes. The Engineer's test results, including all raw data, will be made available to the Contractor when completed and no later than the next working day. The Engineer may increase sampling frequency to ensure that a quality mixture is being produced.
9/1/2023
404-11
Superpave Asphaltic Concrete Pavement and Base
404.7.6.2 Optional Use of Contractor Quality Control Results. The Engineer may allow the use of Contractor quality results under the following conditions: 1) The Contractors Quality Control Personnel and Equipment requirements of MoDOT Section 403.17, Quality Control;
meet
the
2) The Engineer witnesses the materials sampling and performance of volumetric and binder content testing; and 3) The Contractor shall record all test results and furnish a copy, including all raw data, to the Engineer the day of the test, at no additional cost to the County. 404.8 Gradation Control. 404.8.1 In producing mixtures for the project, the plant shall be operated so that no intentional deviations from the job mix formula are made. Gradations are an indicator of the mix properties and will not be used for production shut down unless volumetric properties (VA and VMA) and/or binder content are not within specified Control Limits in Section 404.10.4. The Engineer shall be notified before changes are made to the cold feed settings, hot bin settings, or the binder content. Mixtures as produced shall be subject to the following tolerances and controls: 1) The percent passing the first sieve size smaller than the nominal maximum size shall not exceed 92.0 percent; 2) The maximum variation from the approved job mix formula shall be within the following tolerances: Sieve (Percent Passing by Mass)
Tolerance (Percent)
No. 8
± 3.0
No. 200
± 1.5
3) The quantity of asphalt cement introduced into the mixer shall be that quantity specified in the job-mix formula. No change may be made in the quantity of asphalt cement specified in the job-mix formula without written approval of the Engineer. The quantity of asphalt cement determined by calculation or tests on the final mixture shall not vary more than 0.3 percentage point from the approved job-mix formula. 404.8.1.1 The gradation of the aggregates will be determined from samples taken from the hot bins on batch-type plants or from the composite cold feed belt on drum mix plants. An ignition furnace gradation, performed in accordance with AASHTO T 30, may be used if the mixture has been calibrated.
9/1/2023
404-12
Superpave Asphaltic Concrete Pavement and Base
404.8.2 Preparation of Mixture. 404.8.2.1 Binder. The asphalt cement shall be carefully heated, without damage by overheating, to a workable temperature as designated by the Engineer within the range established by Section 1015.2, "Application Temperatures for Bituminous Materials". If asphalt is measured by volume, the temperature of the asphalt at the time of measuring shall not vary more than 15°F from that designated by the Engineer when the metering device was calibrated. 404.8.2.2 Mixture. The final mixture shall not be crusted over, contain lumps, or be contaminated with deleterious agents such as unburned fuel, objectionable fuel residue, unapproved aggregates, or any other material not inherent to the job-mix formula. In cases of rejected material, the entire load shall be rejected. The final mixture shall not exceed the lesser of: 404.8.2.2.1 350°F when discharged from the pug mill. 404.8.2.2.2 Engineer.
More than 25°F from the mixing temperature designated by the
404.8.3 Moisture. The asphaltic concrete mixture, when sampled immediately behind the paver and tested in accordance with AASHTO Test Method T 110 "Moisture or Volatile Distillate in Hot Mix Asphalt (HMA)", shall not contain more than 0.5 percent moisture by weight of the mixture. 404.9 Production Mixture. After testing has been completed on the mix and the mat is placed and tested in accordance with the specifications, the results will be evaluated for compliance with the specifications.
9/1/2023
404-13
Superpave Asphaltic Concrete Pavement and Base
" When the produced mixture is reheated and compacted within the molding temperature range indicated on the mix design, using the Superpave Gyratory Compactor, the mixture shall meet the following criteria: 404.9.1 Voids in the Mineral Aggregate. The Voids in the Mineral Aggregate (VMA) shall be within -0.5 and +2.0 percent of the minimum required for each type of mixture Ndesign gyrations. The VMA will be determined using the field determined bulk specific gravity (AASHTO T 166) of the two Superpave gyratory compacted specimens, the field calculated percent aggregate, the job mix formula aggregate bulk specific gravity and the field measured percent asphalt as determined by one of the following methods: 1) AASHTO T 287 Nuclear gauge method; 2) AASHTO T 164 "Quantitative Extraction of Bitumen from Bituminous Paving Mixtures"; 3) Or by AASHTO T 308 "Method A-Standard Test Method for Determining Asphalt Content of Hot Mix by the Ignition Method". 404.9.2 Air Voids. The air voids (Va) shall be within 1.0 percent of the approved job mix formula at Ndesign gyrations. The air voids will be calculated from the field determined maximum specific gravity (AASHTO T 209) and the field determined bulk specific gravity (AASHTO T 166). Mixtures placed with air voids (Va) less than 3.0 percent shall be penalized in accordance with Section 404.32.3. 404.9.3 Adjustments to Ninitial and Nmaximum shall be made as Ndesign changes. As the air voids (Va) percentage increases above 4 percent, the difference should be deducted from both Ninitial and Nmaximum. When the air voids (Va) percentage decreases below 4 percent, the difference should be added to both Ninitial and Nmaximum. 404.9.4 On each follow-up field test, two specimens will be compacted to Ndesign. 404.9.5 Production Suspension and Mix Redesign. Should any of the mixture properties specified in Sections 404.8, 404.9, or 404.10.4 be found to be outside of the prescribed tolerances, a second test shall be run immediately. Should the second test confirm the findings of the initial test, production of the asphaltic concrete mixture will be suspended until adjustments are made and passing test results have been achieved. Repeated instances of non-conformance may result in suspension of production and redesign of the asphaltic concrete mixture.
9/1/2023
404-14
Superpave Asphaltic Concrete Pavement and Base
404.10 Field Adjustments of Job Mix Formulas. 404.10.1 When test results indicate the mixture produced does not meet the specification requirements the Contractor may field adjust the job mix formula as noted herein. Field adjustments may consist of changing the percentages of the aggregate fractions as listed on the approved job mix formula and changing the percent binder as listed on the approved job mix by 0.3 percent or less. Additional fractions of materials or new materials will not be permitted as field adjustments. The Engineer shall be notified immediately when any change is made in the cold feed settings, the hot bin settings, and/or the binder content. Engineer prior approval will be required when the aggregate percentages are adjusted by more than a total of 5.0 percent and/or the binder content are adjusted more than 0.3 percent from the job mix formula. 404.10.2 Volumetrics. When a field adjustment is allowed, the Contractor will be permitted to place not more than 750 tons of mixture, once the adjustment is made, to establish new volumetric properties of the mixture, and to verify the mixture meets the specification requirements of Section 404.6.2. The field adjusted job mix formula combined gradation and combined aggregate bulk specific gravity (Gsb) shall be calculated accordingly to reflect any change in the percentages of the aggregate fractions. The maximum theoretical specific gravity of the mixture (Gmm), the bulk specific gravity of the compacted specimens at Ndesign (Gmb), the VMA, the percent filled (VFA), the dust proportioning (-200/Pbe), the percent of effective binder (Vbe) and the percent asphalt binder targets will be established by sampling the material from the roadway after 100 tons have been produced. 404.10.3 Specimen Requirements. A minimum of 2 specimens will be compacted to Ndesign gyrations. The maximum theoretical specific gravity of the mix, percent asphalt binder of the mix and the cold feed gradations shall be determined. The volumetrics of the field- adjusted mix shall be calculated from these test results. The average values of the volumetrics from the Ndesign gyratory compacted specimens will be used to establish the new volumetric targets of the mix. 404.10.4 Control Limits. The new volumetric targets of the mix shall be in compliance with all of the Superpave mix design requirements of Section 404.6.2. When one or more of the Control Limits are exceeded, the Contractor shall take action to adjust production. When the adjustments to the mixture fail to produce a mix that meets specification requirements, the production of the mix will be halted. No mixture will be delivered to the job site until the mixture has been brought within the following Control Limits:
9/1/2023
404-15
Superpave Asphaltic Concrete Pavement and Base
CONTROL LIMITS AND PENALTIES Property
Control Limits
Penalties/Shut Down
Comments
Gradation and Binder Content Control Points Percent Passing JMF given sieve: No.8
±3.0
See Section 404.8
No. 200
±1.5
See Section 404.8
Binder Content, %
±0.3
See Note 2
Gradation used to gauge mix uniformity Gradation used to gauge mix uniformity See Sections 404.8.1 & 404.9.5 when outside control limits
Volumetric Control Points VA (Air Voids), % 1
VMA , %
3.0 ≥ VA ≥ 5.0
See Note 2
Within -0.5 and +2.0 of the VMAMin
See Note 2
See Section 404.32.3 when outside control limits See Section 404.18.1 for 25% unit price reduction application for winter base course paving when VMA < 13
Density Control Points Mat Density (MD),% Unconfined Joint Density (UJD), %
92 ≤ MD ≤ 96
92 > MD > 96
UJD ≥ 90
UJD < 90; Penalties $200/ deficiency*
See Section 404.33 for unit price reduction or removal *As per Section 404.33 $200 penalty per non-conformance; See Section 404.17.8 for shutdown limits
Notes: 1 VMAMin is the minimum VMA required for each type of mixture Ndesign gyrations. 2 Shut down after two consecutive failed tests or as per comments.
After this procedure has established the field adjusted job mix formula that complies with Section 404.6.2 requirements, the Contractor may continue paving operations using the field adjusted job mix formula. 404.10.5 Field Mix Redesign. When a new mix design is required, the Contractor will be permitted to establish the new mix design in the field. The mix shall be designed in accordance with Section 404.5 and shall meet the Superpave mix design requirements of Sections 404.6 and 404.7. A representative sample of the mix shall be submitted with the new mix design to the Materials Laboratory for mixture verification. The amount of mix submitted for verification shall weigh at least 50 pounds. 404.10.5.1 New mix designs established in the field will be approved by the Materials Laboratory. When new mix designs are approved, the Materials Laboratory will assign a new mix number to the mixture. 404.10.5.2 No mix is to be placed on the project until the new field mix design is approved by the Engineer.
9/1/2023
404-16
Superpave Asphaltic Concrete Pavement and Base
404.10.5.3 To keep accurate records, the original job mix formula will be labeled with a revision number consecutively numbered beginning with (R1) behind the last digit of the job mix formula number to signify that the job mix formula has been field adjusted. 404.10.6 Supporting data justifying the need and type of field adjustment shall be submitted to the Engineer. The Engineer will approve all field adjustments. The Contractor must notify the Engineer in writing of the adjustments made, new target values, and any other information required for evaluation of the revised mix. 404.10.7 The Contractor shall submit the field adjusted job mix formula to the Engineer in writing within 24 hours. 404.11 Determination of Optimum Mat and Joint Density Rolling Pattern. The first day of production shall be used for the mix verification process. The establishment of an optimum rolling pattern shall be required for all mixes. During Field Verification production of the HMA, the Contractor shall place and compact at least 500 tons of mix produced within the specified limits of thickness, volumetric and compaction tolerances in order to establish compaction patterns and verify that the equipment and the processes planned for laydown and compaction are satisfactory. The rolling patterns will be used to calibrate density gauges, to verify that the base course or surface course meets the mat and joint density requirements of the specifications and for mix design / production verification as required. 404.11.1 Correction factors shall be specific to the density gauges utilized during construction. In the event that a different gauge needs to be utilized for acceptance, new cores will need to be cut from the ongoing pavement construction to calibrate the new gauge. 404.12 Plant Laboratory. Proper facilities shall be provided for the Engineer to inspect ingredients and processes used in the manufacture and delivery of the mix material. Facilities for obtaining representative samples of each fraction of aggregate, binder, and admixture(s), prior to incorporation into the mix, shall be provided by the producer. Aggregate samples may be taken either by sampling the flowing aggregate stream or by belt sampling. The producer shall furnish the proper equipment and personnel necessary to assist the Engineer in obtaining a representative sample. 404.13 Equipment. Use equipment capable of producing an asphalt mixture that meet specification requirements and is workable at the minimum placement and compaction temperature desired, regardless of storage or haul distance considerations. The asphalt mixing plant shall meet AASHTO M 156 "Requirements for Mixing Plants for Hot-Mixed, Hot-Laid Bituminous Paving Mixtures" as modified as follows. 404.13.1 Plant Site. Sufficient storage space shall be provided for each size of aggregate. Unless otherwise permitted by the Director, stockpiles of coarse aggregate, screenings, and sand shall be built and maintained in accordance with Section 1001.11. Each stockpile shall contain a minimum of 500 tons of material before asphaltic concrete production commences and shall be maintained so that the quantity of material does not fall below the minimum required. Should stockpiles be depleted below this amount, they shall be rebuilt to the minimum prior to next working day. Stockpiles shall be built in an area readily accessible for inspection and sampling.
9/1/2023
404-17
Superpave Asphaltic Concrete Pavement and Base
404.13.2 Plant Permitting and Calibration. An approved Air Quality Construction Permit issued by the Missouri DNR Air Pollution Control Program (APCP) or local air pollution control agency office before setting up, constructing, or modifying a hot mix asphalt plant in Missouri. New portable plants are permitted using the same procedure, except that portable plants may have multiple sites permitted in their original construction permit by including information on each proposed plant site with the application. A plant with a portable construction permit may operate indefinitely at the first permitted site, but upon moving the equipment to a new site, it may not operate more than two years in Missouri without applying to convert to a stationary plant. Relocation of permitted portable plants requires a Portable Source Relocation Request to the APCP or the local agency. Hot mix asphalt plants that do not have a portable source construction permit are required to have an operating permit if the potential emissions of any pollutant from the installation exceed the de minimis emission rate. For hot mix asphalt plants operating in Illinois, the Illinois EPA Division of Air Pollution Control Clean Air Act Permit Program (CAAPP) Permit will be required before setting up, constructing, or modifying a hot mix asphalt plant for manufacturing of materials for use on County projects. A copy of the current permit shall be provided at the time of plant calibration. Personnel, scales, and equipment necessary for calibrating the plant and for verifying the accuracy of proportions shall be furnished by the Contractor and shall be available at all times. If batch-type plants are used, the equipment shall include standard 50-pound test weights equal to 20 percent of the net load capacity of the scales, to the nearest 50-pound increment. However, not more than twenty 50-pound weights will be required. Calibration by an approved commercial scale service will be required for batch-type plants, which have large capacity scales greater than 10,000 pounds or if scales do not meet calibration tolerances. If continuous mixing or drummix plants are used, scales conforming to the requirements of Section 404.13.2.1 shall be provided. Weights shall be calibrated by the governing state body of weights and measures in accordance to the requirements established by the U.S. Department of Agriculture. All equipment shall be calibrated by the Contractor in the presence of and subject to the approval of the Engineer. Plants shall be calibrated at least once each year, or as directed. Plant certification for calibration and verification will not be required, provided that this certification has been furnished to MoDOT or IDOT within a 12-month period prior to the time certification is required by the County. A letter of certification to verify this will be required. This does not preclude interim checks by County forces. 404.13.2.1 Vehicle Scales. Vehicle scales shall be approved by the Engineer and shall conform to the requirements specified herein. 404.13.2.1.1 Basis of Acceptance. Scale acceptance shall be based on one of the following: 1) A valid certification or seal of approval by the Missouri Department of Agriculture, Division of Weights and Measures or equivalent Illinois State Agency. 2) A valid certification or seal of approval by a State of Missouri duly appointed Sealer of Weights and Measures in cities or counties with a population of 75,000 or more.
9/1/2023
404-18
Superpave Asphaltic Concrete Pavement and Base
3) Certification of calibration from a commercial scale service company showing that the scale meets the requirements of these specifications. The Contractor shall furnish the certification of calibration to the Engineer. 4) Calibration from zero weight through the maximum load to be applied by the application of standard weights in the presence of the Engineer by the Contractor's personnel. In lieu of starting the calibration at zero weight, the standard weights may be applied to an unloaded truck, the weight of which has been determined on a certified scale and the calibration continued through the maximum load to be applied. Regardless of the form of acceptance, the calibration shall be within the accuracy requirements specified Section and the scales shall meet all requirements of these specifications. 404.13.2.1.2 Scale Calibration. Scales shall have been calibrated within the 12month period immediately prior to any material being delivered or any time the Engineer has cause to question the accuracy of the scale. Scales shall be accurate within 0.4 percent of the net load applied regardless of the location of the load on the platform. The value of the smallest unit of graduation on a scale shall be not greater than 20 pounds. Sensitivity requirements of scales not equipped with balance indicators shall be twice the value of the minimum graduated interval on the weigh beam, or 0.2 percent of the nominal capacity of the scale, whichever is less. For scales equipped with balance indicators, the sensitivity requirement shall be the value of the minimum graduated interval on the weigh beam. 404.13.2.1.3 Verification of a vehicle scale may be required by the weighing of a hauling unit on another recently calibrated and certified scale. 404.13.2.1.4 If equipment to be weighed is of such length that all axles cannot be weighed simultaneously, a level area of concrete or bituminous pavement shall be provided permitting those axles not on the scale platform to be on the pavement during the weighing operation. The approach shall be at least as wide as the platform and of sufficient length to insure the level positioning of vehicles during weight determinations. The weighing shall be performed with all brakes released. If equipment to be weighed is equipped with an air bag suspension unit on any axle, the equipment including semi-trailers or pup trailers shall be weighed on vehicle scales of sufficient size to weigh all axles of the combination simultaneously. 404.13.2.1.5 All costs incurred in obtaining a certification of calibration or verification shall be borne by the Contractor. 404.13.3 Equipment for Preparation of Asphalt Binder. An asphalt binder storage tank shall be provided at the proportioning and mixing plant. If more than one storage tank is used to deliver asphalt binder to the proportioning unit, piping and valve arrangements shall permit material to be used from any one of the tanks without using from another at the same time. 404.13.3.1 Storage. Tanks for storage of asphalt shall be equipped for heating the material, under effective and positive control at all times, to the temperature requirements set forth in Section 1015.2. Heating shall be by steam or oil coils, electricity, or other means such that no flame shall come in contact with the heating tank.
9/1/2023
404-19
Superpave Asphaltic Concrete Pavement and Base
404.13.3.2 Circulation. A circulating system of adequate capacity shall provide proper and continuous circulation of the asphalt between storage tank and proportioning units during the entire operating period. The discharge end of the circulating pipe shall be maintained below the surface of the asphalt in the storage tank to prevent discharging into the open air. All pipelines and fittings shall be steam or oil-jacketed or otherwise properly insulated to prevent heat loss. Storage tank capacity shall be such as to ensure continuous operation of the plant and uniform temperature of the asphalt when it is introduced into the aggregate. Tanks shall be calibrated accurately to 100-gallon intervals and shall be accessible for measuring the volume of asphalt material at any time. 404.13.3.3 Binder Sampling. The Contractor shall provide a sampling outlet in the asphalt binder feed lines connecting the plant storage tanks to the proportioning or injection system. The sampling outlet shall be installed in a readily accessible location such that representative samples, including chemical admixtures, may be withdrawn safely and slowly at any time during plant operation. A drainage receptacle shall be provided for flushing the outlet prior to sampling. When filled asphalt materials are used, means shall be provided for agitation to maintain a uniform product. When all of the chemical admixtures are added to the plant storage tank prior to use, the Engineer may allow the Contractor to sample the asphalt binder from the storage tanks located at the mixing facilities. Sampling procedures shall be approved by the Engineer prior to samples being taken. 404.13.4 Cold Aggregate Feeder. The plant shall be provided with an accurate mechanical means for uniformly feeding the aggregates into the drier to provide uniform production and temperature. A synchronized method of proportioning the aggregates at the cold feeder shall be provided. 404.13.4.1 Cold Feed Calibration. For all plants producing bituminous mixtures composed of more than one fraction of aggregate, the aggregate cold feeds shall be calibrated as required by the Engineer. On the basis of the calibration, aggregate cold feeds shall be adjusted to ensure the proper percentage of the various aggregate fractions of the mix, as required by the job mix formula. 404.13.4.2 Aggregate Sampling. Safe, adequate, and convenient facilities shall be provided for obtaining representative aggregate samples from the full width and length of the discharge flow of the combined cold feed, or from each hot bin on batch-type plants. 404.13.5 Drier. A drier of any satisfactory design for drying and heating the aggregate shall be provided. The drier shall be capable of drying and heating the aggregate to a temperature within the limits of the range specified in Section 1015 for the grade of asphalt binder used, without leaving any visible unburned oil or objectionable carbon residue on the aggregate. The maximum temperature specified above for mineral aggregate fractions may be increased as necessary in recycled mix to obtain the specified temperature of the recycled mixture at the time of placement. Absorbed moisture in the aggregate shall be reduced to such a quantity that there is no objectionable segregation of asphalt resulting from escaping water vapor in the prepared mixture.
9/1/2023
404-20
Superpave Asphaltic Concrete Pavement and Base
404.13.6 Screens. Plant screens shall have adequate capacity and size range to separate properly all of the aggregate into the sizes required for proportioning, so that they may be recombined consistently within the limits specified in Section 404.8. The screening unit shall separate the usable heated aggregate into at least three sizes. 404.13.7 Aggregate Storage. The plant shall have hot bin storage of sufficient capacity to insure uniform and continuous operation. Bins shall be divided into compartments arranged to insure separate and adequate storage of appropriate fractions of the aggregate. Each compartment shall be provided with an overflow pipe of such size and at such locations as to prevent any backing up of material into other bins or into contact with the screen. The bins shall have a tailing pipe for rejections. The discharge points of overflow and tailing pipes shall be located so they will not create a hazard. Overflow pipes shall not return the material directly to the hot elevator. 404.13.7.1 Filler Storage. If mineral filler or hydrated lime is required, adequate dry storage shall be provided, and provisions shall be made for accurate proportioning. Bag house fines re-circulated into the mix shall be considered as mineral filler. 404.13.7.2 Recycled and Virgin Materials. Provide means to divert the recycled material and virgin aggregates into trucks or other containers for verifying the accuracy of the cold feed delivery systems. Calibrate all systems prior to production for any Department project requiring the addition of any recyclable materials. Do not allow any device used to introduce plant overburden or coated or uncoated asphalt mix into the hot elevator. 404.13.7.3 Storage of Mixtures (Surge Bins). Surge bins may be used in the production of bituminous mixtures, if approved by the Engineer. They shall be equipped with batchers, so located that the mixture is discharged vertically into the center of the bin. Surge bins, except those rated at 75 tons or less shall be covered and insulated. They shall be equipped with heating devices, if necessary, to maintain the temperature of the mixture in accordance with the requirements in Section 404.21.1. Bins shall be equipped with automatic lights, visible to the loading operator, to indicate when the surface of the mixture has been drawn down to the top of the sloped portion of the bin. Mixture shall be transferred from the mixing plant to the surge bins by covered drag slat conveyors, skip hoists, or other methods approved by the Engineer. Mixture with hardened lumps shall not be used. Mixture shall not be withdrawn below the level of the top of the sloped portion of the bin except at the end of each day's operation. Perform an evaluation of a unit to determine the degree of mix composition uniformity, temperature characteristics, and degree of binder hardening of mixture processed through the unit. Consideration for approval will be given for an operation that consistently results in mixtures having gradation and temperature properties of no less quality than specified mixtures discharged directly from the plant’s mixing operation and resulting in asphalt hardening properties which do not exceed the storage limit specified. Mixture, which the Engineer determines visually to be segregated, will be rejected. Material which is produced without inspection from a representative of St. Louis County will be rejected. In the event that an approved storage unit is charged or altered, notify the Materials Engineer of the modifications. Reevaluate any departure from the approved unit. Mixture shall not be stored more than 8 hours. Mixture whose asphalt binder has been treated with silicone (Dow Corning Fluid DC-200 or an approved equal) at a rate of approximately 1 ounce per 500 gallons of asphalt binder may be stored for
9/1/2023
404-21
Superpave Asphaltic Concrete Pavement and Base
not more than 12 hours. The storage time may be reduced by the Materials Engineer if it is determined that asphalt absorption is a problem. 404.13.8 Asphalt Control Unit. Satisfactory means, either by weighing or metering, shall be provided to obtain the proper quantity of asphalt. Metering pumps for asphalt shall deliver accurately to within plus or minus 2.0 percent of the required quantity when tested for accuracy. Asphalt scales shall conform to the requirement of Section 404.13.12.4, "Asphalt Bucket". Where the quantity of asphalt is controlled by metering, provision shall be made whereby the delivery of the meter may be readily checked by actual weight. 404.13.8.1 If a continuous mixing plant is used, a continuously registering measurement meter and a pressure gauge shall be installed in the asphalt line at locations meeting the approval of the Engineer. The meter shall be cumulative with a non-setback register and have accuracy within 2 percent by weight of the material actually being measured in any given period of time. The meter register shall indicate the quantity measured to the nearest 0.25 gallons or less. The pressure gauge shall have a range capable of registering all spraying pressures during plant operation and the dial shall have increments of not more than 1.0 psi. The meter and the pressure gauge shall be so located in the asphalt line that the meter will continuously register the asphalt discharge and the gauge will continuously register the discharge or spraying pressure, and also so that the discharge through both the meter and the gauge can be readily diverted to a container for measurement. During calibration and verification of the asphalt-metering pump and the measurement meter, the discharge pressure shall be controlled by a valve or reduction unit to duplicate the plant's spraying pressure. The accuracy of the measurement meter shall be verified at periodic intervals as designated by the Engineer. In case of meter malfunction, plant operation will not be permitted beyond 24 hours after detection except by written approval of the Engineer. 404.13.9 Thermometric Equipment. A thermometer of suitable range shall be fixed in the asphalt feed line at a suitable location near the discharge at the mixer unit. An accurate registering pyrometer or other approved thermometric instrument shall be installed in the discharge chute of the drier in such manner that the temperature of the heated aggregate is automatically registered. This instrument shall be located where it is in clear view of the drier fireman and readily accessible to the inspector. 404.13.9.1 The plant shall be further equipped with approved recording thermometers, pyrometers, or other recording thermometric instruments placed in two of the hot aggregate bins to register and automatically record the temperature of the heated aggregate. One terminal shall be placed in the hot bin containing the smallest aggregate used in the mix and the other terminal shall be placed in the bin containing the largest aggregate. The terminals shall be located where the hot material will flow around them during the proportioning operation and shall not be located near the corners of the bins or at points where the material will collect or pack around them. The charts shall continuously record both time and temperature. The smallest interval of time shown shall be not more than 15 minutes and the temperature graduations shall be not more than 10°F. The charts shall be furnished to the Engineer at the end of each day's operations. 404.13.10 Control of Mixing Time. The plant shall be equipped with positive means to maintain a constant mixing time.
9/1/2023
404-22
Superpave Asphaltic Concrete Pavement and Base
404.13.10.1 Batch Type Plants. The dry hot virgin aggregates, hydrated lime, RAP or RAS, mineral filler if needed, and asphalt cement shall be accurately proportioned in the quantities required by the job-mix formula. Aggregate shall be charged into the weigh hopper in a sequence that will avoid segregation. The mineral aggregate, RAP or RAS if needed, shall be mixed dry for not less than 15 seconds. For SP190 mixtures the dry mixing time may be reduced to 10 seconds. The dry mixing period shall start when all of the mineral aggregates have been charged into the mixer and end when introduction of the asphalt cement begins. After dry mixing, the asphalt cement shall be charged into the mixer in a manner that will uniformly distribute the asphalt over at least ¾ the full length of the mixer. The time required to add the asphalt shall not exceed 15 seconds. Wet mixing shall begin at the introduction of the asphalt cement and continue for at least 30 seconds, or longer if necessary to produce a complete and uniform coating of the particles and a thorough distribution of the asphalt cement throughout the aggregate. The wet mixing period shall end when the discharge gate is opened. The dry and wet mixing times shall be as directed by the Engineer. 404.13.10.2 Continuous Mixing Plants. Each size of hot aggregate, mineral filler or hydrated lime if needed, and the asphaltic cement shall be accurately proportioned in the quantities required by the job-mix formula. The mixing period shall be determined in by dividing the pugmill dead capacity in pounds by the pugmill output in pounds per second and shall be not less than 35 seconds. The mixing time shall be directed by the Engineer, and may be increased above the minimum specified, if necessary, to produce a complete and uniform coating of the particles and a thorough distribution of the asphalt cement throughout the aggregate. 404.13.11 Safety Requirements. A conveniently located, easily opened gate or door shall be provided in the mixer cover for observation of the mixing operations. Adequate and safe stairways to the mixer platform and sampling points shall be provided, and guarded ladders to other plant units shall be placed at all points where accessibility to plant operations is required. Accessibility to the top of truck bodies shall be provided by a platform or other suitable device to enable the Engineer to obtain samples and mixture temperature data. All gears, pulleys, chains, sprockets, and other dangerous moving parts shall be thoroughly guarded and protected. Ample and unobstructed space shall be provided in and around the truck. This area shall be kept free from drippings from the mixing platform. 404.13.12 Requirements for Batching Plants. 404.13.12.1 Automatic Batching. For all contracts having not more than 5,000 tons of asphaltic concrete mixture, standard manual batching methods, approved by the Engineer, will be permitted. For contracts having more than 5,000 tons of asphaltic concrete mixture, batching plants shall be equipped to operate automatically to the extent that the only manual operation required for the proportioning of all ingredients for one batch shall be a single actuation of a switch or starter. The equipment shall include devices capable of automatically proportioning each ingredient of the mixture in the selected sequence and quantity. Interlocks shall be provided which will hold or delay the automatic batch cycling whenever the batched quantity of any ingredient is not within the specified tolerance. The weight setting and timing controls shall be suitably equipped so they may be locked when directed by the Engineer. Manual operation will not be permitted beyond 24 hours after breakdown in the automatic equipment, except with written approval from the Engineer.
9/1/2023
404-23
Superpave Asphaltic Concrete Pavement and Base
404.13.12.2 Weigh Box or Hopper. The equipment shall include a means for accurately weighing aggregate of each bin into a weigh box or hopper, suspended on scales, and ample in size to hold a full batch without hand raking or running over. Weigh boxes shall be charged through only one gate opening for aggregate of each bin size. The weigh box or hopper shall be supported on fulcrums and knife-edges so constructed that they will not easily be thrown out of alignment or adjustment. Gates on the bins and the hopper shall be so constructed as to prevent leakage when they are closed. 404.13.12.3 Aggregate Scales. Scales for weighing aggregate and mineral filler or hydrated lime may be beam, springless dial, or the electronic digital weigh meter type and shall be of standard make and design having tolerances on over registration and under registration not exceeding 0.4 percent of the indicated weight when tested for accuracy. Each aggregate fraction shall be measured within 1 percent of the total batch weight of the mixture. Mineral filler or hydrated lime shall be measured within 0.5 percent of the total batch weight of the mixture. The total weight of the batch shall be within 2.0 percent of the desired batch weight. The change in load required to change the position of the rest of the indicating element or elements of a non-automatic indicating scale an observable amount shall not be greater than 0.1 percent of the nominal scale capacity. If manual batching methods are used, beam-type scales shall be equipped with a device to indicate to the operator that the required load is being approached. This device shall indicate at least the last 5 percent of the load weighed (determined) on any beam, except that this increment will not be required to be greater than 200 pounds. Multiple beam-type scales shall be equipped with a tare beam and a separate beam for each size of aggregate. Dial scales shall be equipped with adjustable pointers for marking the weight of each material to be weighed into the batch. Graduation intervals for all scales shall not be greater than 0.1 percent of the nominal scale capacity. Quantity indicators necessary for batching shall be in full view of the operator. 404.13.12.3.1 Automatic volumetric batch proportioning approved by the Engineer will be permitted and shall meet the tolerances specified in Section 404.13.12.3. 404.13.12.4 Asphalt Bucket. If a bucket is used for weighing the asphalt binder, it shall be of sufficient capacity to hold and weigh the quantity required for a batch in a single weighing. The filling system and bucket shall be of such design, size, and shape that asphalt will not overflow, splash, or spill outside the confines of the bucket during filling and weighing. The bucket shall be steam or oil-jacketed or equipped with properly insulated electric heating units. 404.13.12.5 Asphalt Scales. Scales for weighing asphalt shall conform to the requirements for aggregate scales, as specified in Section 404.13.12, except a device to indicate at least the last 20 pounds of the approaching total load shall be provided. Bituminous material shall be measured within 0.1 percent of the total batch weight of the mixture. Springless dial scales used for weighing asphalt shall have a tare beam, and a dial graduated in increments not to exceed 0.1 percent of the nominal scale capacity, and the maximum dial capacity shall be not more than 15 percent of the nominal capacity of the mixer.
9/1/2023
404-24
Superpave Asphaltic Concrete Pavement and Base
404.13.12.6 Mixer Unit. The plant shall include an approved twin shaft pug mill mixer capable of producing a uniform mixture. The mixer shall be either electrically heated, hot oil, or steam jacketed, and have a capacity of not less than 2,000 pounds per batch. The mixer shall be so constructed as to prevent leakage of the contents, and the mixer box shall be equipped with a hood to prevent loss of dust. 1) Mixer Blades. The mixer shall be designed to provide means of adjusting the clearance between the mixer blades and liner plates to insure proper and efficient mixing. Not more than one pair of paddle tips on each mixer shaft shall be reversed with respect to the other paddle tips on the shaft, except that for mixers having forty paddles or more, two pair may be reversed on each shaft. The reversed paddle tips shall be located in diagonally opposite corners of the pug mill. The clearance of blades from all fixed and moving parts shall not exceed ¾ inch. 2) Time Lock. The mixer shall have an accurate time lock to control the operation of a complete mixing cycle by locking the weigh box gate after the charging of the mixer until the closing for the mixer gates at the completion of the cycle; it shall lock the asphalt bucket throughout the dry mixing period and shall lock the mixer gate throughout the dry and wet mixing periods. 3) Mixer Rating Plate. A rating plate designating the manufacturer's rated capacity shall be attached to the mixer. The quantity of mixture produced per batch shall not exceed the manufacturer's rated capacity. The manufacturer's rated capacity will not be accepted unconditionally. If the mixer does not produce a satisfactory mixture, or if its production does not coordinate with other plant units, the right is reserved to reduce the size of the batch. The decision of the Engineer as to the permissible capacity of the mixer shall be final. 404.13.13 Requirements for Drum Mix Plants. 404.13.13.1 Drum Mix Plants. The plant shall be specifically designed for drum mixing and be capable of satisfactorily heating, drying, and mixing the bituminous mixtures. The aggregate shall enter the drum from the same end the burner is located and travel parallel to the flame and exhaust air stream. The system shall be equipped with automatic burner controls, and heating shall be controlled to prevent damage to the aggregate or the asphalt cement. The temperature of the mixture when discharged from the mixer shall be within the range specified in Section 1015.2 for the grade of asphalt cement being used. The rate of flow through the drum shall be controlled in order that the bituminous material and aggregate shall be mixed until a homogeneous mixture with all particles uniformly coated is obtained. In no case shall the quantity of mixture produced exceed the lesser of the manufacturer's rated or permitted capacity. 404.13.13.2 Feed Indicators. Each feeding orifice shall have an adjustable gate with an indicator provided to reference the opening setting. On each of the aggregate feeders, a device shall be installed to indicate when the flow of material from the bin is below the point where accurate proportioning through the feeder gates can be accomplished. These indicators shall be positive in action and shall actuate a clearly visible or audible signal to the plant operator or stop the flow of materials to the drum when the level of material in the bin is too low for accurate proportioning. In addition, for those particular cold bins whose aggregate material tends to either bridge or lump
9/1/2023
404-25
Superpave Asphaltic Concrete Pavement and Base
together causing temporary interruptions in feeds, a vibrator or other suitable means shall be provided to insure uniform flow. The order of aggregate feed onto the composite cold feed belt shall be from coarse to fine. When only one aggregate is furnished, two cold bins shall be used. A scalping screen mounted independent of other proportioning or weighing equipment shall be required if directed by the Engineer. 404.13.13.3 Asphalt Meter. Asphalt binder shall be introduced through a continuously registering cumulative indicating meter by a pump specifically designed for dryer-drum plants. The meter shall be located in the asphalt line so that it will continuously register the asphalt discharge to the mixer and so that the discharge through the meter can be readily diverted into a container for measurement. The meter shall be equipped with a non-setback register and shall have accuracy within 2 percent by weight of the material actually being measured in any given period of time. The non-setback register shall register only the asphalt discharged to the mixer and shall not record asphalt circulated back to the storage tank. A device shall be provided in the asphalt storage tank to indicate when the supply of asphalt to the pump and metering device is such that accurate proportioning is not accomplished. The accuracy of the pump and meter shall be verified at periodic intervals as designated by the Engineer. 404.13.13.4 Mineral Filler. If mineral filler or hydrated lime, or both, are used, a separate bin and feeder shall be furnished, and each material shall be dispensed by weight by continuous batching device. The batching device shall have a continuous weight display in clear view of the plant operator. The delivery system shall be variable speed and interlocked with the aggregate weigh belt so the total dry aggregate weight, including mineral filler or hydrated lime, or both, is indicated to the asphalt proportioning system. A continuously registering, cumulative, non-setback register shall record the quantity of mineral filler or hydrated lime, or both, discharged into the mixer. Mineral filler and hydrated lime shall be introduced and uniformly dispersed into the drum mixer at the point of introduction of the asphalt binder without loss to the dust collection system. The mineral filler and hydrated lime proportioning and delivery system shall have an accuracy of 10 percent by weight of the material actually being measured in any given period of time. Means shall be provided to readily divert the flow of mineral filler or hydrated lime into a container for measurement. 404.13.13.5 Belt Scales. The aggregate feed system, including hydrated lime and mineral filler if specified, and the asphalt flow shall be interlocked by a blending system, which will automatically regulate the asphalt flow and cause immediate correction for variations in aggregate flow. The system shall provide positive weight measurement of the combined cold aggregate feed by use of belt scales. The combined cold aggregate feed shall be continuously recorded on a non-setback register. The belt scale shall have accuracy within 2 percent by weight of the material actually being measured in any given period of time. The accuracy of the belt scales shall be verified at periodic intervals as directed by the Engineer. The scale and the conveyor at the scale shall be protected from wind and weather effects. Feed of material to the belt scale shall be controlled to insure at normal operation the combined aggregate flow is between 50 percent and 100 percent of the rated capacity of the scales. The plant shall be equipped so that the proportion of each aggregate can be individually varied. The plant shall also be equipped so that the total aggregate rate can be varied without affecting the proportions. The plant shall be equipped with a moisture-compensating device in the control panel to automatically correct for the moisture in the aggregate passing over the belt scale. Moisture determinations on the combined aggregate will be made periodically during
9/1/2023
404-26
Superpave Asphaltic Concrete Pavement and Base
each day's operations. The plant shall be equipped with a device in the control panel to automatically correct for the specific gravity of the asphalt. The plant shall also be equipped with a device to positively maintain the proportions of aggregates, mineral filler, or hydrated lime, and asphalt cement throughout the full production range. 404.13.13.6 Sampling. Safe, adequate, and convenient facilities shall be provided for obtaining representative asphalt and aggregate samples. The plant shall be equipped with a sampling device capable of providing a sample of sufficient size from the full width of the combined aggregate cold feed flow. It shall be designed so that samples may be taken while the plant is operating at normal production rates. Safe, adequate, and convenient facilities shall be provided for calibrating the asphalt flow, mineral filler or hydrated lime flow, and the aggregate flow. The manufacturer's recommendations shall be followed for calibration. To calibrate the aggregate flow system, means shall be provided to permit a positive and uniform diversion of the aggregate in sufficient quantity for accurate timed weight checks. To calibrate the asphalt metering system for proper proportioning, an asphalt distributor or other equipment approved by the Engineer shall be made available so that an accurate tare, gross and net weight may be obtained of the diverted asphalt discharge. If necessary, manual overrides of the electronic timing equipment shall be provided for testing and calibration. Electronic timing equipment shall be provided for testing and calibration purposes. The rate of flow of the total aggregate and asphalt flow shall not vary by more than 2.0 percent by weight from the required quantity of each. 404.13.13.7 Automatic Ticket Printer. The asphalt plant shall be equipped with an automatic ticket printer connected to the weighing system in such a manner that the printer automatically detects and prints the weight determined by the system. The printer shall store and recall the tare weight when the operator enters the vehicle identification. The weight shall be shown to at least the nearest 20 pounds or nearest. 1.1 of a ton. The automatic printer shall be capable of keeping and printing cumulative totals for each project for each type of bituminous mixture. The automatic printer shall produce a ticket in triplicate to accompany each load delivered to the project and shall be furnished to the Engineer showing the weight for each load that shows the following: 1) Gross, tare and/or net weights; 2) Hauling equipment identification number; 3) Batch date and time; 4) St. Louis County plant mix number assigned to the mix being placed; 5) Unique ticket number (may be preprinted on the ticket); 6) St. Louis County Project Number; 7) Federal Job Number (if applicable).
9/1/2023
404-27
Superpave Asphaltic Concrete Pavement and Base
404.13.13.7.1 Net Weight. When the net weight of bituminous mixture is determined by batch weights, the scales shall meet all requirements of this Section, including automatic ticket printing, except the gross and tare weights will not be required. 404.13.13.7.2 Gross Weight. When the net weight of bituminous mixture is determined by weighing in a vehicle, the vehicle shall be weighed empty for each load, weighed daily, or weighed as the Engineer may direct, in order to establish the tare weight of each load. 404.13.13.7.3 Daily Total. At the end of each day's operation the Contractor shall furnish to the Engineer the total tonnage of mixture produced by the asphalt plant in sufficient detail to determine the amount of asphalt cement used in that day's operation. 404.13.13.7.4 Printer Failure. In the event of automatic ticket printer failure, the Contractor may be allowed, with the Engineer's approval, to furnish manually written tickets to complete that day's operation. 404.13.8 Air Pollution Control Equipment (Bag House). A bag house(s) shall be installed and operated to restrict the emission of particulate matter. The bag house(s) must be used whenever the units, specified in the manufacturing plants permit special conditions, are in operation. Instruments shall be installed to monitor the pressure drop across the bag house. All instruments and control equipment shall be calibrated, maintained, and operated in accordance to the manufacturer's preventative maintenance recommendations. The operator(s) shall check and record the pressure drop across the bag house filter once per operating day during silo loading. The bag house operating pressure drop shall be maintained according to the manufacturer's specifications. 404.13.8.1 The operator(s) shall conduct and document a quarterly inspection and maintenance of the bag house for structural component failures, for leaks and wear, and for the cleaning sequence of the bag house. Replacement bags, made of fibers appropriate for the operating conditions expected to occur, shall be kept on hand at all times to replace defective bags. All inspections, corrective actions, and instrument calibrations shall be recorded. 404.13.8.2 Bag house(s) generally should be operated in the range of 240°F to 250°F, to avoid condensation during production. RAP/RAS content and aggregate moisture content will impact exhaust temperature. Pre-heating up to 350°F at the bag house inlet temperature for 20 minutes when first starting daily starting operations is recommended. The bag material will limit the maximum inlet temperature. 404.13.8.3 Other emissions, such as smoke but excepting water vapor, shall be controlled to be in compliance with applicable permitting limits. Failure of air pollution control equipment will cause asphalt mixing plant operations to cease until bag house operation and emission control is restored.
9/1/2023
404-28
Superpave Asphaltic Concrete Pavement and Base
404.14 Hauling Equipment. Trucks used for hauling bituminous mixtures shall have tight, clean, smooth, metal beds, which have been evenly coated with a minimum quantity of lime solution or an approved non-petroleum based release agent to prevent the mixture from adhering to the beds. After spraying, the bed of the vehicles shall be in a completely raised position and it shall remain in this position until all excess asphalt release agent or water has been drained. Use of diesel fuel, fuel oil or other detrimental products as a bed coating will not be allowed. Amounts of release agent that form visible pools in the truck bed shall be removed prior to loading. Each truck shall have a waterproof cover of canvas or other suitable material of such size as to cover the top of the load and extend down over the sides of the truck. The cover shall extend down over the sides and ends of the bed for a distance of at least 1 foot and shall be fastened securely all around the truck bed to protect the mixture from the weather. The cover shall be capable of withstanding normal handling and material temperatures of up to 350°F without damaging the fabric. Each truck shall have a cover of canvas or other suitable material of such size to protect the mixture from the weather. The cover shall be securely fastened over all sides of the truck bed. Truck beds shall be insulated, when necessary, such that the mixture will be delivered on the road at the specified temperature. 404.14.1 Materials Transfer Vehicle (MTV). An MTV is required with the use of a spray paver. The Contractor may elect to use an MTV, meeting the following requirements, if approved in advance by the Engineer. The MTV shall be capable of independently delivering mixture from the hauling equipment to the paving equipment. The MTV shall be equipped with a high-capacity truck unloading system to receive mixtures; a storage system capable of holding at least 15 tons of material; and a discharge conveyor capable of swiveling to either side to deliver material to the paving spreader while allowing the MTV to operate from an adjacent lane. The MTV shall be equipped with an automatic audible warning signal when operating in reverse. 404.14.2 Provide a paver hopper insert with a minimum capacity of 14 tons in the hopper of conventional paving equipment. 404.14.3 Provide a remixing system to continuously blend the asphalt before placement in order to produce a uniform, non-segregated mix, having a uniform temperature. Remixing may occur within the MTV or in the paver hopper.
9/1/2023
404-29
Superpave Asphaltic Concrete Pavement and Base
404.15 Pavers. 404.15.1 Highway-Class Pavers. Self-propelled highway-class hot mix asphalt pavers, with a tractor and basic screed weight of 40,500 pounds or more and shall be self-contained units, rubber tired or track mounted, provided with an activated 10 foot or wider basic screed or strike-off assembly, equipped with a vibratory system (with amplitude control from 0 to 3,100 rpm) capable of consolidating the warm or hot mix material and a system capable of heating and maintaining the screed to a minimum of 185 degrees above ambient in less than 30 minutes (capable of various temperature settings) which will provide for the spreading and finishing of warm or hot mix material in lane widths applicable to the specific typical section and thicknesses shown on the plans. The maximum paving width of the paver shall be not less than 30 feet. The paver tractor shall have a minimum rated horsepower of 174. The paver shall be equipped with a receiving hopper a minimum of 215 cubic feet (13.5 tons) in capacity and a truck entry width of at least 120 inches. The hopper shall be equipped with a distribution system of sufficient capacity and speed to place the mixture uniformly in front of the screed or strike-off. The hydraulically folding hopper wings shall not be folded together unless authorized by the Engineer. Screed cut-off plates, which mount on the face of the basic screed, shall be provided when paving widths are between 8 and 10 feet. The use of full width auger and tunnel extensions is required when the screed is extended more than 1 foot wider than the fixed screed width to ensure proper distribution of the mixture and maintain a constant head of material in front of the screed. The end gate shall be set to firmly seat on existing pavement surface. The paver shall be equipped with a hydraulic system which will incorporate a screed lock system. The system will automatically lock the screed in position whenever the paver is stopped and return to normal 2 seconds after paving resumes. The screed or strikeoff assembly shall be equipped with an automatic control device as required in Section 404.15.4, "Automatic Screed Control", and shall effectively produce a consolidated finished surface of required evenness and texture without shadow lines, tearing, shoving, or gouging the mixture. When laying mixtures, the paver shall be capable of operation at consistent forward paving speed of up to 220 feet per minute, in a manner which will produce a uniform consolidated mat of paving mix material. The vibratory screed shall be turned on when the paver is moving forward. The paver's slat conveyors shall not be visible during the paving operation. Avoid and minimize start and stop operation or allowing the paver to remain stationary during operation. 404.15.1.1 The paver shall be equipped with a working back-up alarm system. The use of all paving equipment will be subject to the approval of the Engineer. When conditions dictate, the Engineer may disapprove the use of rubber-tired pavers. Uniform tire pressure must be maintained in all pneumatic tires at all times. 404.15.1.2 The use of petroleum distillates to clean the paver or other equipment will not be allowed on any paved surface. The cleaning of hand tools will be allowed inside of containers firmly attached to the paver, which have a sufficient volume to prevent spilling of petroleum distillates on to the surface to be paved. Any spillage on to the surface to be paved will be promptly cleaned up utilizing absorbent material and if necessary, the surface will be re-tacked. If in the opinion of the Engineer, the container attached to the paver is insufficient in any way, it will be removed, and hand tools will be cleaned beyond the paving limits until a suitable container is provided. Petroleum distillates in sprayers or buckets will not be allowed within the boundaries of the area to be paved.
9/1/2023
404-30
Superpave Asphaltic Concrete Pavement and Base
404.15.2 Non-Highway Class Pavers. Self-propelled non-highway class hot mix asphalt pavers with a tractor and screed weight of less than 40,500 pounds are allowed to be used principally to place the specified asphalt mix on temporary detours, parking lots, driveways, paving widths less than 8 feet, and other small projects of less than 300 tons. The paver tractor shall have a minimum rated horsepower of 75. The non-highway or commercial class of paver will be allowed only for small irregular areas, parking lots, and driveways. Equipment for shoulders and tapers 8 feet or less in width shall be approved by the Engineer before use. Widening pavers may be used only for shoulder or median areas. Widening pavers are required to be self-propelled, capable of placing material at variable widths up to 8 feet wide, equipped with hoppers for receiving the mix from the haul units, conveyors to carry the mix to either side of the paver, and have adjustable strike-offs on each side of the paver to allow paving on either side. The strike-off may be adjusted vertically up to 12 inches below or above the grade, depending on the make and model, to allow placing material in lifts. Non-highway class pavers shall comply with Sections 404.15.1.1 and 404.15.1.2. Box spreaders shall not be allowed for paving within the right- ofway. 404.15.2.1 Spray Paver. The spray paver shall meet the requirements of Section 404.15.1 and as modified herein. 404.15.2.1.1 The spray paver shall be equipped with a receiving hopper, feed conveyor, computer-controlled insulated hot oil heating system 500-gallon minimum tack storage tank, a system for measuring the emulsion membrane volume applied, spray bar, and a heated, variable-width bar screed. In accordance with Section 407, the spray system target application rate setting (operating in a range from 0.04 to 0.30 gallons per square yard) shall be verified by the Contractor in the presence of the Engineer for the material being sprayed. Equipment shall be free from leaking fuel, crankcase or transmission oil, engine coolant, and hydraulic fluid. The paver shall be capable of heating, storing, measuring, and spraying the emulsion membrane and applying the asphaltic concrete overlay. The application of the emulsion and leveling the surface of the mat shall be made in one pass. The paver shall include a system to prevent excess spraying of membrane if the spray bar is adjusted to accommodate changes in paving width. The sump pump system is to be operated at all times during the paving operation to prevent emulsion overflow of the tray. 404.15.2.1.2 The paver shall be capable of paving at a controlled speed from 30 to 90 feet per minute. Wheels or other parts of the paving machine shall not come in contact with the tack before the asphaltic material is applied. The screed shall have the ability to crown the pavement at the center, both positively and negatively, and shall have vertically adjusted extensions to accommodate the desired pavement profile. 404.15.2.1.3 The Engineer may waive the use of automatic slope controls in areas where the existing surface (subgrade, base, asphalt layer, etc.) exhibits the desired cross slope of the final surface. The Engineer may also waive the use of automatic slope controls in areas where the use of such equipment is impractical due to irregular shape or cross section (such as resurfacing). When the use of the automatic slope controls is waived, the use of mobile grade references on either or both sides of the paver is required to ensure proper joint matching and smooth pavement. Manual screed operation will be permitted in the construction of
9/1/2023
404-31
Superpave Asphaltic Concrete Pavement and Base
irregularly shaped and minor areas, subject to Engineer approval. Waiver of the use of automatic screed controls does not relieve the Contractor of achieving plan profile grades, joint matching, and cross-slopes. The Engineer will waive the requirement for use of the spray paver for spreading and finishing where irregularities or obstacles make their use impractical. Spread, rake, and lute the mixture by hand methods or other approved methods in these areas. 404.15.2.1.4 The asphaltic material shall not be deposited on the roadway and a pick-up device shall not be used to transfer the material to the paver. 404.15.2.1.5 The use of petroleum distillates shall be in accordance with Section 404.15.1.2. 404.15.2.1.6 When construction is being performed under traffic, all equipment, including loading vehicles and supply trucks will be required to operate in a single lane on which the emulsions and asphaltic material is being applied. The Contractor's equipment for emulsion and asphaltic material placement shall be operated in such a manner that will permit traffic to move safely and expeditiously through and around the work area. 404.15.2.1.7 When equipped with receiving hopper wings, the wings of the paver's receiving hopper shall not be raised during the paving operation. 404.15.3 Special Devices. 404.15.3.1 Notched Wedge Longitudinal Construction Joint. This work shall consist of constructing a notched wedge longitudinal joint between successive passes of hot-mix asphalt (HMA) or warm-mix asphalt (WMA) binder course that is placed in 1¾ inch to 3inch lifts on pavement that is open to traffic. The notched wedge longitudinal joint shall consist of a ¾ inch maximum vertical notch at the centerline or lane line, a 12-inch uniform taper extending into the open lane, and a second ¾ inch vertical notch. An adjustable notched wedge joint device that results in the configuration approved by the Engineer shall be provided. The device shall be installed to the paver in accordance with the manufacturer's guidelines and shall not restrict operation of the main screed. A Wedge Roller, attached to the paver, shall be used to compact the horizontal portion of the joint. A notched wedge device will be required when the adjacent lane is open to traffic and the lane that is paved is opened to traffic before road paving is complete. 404.15.3.2 Safety Edge. The safety edge shall be incorporated on all new construction and maintenance overlays. Pavement will not be required to have a safety edge in the following locations:
9/1/2023
•
On pavement surface treatments that are less than 1.5 inches thick;
•
On pavement that would result in an edge-dropoff of less than 2 inches after new construction or maintenance overlays that are more than 1.5 inches thick;
•
Shoulders greater than or equal to 4 feet in width as demonstrated by Standard Drawing C203.81;
404-32
Superpave Asphaltic Concrete Pavement and Base
•
Next to curbs, dikes, guardrails, barriers, walls and landscape paving;
•
With approval of the Engineer when safety edge length is less than 15 feet;
•
Within 3 feet of driveways, guardrail or intersections; or
•
When the distance from the edge of pavement shoulder to the hinge point is less than 1 foot and there is not enough room for a safety edge.
404.15.3.2.1 Description. The paver shall include an approved longitudinal paver wedge system to create a sloped safety edge to the dimensions shown and at locations designated on the contract documents for temporary and permanent pavements. The Contractor shall submit the proposed system for approval at the Preconstruction Conference. The Engineer may require proof that the system has been used on previous projects with acceptable results or may require a test section constructed prior to the beginning of work to demonstrate that it creates an acceptable wedge shape and compaction. Paving shall not begin until the system is approved in writing by the Engineer. The finished shape of the Safety Edge shall conform to the cross-section drawings shown in Exhibit "A". The Safety Edge shall be constructed monolithically with the pavement.
Exhibit "A" Safety Edge configurations for asphalt pavements and asphalt overlays. *Note 1: The slope construction tolerance is equal to 30 degrees ±5 degrees as measure from the horizontal and the slope range is actually 1.43:1 to 2.15:1. Note 2: Configuration 1 depicts constructing the Safety Edge with the final two lifts of asphalt while Configuration 2 (alternate) depicts constructing it with only the final lift of asphalt.
9/1/2023
404-33
Superpave Asphaltic Concrete Pavement and Base
404.15.3.2.2 Equipment. The Safety Edge may be constructed on each lift of HMA or WMA or on the full-specified plan depth on the final lift. The finished shape of the Safety Edge shall extend for the full depth of the asphalt pavement or for the top 5 inches whichever is less. Utilize an approved longitudinal Safety Edge system to create a sloped edge profile onto the roadway shoulder. Utilize an approved Safety Edge system that compacts the HMA or WMA and provides a sloped wedge equal to 25 degrees to 35 degrees measured from the pavement surface cross slope extended after final compaction of the final surface course. The device must be designed to constrain the asphalt material and reduce the area by 10 to 15 percent thereby increasing the consolidation of the extruded profile. The device shall produce a wedge with uniform texture and shape while adjusting automatically to varying heights encountered along the roadway shoulder (crossroads, driveways, and obstructions). The device must be removable or be able to be lifted when not in use for projects that do not require a sloped edge profile. The use of a single plate strike off is not permitted. Utilize an approved Safety Edge system that is adjustable to accommodate varying paving thicknesses. All Safety Edge systems to be used for the purpose of creating a Safety Edge must meet the approval of the Engineer. The Engineer may require proof that the system has been used on previous projects with acceptable results or may require a test section constructed prior to the beginning of work to demonstrate the edge shape and compaction to the satisfaction of the Engineer. 404.15.3.2.3 Construction Requirements. a) Shoulder Preparation. Prior to placing asphalt, prepare the shoulder material where the Safety Edge will be placed to provide a foundation that shall be graded, compacted and brought to true in accordance with Section 209 so that it will support the placement of the Safety Edge. For each inch of vertical pavement drop-off depth (top of proposed surface to prepared shoulder base) shoulder "clipping" shall be performed 3 inches ± beyond the edge of pavement (for example, if there is a 2 inch overlay planned and there is a 4 inch drop-off, clipping would be required 18 inches ((2+4)*3) beyond the edge of pavement). b) Density Adjacent to Safety Edge. The percent compaction of the HMA or WMA adjacent to the Safety Edge shall be in accordance with Section 404.17.7. c) Shoulder Backing Material. When specified in the contract documents, furnish, place and compact Type 5 Aggregate shoulder backing material to the top of the Safety Edge as shown in Exhibit "A" in accordance with Section 304. d) Handwork. Attain approval in advance from the Engineer for short sections of handwork such as transitions at driveways, intersections, interchanges, drainage structures and bridges.
9/1/2023
404-34
Superpave Asphaltic Concrete Pavement and Base
404.15.4 Automatic Screed Control. The use of automatic screed control devices will be required for all full depth construction except for paving small irregular areas, shoulders, entrances, and side road connections. The screed of the mechanical spreading and finishing machine shall be regulated by an automatically controlled grade leveling and slope control device approved by the Engineer. The device shall be of a standard commercial quality adapted to the type of paver used and shall provide control for producing a uniform surface to the established grade and a cross slope conforming to the requirements of the typical section. The device shall also be equipped with the necessary controls to permit the operator to adjust or vary the slope throughout superelevated curves. The main screed shall have a center crown adjustment range of 3 inches positive to ¾ inch negative. 404.15.4.1 Grade Reference. Except as modified above or by the contract, an established grade reference shall be used to achieve smoothness and joint density. When paving width is greater than 17 feet, grade references shall be used on both sides of the paver. The Engineer will establish the grade and will furnish variable thickness values at intervals along the centerline of the roadway for the use of the Contractor in setting a grade reference. The initial pass of the paver, when placing the first continuous layer, shall be made with the sensor following the established grade reference maintained true to grade. If the established grade reference is not required, the initial pass of the paver, when placing the first continuous layer, shall be made with the sensor following a traveling reference plane not less than 30 feet in length, segmented, supported on pads parallel to the paver, and mounted as an integral part of the paver. The Contractor may submit a non-contact Global Positioning System (GPS) system for Engineer review and approval. Regardless of the method used for placing the first continuous layer, other layers shall be placed by use of a shoe-type (joint matching) sensor or indicator mounted a few feet in front of the auger, the traveling reference plane (walking beam), or by additional use of the established grade reference as follows: a) Surface Course. If the current construction consists of only one bituminous or asphaltic layer, a shoe-type sensor or indicator resting on the adjacent surface (cold side) shall be used for control of subsequent passes of the paver for that layer. When more than two adjacent passes of the paver are required to place the material the full width of the riding surface, additional use of the established grade reference is required. b) Wedge and Level with Surface Course. If the current construction consists of two bituminous or asphaltic layers, subsequent passes of the paver for the first layer and the first pass of the paver for the second layer shall be made with the sensor following the traveling reference. The adjacent passes of the paver for the second layer shall be made with a shoe-type sensor or indicator resting on the previously placed second layer. When more than two adjacent passes of the paver are required to place the second layer the full width of the riding surface, additional use of the established grade reference or the traveling reference is required. c) Full-Depth Construction. If the current construction consists of three or more bituminous or asphaltic layers, subsequent passes of the paver for the same layer and each pass of the paver for all additional layers except the top layer, shall be made with the sensor following the traveling reference. When more than two adjacent passes of the paver are required to place the surfacing material, except for the top layer, the full width of the riding surface, additional use of the
9/1/2023
404-35
Superpave Asphaltic Concrete Pavement and Base
established grade reference is required. The automatic screed control device need not be used when placing the surface course if the current construction consists of three or more full layers of a bituminous or asphaltic mixture. 404.15.4.2 The spreading operation shall be discontinued in the event of failure of the automatic control device, except that placement will be permitted of mixtures already produced at the time of the failure and only if specified results are obtained. The use of the automatic control equipment does not preclude the need for manual control of the screed adjustment for wedging operations over small areas requiring more correction than the maximum thickness permitted for an individual layer of the type of material being placed. Suspend paving if the specified surface tolerance is not met. Resume paving only after correcting the situation. 404.15.4.3 For overlay of an established depth on a milled surface or wedged course, the use of the automatic screed control maybe eliminated if in the opinion of the Engineer the surface tolerances maybe met. For safety of the motoring public, the automatic screed control may be eliminated if such action is necessary due to width restrictions on the roadway. 404.15.5 Equipment Operation and Maintenance. The Contractor shall operate and maintain equipment used in the construction of mix to prevent soil contamination and storm water pollution. Equipment shall be properly handled, stored, and maintained. 404.15.5.1 Storm drains or watercourses shall be protected from contamination. Park equipment away from storm drain inlets, drainage facilities, or watercourses. Inlet drains and manholes shall be covered with filter fabric when applying tack. 404.15.5.2 When paving equipment is kept on site and to prevent soil contamination, paving equipment shall be parked over plastic sheeting. Use barriers such as berms, sandbags, or dikes to direct storm water away from areas where equipment or vehicles are being repaired, maintained, assembled, fueled, or parked. 404.15.5.3 Properly dispose of construction waste, hardened asphalt, used oil, fluids, lubricants, and spill clean-up materials. Clean equipment offsite whenever possible. 404.15.5.4 The Contractor shall plan the lane sequence so as to pave from low to high, preventing the overlapped joint material from impeding water flow on the surface. 404.16 Sawing, Coring and Grinding. Monitor working tasks such as saw-cutting or surface operations daily to ensure proper methods are employed or as directed by the Resident Engineer or Construction Inspector. Saw-cutting and surfacing operations include, but are not limited to, sawing, coring, grinding, roughening, grooving, or hydro-demolition. 404.16.1 All material generated as part of saw cutting or surface operation shall be collected and disposed of, to the maximum extent practicable, in an approved landfill or buried on site. Slurry material buried on site shall be de-watered. If the material generated is buried on site it shall have a 2-foot cover, minimum. The 2-foot cover shall match the adjacent finished grade.
9/1/2023
404-36
Superpave Asphaltic Concrete Pavement and Base
404.16.2 Saw-cutting and surface operation Portland cement concrete or asphalt pavement material (slurry or dry) should not be allowed to become airborne, flow across pavement lanes or enter storm drains or watercourses. Material should be picked up by means of a vacuum device or swept up before exposure to traffic and recycled or disposed of properly. Compressed air shall not be used to clean the material off the pavement. Material shall not be allowed to flow or blow across the pavement and shall not be left on the surface of the pavement when traffic is present, when precipitation is anticipated before the end of clean up or overnight. 404.16.3 Cleaning waste material and demolition debris should be handled and disposed of in a manner that does not cause contamination to air or water. 404.17 Rollers. All rollers, vibrators, or other equipment used to compact the asphaltic mixture shall be in satisfactory working condition, free from fuel, oil, or hydraulic leaks. Steel drums shall be smooth and have a uniform surface. Rubber-tired and pneumatic equipment shall be equipped with tires in good condition, free of surface defects. All rollers shall be capable of reversing without backlash, and steel wheel rollers shall be equipped with scrapers, scouring pads, and a controlled flow watering system. All rollers shall have a scouring pad and a system for moistening each wheel or roller. For Superpave mixes, it will be the Contractor's responsibility to use the appropriate number and types of rollers to achieve compaction. A minimum of three rollers will be required (Breakdown, Intermediate, and Final). The roller requirements and equipment definitions are listed below. Vibratory frequency and pattern will be established by test strip and will not be altered unless field monitoring indicates compaction outside the acceptable range. It will be the Contractor's responsibility to establish and operate within these parameters. The Contractor shall submit a certification of weight or other suitable documentation certifying compliance with specifications for each piece of compactive equipment proposed for use. Non-certified equipment will not be permitted to operate. No direct payment will be made for the cost of complying with the requirements of this section. 404.17.1 Irregular Areas. 404.17.1.1 Intersections and Commercial Approaches. A 3-to-5-ton vibratory roller will be required for intersections and commercial approaches to eliminate roller marks and indentations. 404.17.1.2 Inaccessible Areas. Trench rollers, vibrators, and other special equipment used for compacting mixtures placed in areas inaccessible to the rollers specified shall be of a weight and design approved by the Engineer. For isolated pavement repair removal and replacement areas where a trench roller is not practical, the Contractor shall utilize a reversible vibratory plate-type compactor with a minimum centrifugal force rating of 6,520 pounds to achieve the mixture compaction specified. When approved by the Engineer, the mixture for the isolated pavement repair removal and replacement areas may be compacted by a minimum of four complete reversible vibratory compactor coverages when not over excavated utility trenches.
9/1/2023
404-37
Superpave Asphaltic Concrete Pavement and Base
TABLE – MINIMUM ROLLER REQUIREMENTS Notched Wedge Longitudinal Joint
Breakdown Roller (one of the following)
Intermediate Roller
Final Roller (one or more of the following)
WR
VD, TB, 3W
Vs or P*
VS, TB, TF
Note: *optional EQUIPMENT DEFINITION VS - Vibratory Roller, Static Mode (All Rolling Conditions): Minimum 125 pounds/inch of roller width. The operating speed shall not exceed 3 mph or 264 feet/minute. If the vibratory roller does not eliminate roller marks, its use shall be discontinued and a tandem roller, adequately ballasted to remove roller marks, shall be used. VD - Vibratory Roller, Dynamic Mode (Breakdown or Intermediate Rolling): Minimum 125 pounds/inch of roller width. To be operated at a speed not to exceed 3 mph or 264 feet/minute to produce not less than 10 impacts per foot. Not to be operated in vibratory mode when mixture temperature falls below 225°F or 200°F when warm mix is used. P - Pneumatic-Tired Roller (Breakdown or Intermediate): With a maximum speed of 3½ mph or 308 feet/minute. Pneumatic tired rollers shall be self-propelled, of the oscillating type, and equipped with smooth tires of equal size, diameter, and ply rating, all maintained at the same inflation pressure. The pneumatic-tired roller shall have a minimum tire pressure of 80-psi ± 5 psi and shall be equipped with heat retention shields. The self- propelled pneumatic-tired roller shall develop a compression within 300 to 500 pounds per inch of width of the tire tread in contact with the HMA surface. A vibratory roller may be used in lieu of the pneumatic-tired roller on mixtures containing PG 76-22 or PG 70-22 asphalt binder. TB - Tandem Roller for Breakdown Rolling: 10 to 12 tons, 300 to 400 pounds/inch of roller width, with a maximum speed of 3½ mph or 308 feet/minute. TF - Tandem Roller for Final Rolling: 10 to 12 tons, 300 to 400 pounds/inch of roller width with minimum roller width of 50 inches and maximum speed of 3½ mph or 308 feet/minute. Ballast shall be increased if roller marks are not eliminated. Ballast shall be decreased if the mat shoves or distorts. 3W - Three Wheel Roller (All Rolling Conditions): The maximum speed of 3 mph or 264 feet/minute and shall develop a compression within 300 to 400 pounds/inch of roller width in contact with the HMA surface. The three-wheel roller shall weigh 10 to 12 tons. WR - Wedge Roller: The wedge roller, used to compact the notched wedge longitudinal joint, shall have a minimum diameter of 12 inches, a minimum weight of 50 pounds/inch of width, and a width equal to the wedge slope. The roller shall be attached to the paver.
9/1/2023
404-38
Superpave Asphaltic Concrete Pavement and Base
404.17.2 After the asphaltic mixture has been spread, struck off, and surface irregularities adjusted, it shall be thoroughly and uniformly compacted by rolling. Rolling shall begin as soon after spreading the mixture as it will bear the weight of the roller without undue displacement. The number of rollers furnished shall be sufficient to obtain the required compaction while the mixture is in a workable condition. Except for projects involving small quantities of mixture, the compacting equipment requirements shall meet specifications set forth in Section 404.17. If equipment breaks down or rolling does not keep up with the spreader, all work will be stopped. The Engineer will have the option of rejecting any pavement not meeting the rolling or density requirements of Section 404.17.7. If pavement is designated to remain in place, penalties will be assessed for the affected material in accordance to Section 404.33. 404.17.2.1 Rollers shall move at a uniform speed with the drive roller or wheels nearest the paver. Rolling shall begin at the sides and proceed longitudinally parallel to the road centerline, each trip overlapping one-half the roller width, gradually progressing to the crown of the road. When paving in echelon or abutting a previously placed lane, the longitudinal joint shall be rolled first using a vibratory roller, followed by the regular rolling procedure. The first pass of the vibratory roller shall stay back from the longitudinal joint 6 - 8 inches on the first pass. Where practical the second pass should then overlap the cold longitudinal lane joints and be "pinched" by rolling 4 - 6 inches from the existing portion of roadway. On superelevated curves the rolling shall begin at the low side and progress to the high side by overlapping of longitudinal trips parallel to the centerline. Alternate trips of the roller shall be terminated in steps to prevent the formation of surface irregularities. The alternate stops shall be spaced in such manner that any excess water will drain quickly. Lateral or diagonal rolling may be permitted to remove high spots, provided the rolling is done in such manner and at such time that shoving or cracking will not result. Rolling shall be continued until all roller marks are eliminated. Lateral or cross-rolling will be required at all butt or construction joints. 404.17.3 Rolling. Any displacement occurring as a result of starting, stopping, or changing direction of a roller, or from other causes, shall be avoided. Areas of displacement shall be corrected at once by the use of rakes and addition of fresh mixture when required. Care shall be exercised in rolling not to displace the line and grade of the edges of the asphaltic concrete. If necessary to prevent adhesion of the mixture to the rollers, the wheels and rollers shall be kept properly moistened with water or water mixed with very small quantities of detergent or other approved material. Excess liquid will not be permitted. 404.17.3.1 Inaccessible Areas. Along forms, curbs, inlet sumps, headers, walls, and other places not accessible to the rollers, the mixture shall be thoroughly compacted with hot hand tampers, smoothing irons, or with a reversible vibratory plate-type compactor with a minimum centrifugal force rating of 6,520 pounds. A trench roller shall be used on depressed areas inaccessible to regular width equipment. A one-ton roller or hand roller will be required to adequately compact tapered pavement edges, against island and median faces, and street intersections as directed by the Engineer. 404.17.4 Defective Mixture. Any mixture that becomes loose and broken, mixed with dirt, or is in any way defective shall be removed and replaced with fresh, hot mixture, which shall be compacted to conform to the surrounding area. Any area showing an excess or deficiency of asphalt cement shall be removed and replaced.
9/1/2023
404-39
Superpave Asphaltic Concrete Pavement and Base
404.17.5 Non-Traffic Areas. Mixtures used for surfacing medians and similar areas, shoulders adjacent to rigid or flexible pavement and shoulders adjacent to resurfaced pavement shall be compacted to the specified densities for the mixture. Once an established rolling pattern has been demonstrated to provide the required density for shoulders, at the Engineer's discretion, the pattern may be used in lieu of density tests provided no changes in the material, typical location, or temperatures are made. Regardless of the method, density will still be required and subject to testing as deemed necessary by the Engineer. In lieu of roller and density requirements, temporary bypasses to be maintained at the expense of the Contractor shall be thoroughly compacted. The rolling shall be performed at proper time intervals and shall be continued until there is no visible evidence of further consolidation. 404.17.6 Minimum Compacting Temperatures. Rollers operating in the vibratory mode shall not be operated when the mixture is below 225°F or when the warm mix technology mixture is below 200°F. Rolling shall be continued until all roller marks are eliminated and before the PG64-22 binder mixture is below 185°F, the warm mix technology modified mixture or the PG70-22 or PG76-22 binder mixture is below 200°F (or as recommended by the manufacturer), except as otherwise specified. 404.17.7 Density. 404.17.7.1 Mat Density. Mat density testing and the associated requirements listed below do not apply for wedge/leveling courses or lift thicknesses less than the minimum thickness. The final density of the in-place mixture shall be between 92 and 96 percent of the field determined maximum specific gravity (AASHTO T 209 "Maximum Specific Gravity of Bituminous Paving Mixtures"). The applicable density will be determined by the Engineer to correspond with the mix design test method. Density will be determined by gauge methods as per St. Louis County Test Method QA-26 "In-Place Density of Bituminous Mixes" using a Density Gauge or by a specific gravity method. 404.17.7.2 Joint Density. The minimum density of all traveled way pavement within 6 to 8 inches of a longitudinal joint, including the pavement on the traveled way side of the shoulder joint, shall not be less than 90 percent of the field determined maximum specific gravity as determined by AASHTO T-209 "Maximum Specific Gravity of Bituminous Paving Mixtures" or the Mat Density minus Joint Density shall be less than or equal to 3.0 pounds per cubic foot, when unconfined. The density of the longitudinal joint when confined shall be determined as in Section 404.17.7.1 and included in the evaluation of the remainder of the mat. 404.17.7.2.1 Joint density testing and the associated requirements listed below do not apply for lift thicknesses less than or equal to 1 inch. Evaluate the longitudinal joint density using methods outlined in St. Louis County QA-26 "In-Place Density of Bituminous Mixes" using a Density Gauge. Although it is the Contractor's responsibility to perform the joint density evaluation, the Engineer may make as many independent joint density verifications as deemed necessary at the random sample locations. The Engineer's results will be used for acceptance for joint density, whenever available.
9/1/2023
404-40
Superpave Asphaltic Concrete Pavement and Base
404.17.8 Suspension of Work. If the results of 2 consecutive joint density profiles fail to comply with Section 404.17.7.2, Joint Density, the plant production and paving operations will be suspended until the Contractor can demonstrate that density can be achieved to meet specifications. Follow the procedures listed in St. Louis County QA-26 "In-Place Density of Bituminous Mixes" using a Density Gauge. Density gauges are to be used to verify when density can meet specifications. Production may be resumed after the Engineer evaluates and approves methods that allow plant production and paving operations that can meet density and volumetric specifications.
9/1/2023
404-41
Superpave Asphaltic Concrete Pavement and Base
PAVING PROCEDURES 404.18 Weather Limitations. Hot or Warm Mix Asphaltic concrete shall not be placed: 1) When either the ambient temperature or the temperature of the surface on which the mixture is to be placed is below 50°F for the wedge or surface courses or below 40°F for base courses; 2) On any wet or frozen surface; 3) When weather conditions prevent the proper handling, compaction, or finishing of the mixture; 4) Between November 1st and March 1st except when authorized by the Engineer. Placement within these dates will be permitted only when it is to the Department's advantage to do so. The Contractor shall conduct operations in such a manner that all base courses are covered with surface course prior to November 1st. With the approval of the Engineer, base course may be exposed through the winter months (November 1 through March 1) with the following requirements: a) The in-place density shall be between 93 and 96 percent; b) The Voids in Mineral Aggregate (VMA) shall not be lower than 13. 404.18.1 November 1st through March 1st Base Course VMA and Density Determination and Penalty Assessment. The Voids in Mineral Aggregate (VMA) will be determined in accordance with Section 404.9.1 and the in-place densities in accordance with Section 404.17.7. Base pavement that fails to meet the VMA of these requirements shall receive a deduction in unit price per ton of 25 percent. In addition, base pavement that fails to meet the density of these requirements shall receive a deduction in unit price per ton in accordance with Section 404.33.1.3. 404.18.2 Placement Temperature Deviations. During critical temperature periods in the fall of the year, the Director may authorize the placement of surface course when the on-site ambient temperature is 45°F and rising with an anticipated high temperature of at least 50°F. No further deviation in weather restrictions or temperature limitations will be granted. 404.18.3 Cold Weather Paving. When on-site ambient temperatures at the time of paving are less than 50°F, surface mixtures will require the use of a warm mix admixture and an approved MTV. 404.19 Subgrade and Aggregate Base Preparation. The subgrade upon which the base course mixture is to be placed shall be compacted and brought to true in accordance with Section 209 and proof-rolled prior to placement of the aggregate base. The aggregate base shall be brought to proper cross section and compacted in accordance with Section 304 prior to placement of the first lift of base course. 404.19.1 Proof-Rolling. The subgrade shall be proof rolled immediately prior to placement of base. The proof rolling shall be performed by the use of a loaded aggregate hauling vehicle, weighing between 25 and 50 tons, with tires inflated to not less than 125 psi, and making two passes over the area. Each pass shall be offset by no more than 1 tire width.
9/1/2023
404-42
Superpave Asphaltic Concrete Pavement and Base
Areas that rut or shove in excess of 1 inch shall be removed and restabilized with a 2-inch maximum size granular-type material (with a plasticity index not exceeding 10 and a gradation such that at least 50 percent of the material will be retained on the No. 4 sieve) to a depth approved by the Engineer that shall not exceed 3 feet. The grade shall then be checked for cross-section and re-approved by the Engineer before base placement. When removal is made in a cut section it shall be measured and paid for in accordance with Section 203.7.3. No additional payment will be made when removal is required in a fill section. 404.19.2 For widening work, the bottom of the trench shall be compacted until it is stable by use of a trench roller having a weight of not less than 250 pounds/inch of width of rear roller, or by mechanical tampers or other methods approved by the Engineer. Suitable excavated material may be used in shouldering operations. All surplus excavated material shall be disposed of by the Contractor in areas to be secured by him beyond the right-of-way limits, and as specified in Section 203.2.16. 404.19.2.1 On the outside of curves, the design depth of trench at the beginning of the superelevation transition shall be varied gradually to the minimum depth at the end of the superelevation transition. Slight transitioning of the width of the base widening will be necessary to permit the indicated angle of repose or shear angle outside of the ultimate edge of surface. The bottom of the trench shall in no case be less than 3 inches below the surface of the existing pavement. 404.20 Application of Prime or Tack. The prime or tack coat, when specified, shall be applied as set forth in Sections 407 or 408, whichever is applicable. A tack coat is required on all existing pavement and shoulder surfaces that will be overlaid with an asphalt mixture. Tack coat is also required between all lifts of pavements placed within the driving and turn lanes, unless otherwise specified in the contract. All construction requirements of a tacked surface shall be in accordance with Section 407 and specified herein. The tack coat shall be applied uniformly and shall completely cover the surface upon which the asphalt mixture is to be placed. Asphalt mixture shall not be placed upon a tacked surface that is not uniformly covered or surfaces that have experienced excessive loss of tack due to tracking. Re-application of tack due to excess tracking or non-uniform coverage shall be at the Contractor's expense. 404.21 Spreading and Finishing. The base course, primed or tacked surface, or preceding course or layer shall be cleaned of all dirt, packed soil, or any other foreign material prior to spreading the asphalt mixture. 404.21.1 Mixing and Compaction Temperature. The mixture shall not exceed the lesser of 350°F or 25°F above the optimum mixing temperature designated by the Engineer (for example: if optimum mixing temperature was 300°F, then 325°F would be the maximum allowable temperature. If the optimum mixing temperature was 330°F, then 350°F would be the maximum allowable temperature). When delivered to the spreading and finishing machine, the minimum spreading and finishing temperature shall be within 25°F of the optimum compaction temperature designated by the Engineer. Exceptions to these spreading and finishing temperatures will be submitted by the material supplier with the mix design for Engineer review and approval. Optimum temperatures will be computed using the average of mixing and compaction temperature range and rounding to the nearest 5°F (for example, if the mixing temperature range is 312°F to 321°F, the average is 316.5°F. The optimum, to the nearest 5°F, is then 315°F).
9/1/2023
404-43
Superpave Asphaltic Concrete Pavement and Base
404.21.2 Paver Operating Speed. The paver shall be operated at a speed consistent with prevailing conditions that will give the best results, but shall not exceed 2½ mph (220 feet per minute). The rate of delivery of the mixture to the paver shall be coordinated so as to provide, where practical, a uniform rate of placement without intermittent operation of the paver. 404.21.3 Lane Configuration. Unless specified otherwise, paver screed or strike off widths will reproduce the same lane configuration present when the reconstruction commenced. The use of specialized equipment to comply with this requirement will not be considered a cause for additional compensation. Any change in lane configuration will fall within the normal operating tolerance of a standard 10-foot screed or strike off paver and will be made prior to the commencement of paving operations. 404.21.4 Segregation Reduction. Do not raise (dump) the wings of the paver receiving hopper at any time during the paving operation. The Engineer may waive this requirement if it is determined that raising (dumping) the wings will not produce detrimental segregation. Approved wing dumping shall only take place when hot mix fully covers the paver's slat conveyor. If segregation or irregularities in the pavement surface or density are noted, the Contractor shall add a MTV, review the plant, hauling, and paving operations and take corrective action. 404.21.5 Lift Thickness Limitations. The thickness of each course shall conform to the typical section in the contract. The Engineer may increase the compacted layer thickness for base course mixtures when used for full-depth base repair or in areas where the above specified layer thickness is not deemed practical. In these areas the approved compaction methods shall be performed at the proper intervals and duration until there is no further evidence of consolidation. These areas will not be subject to compaction penalties. The Contractor may construct each course in any number of layers he chooses, within the following lift thickness limitations: Compacted Thickness (inches) Mix Type Minimum
Maximum
SP 48
0.75
1.5
SP 95
1.25
2
SP 125
1.5
3
SP 190
2.25
4
404.21.5.1 Lane Width Equipment Configuration. Unless specified otherwise, paver screed or strike off widths will reproduce the same lane configuration present when the reconstruction commences. The use of specialized equipment to comply with this requirement will not be considered a cause for additional compensation. Any change in lane configuration will fall within the normal operating tolerance of a standard 10-foot screed or strike off paver and will be made prior to the commencement of paving operations.
9/1/2023
404-44
Superpave Asphaltic Concrete Pavement and Base
404.21.6 Lane Width. For pavements having a width of 20 to 24 feet, inclusive, the asphaltic concrete pavement shall be laid in lanes approximately one half the full width of the completed pavement and the full width completed as soon as practical. Unless otherwise permitted, a single lane of any course shall not be constructed to a length which cannot be completed to full width of the pavement on the succeeding operating day unless otherwise permitted. For pavements greater than 24 feet in width, single lane width construction shall be limited to one day's production and completion to full width shall be accomplished as soon as practical. For width less than 20 feet, a cut off plate or specialized paver will be required. 404.21.7 Segregation and Edge Treatment. No segregation will be permitted in handling the mixture at the plant, from the truck, or during spreading operations on the roadway. Where only the top layer of the surfacing continues across a bridge, the bottom layers shall be ended at a vertical edge. Unless otherwise directed by the Engineer or shown on the plans, all lift edges shall be sloped or tapered and be extended to provide a smooth transition at side streets and driveways. Under all conditions, the final lift shall be tapered to a 3:1 (H:V) slope unless adjacent to concrete curb and gutter. 404.21.7.1 Removal and Replacement. Segregated mixture shall be removed and replaced to the limits as determined by the Engineer. In a situation when there is a dispute in the existence of mixture segregation, the area will be tested in accordance with MoDOT Test Method TM 75. Mixture production will cease if either criteria of MoDOT Test Method TM 75 fails. 404.21.8 Multiple Lifts. The Contractor shall keep the traffic off the asphaltic concrete until it has cooled sufficiently to prevent flushing of the asphalt to the surface, marking or distorting the surface, or breaking down the edges, and in any case until the temperature of the asphaltic concrete is 140°F or below. When the asphaltic concrete construction consists of more than a single layer, each layer shall be compacted as specified and allowed to cool to the ambient temperature before the next layer is placed. The final surface layer shall be laid in a continuous sequence over the entire project unless otherwise approved by the Engineer. 404.21.9 Spot Wedging and Leveling Course. The Engineer will determine the locations and thickness of spot wedging and the thickness of leveling course to obtain the smoothest possible riding surface. This procedure may result in spot wedging operations over small areas with feather edging at high points and ends of wedge areas. Rigid control of the placement thickness of the leveling course will be required. A leveling course, consisting of a layer of asphaltic concrete of variable thickness used to superelevate curves and eliminate irregularities in the existing base, shall be spread uniformly to the desired profile grade and cross section. The use of an approved finishing machine with automatic screed control will be required on the spot wedge and the leveling course. Superpave SP 48 (PG70-22)E mixture shall be used for spot wedging on CRS or CRS-Collector roads ¾ inch or less in depth. Superpave SP 95 (PG70-22)C mixture shall be used for spot wedging 1 inch or less in depth. Superpave SP 125 (PG70-22)C mixture shall be used for spot wedging areas greater than 1 inch but less than 3 inches in depth. Superpave SP 190 (PG70-22)C mixture shall be used for spot wedging 3 inches or greater in depth. The type of mixture to be used for the leveling course will be designated in the contract or as specified by the Engineer. Surface grades will be established in advance of the Contractor's wedge and level operations to prevent unnecessary interruptions in the work.
9/1/2023
404-45
Superpave Asphaltic Concrete Pavement and Base
404.21.9.1 Intersection Treatment. At intersections between arterial and/or collector streets, the lane width of the pavement shall be completed for a minimum length of 100 feet on either side of the intersection centerline and feathered at the edges in a single operating day so that a uniform, smooth riding surface is maintained across the intersection. When the asphaltic concrete construction consists of more than one layer and a vertical face remains at a cross street at the end of a workday, temporary asphaltic material shall be added along the edges to provide a smooth riding surface. 404.22 Placement of Temporary Pavement. Where conditions are such that the use of a finishing machine is not deemed practical by the Engineer for constructing the wedge and leveling course, the base course on the subgrade or aggregate base, narrow pavement widths or small irregularly shaped areas, the Engineer may allow the use of bladed motor equipment or box spreaders for this construction. The base courses for temporary pavements shall be placed with either a non-highway or highway class-finishing machine. The finish course for temporary pavements shall be placed with a highway-class finishing machine. 404.22.1 Compaction. In lieu of roller and density requirements, mixtures used for surfacing medians and similar areas, shoulders adjacent to rigid pavement, shoulders adjacent to resurfaced rigid pavement, and temporary by-passes to be maintained at the expense of the Contractor shall be thoroughly compacted by at least three complete coverages over the entire area, with a tandem-type steel wheel roller weighing not less than 10 tons (300 pounds per inch of roller width). The rolling shall be performed at the proper time intervals and shall be continued until there is no visible evidence of further consolidation. 404.23 Joints. Longitudinal and transverse joints shall be carefully made and well bonded. Do not broadcast excess material across the mat. Avoid luting or raking the overlapped material. If the overlap exceeds 1.5 inches, carefully remove the excess with a flat-end shovel. Irregularities in the outside edge alignment shall be corrected by removing or adding mixture before compaction to produce a straight, uniform joint. Tack material shall be applied to the exposed edge before the joint is made. Place enough material on the hot side of the joint so that, after rolling, the surface is slightly higher (0.1 inch) than the cold side. 404.23.1 Transverse Joints. Transverse joints shall be formed in accordance with standard drawings that will produce a dense, vertical section for use when laying is resumed. The joint formed when the fresh mixture is placed shall be dense, well-sealed, and the grade, line, and surface texture of the succeeding surface shall conform to that of the joined surface. The vertical face of transverse joint shall be painted with a light coating of tack material. Hand manipulation of the mixture shall be minimized to avoid unsightly texture. 404.23.2 Longitudinal Joints. Longitudinal joints shall be formed by the use of an edging plate fixed on both sides of the finishing machine. These plates shall be adjustable, and the outside plate shall be set at an angle of approximately 45 degrees with the surface of the roadbed and in a position that will lightly compact the mixture. The inside plate, or that placing material for the longitudinal joint, shall be normal to the roadbed. When placing the first lane, if the mixture at the longitudinal joint tends to slump, it shall be set up to a vertical edge by light compaction with the back of the rake. Care shall be taken to obtain a well- bonded and sealed longitudinal joint by placing the hot mixture in a manner insuring maximum compaction at this joint. A light coating of tack shall be applied to the exposed edge before the joint is made. Irregularities in the outside edge alignment shall be corrected
9/1/2023
404-46
Superpave Asphaltic Concrete Pavement and Base
by removing or adding mixture before the surface is compacted. Irregularities in the outside edge alignment shall be corrected by removing or adding mixture before the surface is compacted. No additional payment beyond the unit prices bid for tack materials will be made for compliance with this requirement. 404.23.2.1 Joint Offset. The longitudinal joint in any layer shall offset that in the layer immediately below by approximately 6 inches; however, the joints in the completed surfacing shall be at the lane lines of the travel way, when field conditions permit. 404.23.2.2 Special Traffic Control. At locations where construction operations result in a differential in elevation exceeding 3 inches between the edge of pavement or edge of shoulder within 3 feet of the edge of pavement or aggregate shoulder require special traffic control. MUTCD Type I or II barricades or vertical panels, in accordance with Section 1063.3, shall be placed at 100-foot centers on roadways where the posted speed limit is 45 mph or greater and at 50-foot centers on roadways where the posted speed limit is less than 45 mph. 404.23.2.3 Side Streets. Hot joints are required at the juncture of mainline pavement overlay and the overlay for side streets, except where mainline Superpave (SP) Asphaltic Concrete Mixtures with PG76-22 or PG70-22 binders are being placed. The Contractor shall arrange his operations so that the overlay of adjacent side streets are completed as the mainline overlay proceeds in order to obtain the conditions necessary to meet this requirement. 404.23.3 Required Butt Joint. Butt joints shall be constructed in accordance with Section 412. When closing a butt joint or notched wedge joint, overlap by 1-inch ± ½ inch. If joint is milled or cut back, the overlap should be approximately ½ inch. 404.23.4 Shoulder Density. Density on non-integral shoulders shall be in accordance with Section 404.17.5. 404.23.5 Integral Shoulder. When shoulders are placed integrally with the traveled way, tests shall be taken on the traveled way. 404.23.6 No additional payment beyond the contract unit prices for asphaltic materials will be made for compliance with these requirements. 404.24 Surface Tolerance. The surface of each layer shall be substantially free from waves or irregularities and shall be measured in accordance with St. Louis County Test Method QA-28 "Determining Pavement Smoothness by Two-Wheeled Device 10 feet in Length". On arterial roadways and collector streets, the final surface (except on medians and similar areas, shoulders adjacent to rigid pavement, and temporary bypasses) shall not vary from a 10-foot straightedge, applied parallel to the centerline, by more than ⅜ inch and will be plainly marked for removal. At transverse construction joints, surface tolerances shall not vary from the 10-foot straightedge by more than ¼ inch and will be plainly marked for removal. The Engineer shall mark these deficiencies.
9/1/2023
404-47
Superpave Asphaltic Concrete Pavement and Base
404.24.1 Correction of Irregularities. Surface irregularities in the final lift shall be addressed immediately and corrected in the final rolling process before the temperature of the asphalt drops below that which is required to roll the pavement in a workable state. Should the Contractor fail to pave within the required tolerances, the operation will be halted. If surface irregularities still exist, the affected pavement shall be removed and replaced by milling to the minimum depth of the mix type specified or treated by other methods as directed by the Engineer. Isolated surface course bump or dip corrections shall be made by grinding only. 404.24.1.1 Equipment. Grinding shall be performed using diamond blades mounted on a self-propelled machine designed for grinding and texturing pavement. The equipment shall weigh a minimum 35,000 pounds, including the grinding head with diamond blades mounted in series, and be of a size that will grind a strip at least 3 feet wide in a single pass. The effective wheelbase of the machine shall be no less than 12 feet. 1)
The equipment shall have a positive means of vacuuming the grinding residue from the pavement surface, leaving the surface in a clean, near-dry condition.
2)
Grinding equipment that causes raveling, aggregate fractures, or disturbance to the transverse or longitudinal joints shall not be permitted.
3)
Diamond blades shall be of the proper type based on the coarse aggregate to be ground.
4)
The equipment shall be maintained to ensure it is in proper working order, with attention paid to the "roundness" of the match and depth control wheels. Any wheel found to be out of round shall be replaced immediately.
5)
Optional Carbide Bump Grinding. Use grinders of the walk-behind type that have cutting heads of carbide tipped shackles, stars, or blades and have a locking depth control to produce a uniform pavement surface texture. a) Provide a pavement surface texture consisting of parallel grooves between 3⁄32 inch and ¼ inch wide width a "land area" between grooves 1 ⁄16 inch and 3⁄16 inch. Operate the grinder by making multiple passes, if necessary, with a maximum depth of any single pass of ⅛ inch. Grind longitudinally or transversely across the pavement surface.
404.24.1.2 For asphalt pavements, the surface correction shall be accomplished by diamond grinding, by overlaying the area, by replacing the area, or by inlaying the area. Grinding bumps shall only be permitted for 1½ inch or greater single lift overlays. Grinding depth shall be limited to ¼ inch. The final surface texture of corrected pavement shall be comparable to the adjacent sections that do not require correcting. 404.24.1.3 If the surface is corrected by diamond or carbide grinding, the work and equipment shall be the same as specified for concrete pavement except that the ground surface shall be covered with an asphalt-based sealer approved in advance by the Engineer.
9/1/2023
404-48
Superpave Asphaltic Concrete Pavement and Base
404.24.1.4 If the surface is corrected by overlay, replacement or inlay, the surface correction shall begin and end with a transverse saw cut normal to the pavement lane lines or edge lines within any one area. Profile of surface must be smooth with no bumps or dips at beginning or end of correction. Overlay correction must be for the entire pavement width. Pavement cross slope must be maintained through the corrected areas. The remaining requirements of this specification shall be followed. 404.24.2 Subdivision Streets. On subdivision streets (up to 26 feet in width), testing in accordance to Section 404.24 will be performed, except that surface variations exceeding ½ inch in 10 feet will be plainly marked for removal. 404.24.3 Surface Tolerance Exclusions. The following areas are excluded from surface tolerance measurement: 1) Pavement surfaces that have been purposely warped to meet fixtures (manholes, drainage inlets, catch basins); 2) Existing curb and gutter and cross- and side-road connections; 3) Any section less than 50 feet in length; 4) Side streets less than 500 feet in length; 5) Sections 50 feet or less from bridge approach slabs or an existing pavement; 6) Superelevated transitions; and 7) Driveway aprons. 404.24.4 Bump Grinding. A bump is defined as a deviation in the profile greater than that specified in Section 404.24. If corrective work is required, the Contractor shall submit a written corrective work proposal to the Engineer, which shall include the description of the equipment, methods and procedures that will be used. The Contractor will not commence corrective work until the equipment, methods and procedures have been approved in writing by the Engineer. Corrective bump grinding shall take place under the same weather restrictions specified in Section 404 for hot mix asphalt pavement placement, after Engineer- approved pavement restoration, and before joint sealing. Use grinders of the walk-behind type in accordance with Section 404.24 for correcting areas 15 feet in length or less. Grind longitudinally or transversely across the pavement surface. If the Engineer directs removal, remove an area at least 6 feet long, extending across the full lane width. Also remove adjacent pavement less than 6 feet from a transverse joint. Areas of pavement that exceed these allowable tolerances shall be removed by an approved grinding device in accordance with Section 404.24. The use of a bush hammer or other impact device will not be permitted. Such grinding shall be tapered in all directions to provide smooth transitions to areas not requiring grinding. The final pavement wearing surface shall not be ground by more than ¼ inch without approval of the Engineer.
9/1/2023
404-49
Superpave Asphaltic Concrete Pavement and Base
404.25 Testing Pavement. The finished courses shall have the nominal thickness shown on the plans. Tests will be made to ensure that each course is being constructed of proper thickness, composition, and density. The Contractor shall cut samples from any layer of the compacted mixture at locations designated by the Engineer in accordance with St. Louis County Test Method QA-29 "Obtaining Drilled Cores of Asphalt". The samples shall be cut and delivered to the Engineer, as directed, so that samples can be processed by the Materials Laboratory during normal lab working hours. Ice may be used to cool the pavement immediately prior to sawing or coring the samples. Samples may be obtained by either sawing with a power saw or by drilling 4 inch or 6-inch nominal diameter cores. Each sawed sample shall consist of a single piece of the pavement of the size designated by the Engineer, but no larger than 12 inches square. The samples (for mat density: 4-4” or 1-6” core or one sawed. For unconfined joint density, 2-4” or 16” core/unconfined joint) shall be delivered by the Engineer to the St. Louis County Department of Transportation, Materials Testing Lab, 11283 Schaefer Drive, Maryland Heights, Missouri 63043, and identified with the following information: 1) Project Name and Number; 2) Mix Type, mix design number, and Street Name; 3) Time and date sampled; 4) Street Address or Station and Offset; 5) Project Resident / Inspector Name. Test results shall be available within one work day of delivery to the Materials Lab, exclusive of weekends and Holidays recognized by St. Louis County. 404.25.1 Density Sample. If a density gauge is not used and only cores are used for mat and joint density determination, a set of cores (4-4” or 1-6” mat and 2-4” or 1-6” per unconfined joint, if applicable) are required every 2000 lane feet or fraction thereof and will be sampled in accordance with St. Louis County Test Method QA-29 "Obtaining Drilled Cores of Asphalt". At least one set of core samples will be taken for each day's production. All samples, whether sawed or cored, shall consist of an undisturbed portion of the compacted mixture. This should be done for each different mix that might be used. The cores shall consist of the full depth of the lift or layer to be tested. 404.25.1.1 Density Correlation. If r gauge readings are used for mat and joint densities, a set of cores will be required for correlation each day for each mixture used. Cores used to establish a gauge correction factor shall be taken in a number designated by the Engineer and each set of cores or fraction thereof shall be considered a sample. The Contractor shall coordinate this work in a manner that traffic shall be prohibited from traveling on the pavement until after the test pattern has been performed and that area is cored and the pavement is repaired. Initial gauge test results, without a correlation with cores, does not imply acceptance by St. Louis County. The gauge is required to be correlated with core densities that are taken from the same location as was the gauge pattern readings were performed. This shall be done for each different mix design that is used.
9/1/2023
404-50
Superpave Asphaltic Concrete Pavement and Base
404.25.1.2 Density Testing Frequency. When a density gauge is used, no less than one set of readings (mat and unconfined joint, when applicable) every 1,000-lane feet or fraction thereof per day of paving shall be taken. Gauge readings will be adjusted daily based on correlated core density results. The correction factor is calculated by comparing the density results to the results obtained by using Test Method AASHTO T 166, "Bulk Specific Gravity of Hot Mix Asphalt (HMA) Using Saturated Surface-Dry Specimens" or AASHTO T 331, "Bulk Specific Gravity and Density of Hot Mix Asphalt Using Automatic Vacuum Sealing Method". The percent difference between the gauge density reading and bulk density of the cores will be used as the correction factor. A rolling average should be used when available. The Engineer may re-start the rolling average when there is a change in lift thickness, a change in design binder content, a change in aggregate blend, or a change in underlying material type. Failing density readings will require cores in accordance with Section 404.25.1 and if found deficient, penalties shall be applied in accordance with Sections 404.32 and 404.33. 404.25.1.3 Restoration of Sample Holes. The cored or sawed hole(s) from which samples have been taken shall be restored by the Contractor with the mixture then being produced at the time the holes are made. If paving has been completed, the Contractor shall immediately restore the holes from which samples have been taken with an approved commercial mixture acceptable to the Engineer. 404.25.1.4 Payment for Coring or Sawing. No direct payment will be made for coring or sawing of compacted mixture from the pavement and replacing the holes with approved material. All labor, equipment, and material required for coring or sawing samples shall be incidental to paving operations. 404.25.1.5 Suspension of Work and Penalty for Density Sample Non-Delivery. If the sample is not cut and delivered as stated, the asphalt laydown operation shall be suspended until the samples are cut, the core holes restored, and the cores are delivered to the Engineer. 404.26 General Requirements. 404.26.1 Sequence of Operations. To reduce inconvenience to the traveling public during widening or surfacing, the Contractor will not be permitted to place any final surface course until the base widening, and the wedge and leveling course, have been completed throughout the entire combination of sections, unless otherwise authorized by the Engineer. The proper condition of the base widening, the leveling course, and the base course, at the time of placing the surface course, shall be the Contractor's responsibility.
9/1/2023
404-51
Superpave Asphaltic Concrete Pavement and Base
404.27 Surfaced Approaches. At locations designated in the contract or as directed by the Engineer, approaches are to be tacked in accordance with Section 407 and surfaced with bituminous pavement in accordance with Section 405. The bituminous pavement surface shall be placed in accordance with details shown on the typical section or as directed by the Engineer. No direct payment will be made for any work required to condition and prepare the subgrade or aggregate base, when specified, on the approaches. 404.28 Filling Drain Basins. If shown on the plans or designated by the Engineer, existing drain basins shall be filled to the top of the lip with base course mixture, compacted in lifts, from the pavement edge to the edge of the shoulder. Any difficulty or delay created by this requirement will be at the Contractor's expense. 404.29 Pavement Repairs (Blow-ups). A blow-up will be considered that area where excessive expansion has resulted in distress to the existing pavement. Blow-ups occurring prior to the application of the tack coat on the existing surface will generally be repaired by the St. Louis County. Blow-ups occurring after the application of the tack coat shall be repaired by the Contractor by removing the distressed concrete, aggregate base, and subgrade, and replacing with designated asphaltic concrete mixture in lifts thoroughly compacted to the full depth of the repair. 404.29.1 Interlayer Paving Mat. Paving mat geotextile installation and materials shall be performed in accordance with Section 403 to be used as reinforcement for patching, and for waterproofing when specified in the contract. A "full width" fabric overlay shall be installed in continuous strips of 12 feet or greater in width using the manufacturer's construction procedures. 404.30 Method of Measurement. The weight of the mixture will be determined from the batch weights when a batch-type plant is used; and will be determined by weighing each truck load in accordance with the requirements of Section 310.4.2 when other types of plants are used. Measurement will be made to the nearest 0.1 ton for the total tonnage of material accepted. Safety edge shoulder preparation will not be measured for payment. Measurement for shoulder backing material shall be made in accordance with Type 5 Aggregate Base, to the nearest 0.1 ton, in accordance with Section 304. 404.31 Basis of Payment. 404.31.1 Due to possible variations in the specific gravity of the aggregates, the tonnage used may vary from the proposal quantities and no adjustment in contract unit price will be made because of such variation. 404.31.2 Payment for Pavement Repairs (Blow-ups). Payment for removing and disposing of the broken concrete and for preparing subgrade and aggregate base will be made as provided in contract bid items or in Section 104.3. Payment for furnishing, placing, and compacting the asphaltic concrete replacement material will be at the contract unit bid price for the mixture used.
9/1/2023
404-52
Superpave Asphaltic Concrete Pavement and Base
404.31.3 Spot Wedging. The accepted quantities of asphaltic concrete will be paid for at the unit bid price, to the nearest 0.1 ton, for each of the pay items included in the contract. When SP 190, SP 125, SP 95, or SP 48 material is required to be used for spot wedging and approved by the Engineer, payment for the material will be at 125% of the unit price of the approved SP mix used for spot wedging.: 404.31.4 Interlayer Paving Geotextile. Payment for interlayer paving mat geotextile material will be made for the surface area covered with geotextile, to the nearest square yard. No additional payment will be made for geotextile laps, splices, repair, etc. 404.31.5 Safety Edge and Notched Wedge. No separate payment will be made for shoulder preparation or the construction of the Safety Edge or Notched Wedge. All work associated in the Safety Edge or Notched Wedge construction shall be integral to the pavement work and shall be included in the contract pricing for those pay items. The accepted quantities for shoulder backing material will be paid for at the unit price for each of the pay items included in the contract. No direct payment will be made for fine grading, shaping, compaction, or the addition of water used in performing shoulder backing material. 404.32 Compensation for Deficiencies. The drilling of cores for thickness or density in irregular placement areas or thicknesses, or on projects involving less than 1,000 tons of each warm or hot asphaltic mixture specified, may be waived by the Engineer. Percent reduction for deficiencies, when combined for thickness and density shall not exceed 100 percent. No penalty will be accessed for joint density deficiencies when pavement mat deficiencies are 100 percent or the represented material requires removal and replacement. 404.32.1 Compensation for Thickness Deficiencies. In new construction, cores shall be cut to determine pavement thickness in accordance with St. Louis County Test Methods QA29, "Obtaining Drilled Cores of Asphalt", and QA-29A, "Measuring the Length of Drilled Asphalt Cores". If any core measurement is less than the thickness indicated in the plans, penalties shall be assessed in accordance with the following schedule:
9/1/2023
Deficiency in Thickness, inch
Deduction, in Unit Price Per Ton
0.0 to 0.2
None
Over 0.2 to 0.4
20 percent Reduction
Over 0.4 to 0.6
60 percent Reduction
Over 0.6
100 percent Reduction
404-53
Superpave Asphaltic Concrete Pavement and Base
404.32.2 Pavement Thickness. Cores will be taken for each completed course. Lift thickness may be determined by the average thickness of cores taken for density measurements. For the purpose of determining the constructed thickness of full depth pavement, cores shall be taken at random intervals in each traffic lane at the rate of 1 core per 1,000 feet or increment thereof, or at any other locations as may be determined by the Engineer and measured in accordance with St. Louis County Test Method QA-29A, "Measuring the Length of Drilled Asphalt Cores". In addition, cores will be taken at all locations where thickness measurements taken during the course of construction indicate a thickness deficiency sufficient to justify a deduction from the contract unit bid price, or at any other locations as may be determined by the Engineer. When the measurement of any core is deficient in excess of 0.2 inch from the plan thickness, additional cores will be taken at intervals designated by the Engineer that are no less than 100 feet nor more than 500 feet parallel to centerline ahead and back of the affected location until the extent of the deficiency has been determined. The in-place unit weight of the core sample as computed by AASHTO T 166, "Bulk Specific Gravity of Compacted Asphalt Mixtures Using Saturated Surface-Dry Specimens", will be used to compute the tonnage of each mixture specified in the affected area subject to deduction. 404.32.3 Compensation for Air Void Deficiencies. The percent air voids (VA), computed in accordance with Section 404.9.2, and subject to the limits specified in Section 404.10.4, the mix shall be subject to deductions. If the air voids exceed the control limits indicated, penalties shall be assessed in accordance with the following schedule: Deficiency in Air Voids (percent)
Deduction, in Unit Price Per Ton
5.0 ≥ VA ≥ 3.0
None
3.0 > VA ≥ 2.7
5 percent Reduction
VA ≤ 2.6
15 percent Reduction
If any test is below 2.6 percent will be cause for immediate shut down. No mix will continue to be placed with air voids below 3.0 percent or above 5.0 percent.
Penalties will be based on the resampled material. 404.33 Pavement Density Penalty. Pavement shall be tested in accordance to Sections 404.17.7 and/or 404.25.1. Mat and unconfined joint density values for each lift of asphaltic concrete will be determined. Pavement, which is not compacted to the desired density requirement specified, shall be removed and replaced. If in the judgment of the Engineer the inadequately compacted pavement would not seriously impair traffic service, penalties may be assessed for inadequate mat density results in lieu of the removal and replacement of pavement. Penalties will be assessed using cores taken in Section 404.32.2. 1) Mat Density. When the measurement of any mat density is less than 92 percent or greater than 96 percent compaction, the pavement shall be cored and additional sets of 4 cores will be taken at intervals designated by the Engineer that are no less than 100 feet nor more than 500 feet intervals parallel to centerline ahead and back of the affected location until the extent of the deficiency has been determined. The in-place unit weight of the core sample will be used to compute the tonnage of each mixture specified in the affected area subject to deduction.
9/1/2023
404-54
Superpave Asphaltic Concrete Pavement and Base
2) Unconfined Joint Density. When the measurement of any unconfined joint density is less than 90 percent or the mat density minus the joint density is greater than 3.0 pounds per cubic foot, the pavement joint shall be cored and additional sets of 2 cores will be taken at no more than 500 feet intervals parallel to centerline ahead and back of the affected location until the extent of the deficiency has been determined. The unconfined joint density penalty for inadequate compaction shall be $200 per deficiency. 404.33.1 Rounding for compaction penalties shall be in accordance with ASTM E 29, Section 6 Rounding Method. At the Director's option, penalties for inadequate mat compaction will be assessed as follows: Compaction Results (Percent of Field Determined Maximum Specific Gravity, Gmm)
Deduction in Unit Price per Ton
> 97 Percent........................................... 100 percent Reduction or Remove and Replace 97 Percent ....................................................................................... 25 percent Reduction 92 to 96 Percent .......................................................................................... No Deduction 91 Percent ........................................................................................ 5 percent Reduction 90 Percent ....................................................................................... 25 percent Reduction < 90 Percent........................................... 100 percent Reduction or Remove and Replace 404.33.1.1 These penalties do not apply for wedge/leveling courses or lift thicknesses less than the minimum thickness. 404.33.1.2 Penalty for thickness and density may overlap. If so, the percent deductions will be summed up by the Engineer and the deductions will be applied to the deficient area(s). 404.33.1.3 November 1st through March 1st Base Course Compaction Penalty Assessment. With the approval of the Engineer, base course that is not covered with surface course through the winter months (November 1 through March 1) will be penalized for inadequate mat compaction as follows: Compaction Results (Percent of Field Determined Maximum Specific Gravity, Gmm)
Deduction in Unit Price per Ton
> 97 Percent........................................... 100 percent Reduction or Remove and Replace 97 Percent ....................................................................................... 25 percent Reduction 93 to 96 Percent .......................................................................................... No Deduction 92 Percent ...................................................................................... 25 percent Reduction 91 Percent ....................................................................................... 50 percent Reduction < 90 Percent........................................... 100 percent Reduction or Remove and Replace
9/1/2023
404-55
Superpave Asphaltic Concrete Pavement and Base
(This Page Intentionally Left Blank)
9/1/2023
404-56
Superpave Asphaltic Concrete Pavement and Base
Section 405
Bituminous Pavements and Base
405.1 Description. This work shall consist of a mixture of aggregate, mineral filler and / or hydrated lime if needed, warm mix additive, anti-strip additive, and asphalt cement, prepared in a stationary bituminous mixing plant as specified in Section 404 that meets the gradation and volumetric requirements of the job-mix formula. 405.1.1 Bituminous mixtures are to be hauled, placed, compacted, measured, paid for, and otherwise constructed in accordance to the requirements specified in Section 404, unless specified herein. Nighttime lighting requirements shall be in accordance with Section 612.80. 405.1.2 Production Notification. Manufacturing plant inspection is typically required for quantities at or above 250 tons. The plant shall certify loads when the quantity produced is less than 250 tons and / or inspection is not performed. Whenever production is made for the Department, the Contractor shall notify the Engineer by 2:30 pm at least one business day before the day of production with the mix number, amount, and loading time. 405.1.2.1 Pre-Paving Meeting. The requirement for a pre-paving meeting is in accordance with Section 404.1.5.1. 405.1.3 Warm Mix Design. Bituminous warm mix asphalt use is allowed as long as the mix is conformance with these specifications. Warm mix technologies can be added to the binder, added to the mix during production, be wet aggregate mixtures, or a plant foaming process. These technologies can be used as coating and compaction aids while lowering the mixture production temperature 50°F or lower. 405.1.4 Reclaimed Asphalt Pavement (RAP) or Shingles (RAS). Bituminous manufactured with reclaimed asphalt pavement (RAP) and reclaimed asphalt shingles (RAS) is allowed as long as the mix is conformance with these specifications. 405.2 Materials. All materials, proportioning, volumetrics, and transporting for bituminous pavement and base shall be in accordance with Section 404 or as modified herein. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Asphaltic Concrete Incorporating Reclaimed (RAP or RAS) Asphaltic Pavement
413
Asphalt Cement (PG Grade)
1015.4
Coarse Aggregate (Limestone)
1004.1
Fine Aggregate
1004.2
Screenings
1004.3
Mineral Filler
1004.4
Hydrated Lime
1004.7
Anti-Strip Additive
1071
7/1/2016
405-1
Bituminous Pavements and Base
The grade of asphalt cement will be PG 64-22, unless required by mix design or specified otherwise in the contract. 405.3 Composition of Mixtures. 405.3.1 Prior to mixing with asphalt cement, the total aggregate, including filler if needed, shall meet the following gradation for the type of mixture specified in the contract. TYPE C BITUMINOUS PAVEMENT Sieve Size
Percent Passing Min. - Max.
¾ inch.............................................................................................................. 100 ½ inch......................................................................................................... 92-100 ⅜ inch........................................................................................................... 75-95 No. 4 ............................................................................................................ 45-70 No. 8 ........................................................................................................... 30-55 No. 30........................................................................................................... 12-30 No. 200........................................................................................................... 2-10
TYPE D BITUMINOUS PAVEMENT Sieve Size
Percent Passing Min. - Max.
½ inch.............................................................................................................. 100 No. 4 ............................................................................................................ 60-90 No. 8 ............................................................................................................ 35-65 No. 30........................................................................................................... 10-30 No. 200........................................................................................................... 2-10
TYPE X BITUMINOUS PAVEMENT Sieve Size
Percent Passing Min. - Max.
1 inch .............................................................................................................. 100 ½ inch........................................................................................................... 60-90 No. 4 ............................................................................................................ 35-65 No. 8 ............................................................................................................ 25-50 No. 30........................................................................................................... 10-35 No. 200........................................................................................................... 2-12
7/1/2016
405-2
Bituminous Pavements and Base
405.3.2 With written approval of the Engineer, combinations of coarse aggregate, limestone screenings, fine aggregate, and mineral filler, or hydrated lime as specified in Section 405.2 may be used. Not more than 20 percent natural fine aggregate, as specified in Section 405.2 shall be added as a separate ingredient. Each size and type of aggregate shall be added as a separate ingredient. Each size and type of aggregate shall be kept separate and fed through separate calibrated cold aggregate feeders to insure accurate proportioning. No mixture will be approved which contains less than 30 percent of any one type of coarse aggregate in the combination. In addition all plus No. 8 sieve fractions shall contain material from each type of coarse aggregate in the approved combination. 405.3.2.1 If gravel, or if flint chat as produced in the Joplin area, is used, not less than 15 percent nor more than 30 percent crushed stone screenings, or dolomite chat screenings as produced in the Southeast Missouri Lead Belt Area, or not less than 4 percent mineral filler by weight shall be added as a separate ingredient. Screenings shall consist of tough durable particles of approved quality, shall be free from dirt or other objectionable material, and shall have 95 percent passing the ⅜ inch sieve. 405.3.2.2 Reclaimed Asphaltic Pavement (RAP) and Reclaimed Asphalt Shingles (RAS) will be used in accordance with Sec 413. 405.3.2.3 The composition of the mixture shall conform to the following limits by weight: Material
Percent
Total Mineral Aggregate................................................................... 92-96 percent Asphalt Cement (Type C, D, Mixtures)................................................. 4-8 percent Asphalt Cement (Type X Mixture) ..................................................... 3.5-7 percent 405.3.3 Mix Design Parameters. At least 45 days prior to preparing any of the mixture on the project, the Contractor shall obtain, in the presence of the Engineer, representative samples of asphalt cement and mineral aggregates for tests. Aggregate fractions shall be provided in the same proportions as the proposed job mix formula. A minimum of 150 pounds will be required for any individual fraction. The amount of each ingredient submitted shall be as follows for each mix design to be verified: Ingredient
Minimum Amount
Aggregate
60 pounds
Hydrated Lime, Mineral Filler, and / or Baghouse Fines
20 pounds
Asphalt Binder
2 gallons
Reclaimed Asphalt Pavement (RAP and / or Reclaimed Asphalt Shingles (RAS)
50 pounds
Additives
7/1/2016
To be determined by supplier
405-3
Bituminous Pavements and Base
405.4 Job Mix Formula. The Contractor shall also submit for the Engineer's approval, a jobmix formula for each mixture to be supplied for the project. No mixture will be accepted for use until the job-mix formula for the project is approved by the Engineer. The job-mix formula shall be within the master range specified for the particular type of bituminous mixture and contain the relative quantity of each ingredient, and shall state a definite percentage for each sieve fraction of aggregate and for asphalt cement. The mixture shall be designed in accordance with Asphalt Institute Publication MS-2, "Mix Design Methods for Asphalt Concrete and Other HotMix Types". The mixture shall be compacted and tested at a minimum of three asphalt contents separated by a maximum of 0.5 percent in accordance with AASHTO T 245 except as herein noted. The test method shall be modified by short term aging the specimens in accordance with AASHTO R 30. A detailed description of the mix design process shall be included with the job mix formula. 405.4.1 Proficiency Sample Program. Laboratories that participate in and achieve a score of three or greater in the AASHTO proficiency sample program for T 11, T 27, T 84, T 85, T 166, T 209, T 308 and T 245 will have the mixture verification process waived. The mix design shall be submitted to Materials Testing Laboratory for approval at least 10 working days prior to mixture production. 405.4.2 Required Information. When a mix design is designated for a specific project, the Project Name, County Project Number, and Federal Job Number on which the mixture will be used shall be specified. All mix designs shall contain the following information: 1)
Source, grade, and specific gravity of asphalt binder.
2)
Warm mix additive source, trade name, target rate for water and / or additives, acceptable variation for production, and technology description (organic or chemical), material safety data sheets, and equipment used. a) Asphalt binder performance grade test data over the range of warm mix additive percentages proposed for use. b) Documentation of past warm mix additive technology field applications including project type, project owner, tonnage, location, mix design, mixture volumetrics, field density, and performance.
3)
Source, trade name, and target rate of anti-strip used.
4)
Source, type (formation, etc.), ledge number, if applicable, and gradation of the mineral aggregates. The gradation of the component materials shall be representative of the material at the time of use.
5)
Bulk and apparent specific gravities and absorption of each aggregate fraction in accordance with AASHTO T 85 for coarse aggregates and AASHTO T 84 for fine aggregates.
6)
Specific gravity of hydrated lime or mineral filler, if used, in accordance with AASHTO T 100.
7)
Percentage of each aggregate component.
7/1/2016
405-4
Bituminous Pavements and Base
8)
Combined gradation of the job mixture.
9)
Percent asphalt binder, by mass, based on the total mix intended to be incorporated in the completed mixture, shown to the nearest 0.1 percent.
10)
Bulk specific gravity (Gmb), by AASHTO T 166 Method A, of a laboratory compacted mixture.
11)
Percent air voids (Va) of the laboratory compacted specimen.
12)
Voids in the mineral aggregate (VMA) and voids in the mineral aggregate filled with asphalt binder (VFA).
13)
Theoretical maximum specific gravity (Gmm) as determined by AASHTO T 209 after the sample has been short term aged in accordance with AASHTO R 30.
14)
The tensile strength ratio as determined by AASHTO T 283 including all raw data.
15)
Mixing temperature and molding temperature range in accordance with Section 405.5.3.1.
16)
Compaction temperature range in accordance with Section 405.5.3.2.
17)
Dust proportion ratio (No. 200 / asphalt binder).
18)
Bulk specific gravity (Gsb) of the combined aggregate.
19)
Percent chert contained in each aggregate fraction.
20)
Baghouse fines added for design. a) Batch and continuous mix plants - Indicate which aggregate fraction to add baghouse percentage during production. b) Drum mix plants - Provide cold feed settings with and without baghouse percentage.
405.4.3 Volumetrics. The Engineer may make adjustments in the job-mix formula submitted by the Contractor in order that 65 to 78 percent of the VMA are filled with asphalt and the ratio of the minus No. 200 material to asphalt cement is between 0.6 and 1.2 for Type C mixtures and 0.6 to 1.5 for Type X and D mixtures. The percentage of VMA, and VMA filled with asphalt will be specified in Asphalt Institute Publication MS-2, "Mix Design Methods for Asphalt Concrete and Other Hot-Mix Types". Approved mixtures, when compacted and tested in the laboratory in accordance with AASHTO T 245 (50 Blow Marshall), shall yield stability values of 1,500 pounds for Type C and X mixtures and 1,000 pounds for Type D mixtures. The flow values for all asphaltic mixes shall be not less than 8 or more than 16 when measured in 0.01 inch gradations. The mixture of aggregates, mineral filler if needed, and asphalt binder shall demonstrate satisfactory cohesion.
7/1/2016
405-5
Bituminous Pavements and Base
405.4.3.1 Gyratory Option. For use as a mix for low-volume parking lots of less than 500 stalls, bike paths, sidewalks, residential paved approaches, on airports with aircraft of a 7,500 pound maximum gross weight, or for traffic level less than 300,000 ESAL's (non-collector CRS roads), a 40 gyration mix design may be used as an alternative to the 50 blow Marshall design method. For use as a mix for parking lots with more than 500 stalls, bike paths, sidewalks, commercial paved approaches, on airports with aircraft of a 15,000 pound maximum gross weight or for traffic levels over 300,000 ESAL's (collector CRS or low-volume ARS roads), a level F Superpave 50 gyration mix design may be used as an alternative to the 50 blow Marshall design method. Except for the gyration requirements for gyratory compaction in Section 404, the mixtures shall meet the requirements of Section 405. 405.4.3.2 Tensile Strength Ratio. The mixture shall have a tensile strength ratio (TSR) greater than 75 percent when tested in accordance with AASHTO T 283. Specimens for AASHTO T 283 shall be compacted in accordance with the method in AASHTO T 312. The mixture shall be compacted to 7.0 ± 0.5 percent air voids. If the strength ratio is less than 75 percent, remedial action, such as the use of anti-strip agents, is required to improve the moisture susceptibility of the mix. When remedial agents are used to modify the asphalt binder, retest the mix to assure compliance with a minimum TSR greater than 75 percent. 405.4.3.3 Time Limit. A mix design may be transferred to other projects for a period of two years from the original approval date or the last field verification date provided that satisfactory results are obtained during production and placement. 405.4.3.4 Gradation Control. In producing mixtures for the project, the plant shall be operated so that no intentional deviations from the job-mix formula are made. Gradations are an indicator of the mix properties and will not be used for production shut down unless volumetric properties (VA and VMA) and/or binder content are not within specifications. Volumetric properties and binder content will control production acceptance and rejection. Mixtures as produced shall be subject to the following tolerances and controls: 1) The total aggregate gradation shall be within the master range specified in Section 405.3.1 for the particular grade of mixture specified. 2) The maximum variation from the approved job-mix formula shall be within the following tolerances: Sieve (Percent Passing by Mass)
Tolerance (Percent)
No. 8
± 5.0
No. 200
± 2.0
3) The quantity of asphalt cement introduced into the mixer shall be that quantity specified in the job-mix formula. No change may be made in the quantity of asphalt cement specified in the job-mix formula without written approval of the
7/1/2016
405-6
Bituminous Pavements and Base
Engineer. The quantity of asphalt cement determined by calculation or tests on the final mixture shall not vary more than ± 0.3 percentage points from the jobmix formula. 4) The screening unit shall separate the useable heated aggregate into at least three sizes. For Type D Bituminous Pavement Production, aggregate shall be separated into at least two sizes. 405.4.3.5 The gradations of the total aggregate will be determined from samples taken from the hot bins on batch type or continuous mixing plants or from the combined cold feed on dryer-drum mixing plants. An ignition furnace gradation, performed in accordance with AASHTO T 30, may be used if the mixture has been calibrated. 405.4.4 Screens. Plant screens shall have adequate capacity and size range to separate properly all of the aggregate into the sizes required for proportioning, so that they may be recombined consistently within the limits specified in Section 405.3. The screening unit shall separate the usable heated aggregate into at least three sizes, except that for Type D bituminous mixtures the screening unit shall be required to separate the useable heated aggregate into at least two sizes. 405.5 Control of Mixing. Mixing procedures for bituminous mixtures shall be set in accordance to following section. 405.5.1 Batch Type Plants. Batch plants shall be in accordance with Section 404.13.12. The dry hot aggregates, hydrated lime, mineral filler if needed, and asphalt cement shall be accurately proportioned in the quantities required by the job-mix formula. Aggregate shall be charged into the weigh hopper in a sequence that will avoid segregation. The mineral aggregate shall be mixed dry for not less than 15 seconds in accordance with Section 404.13.10.1. For Type X bituminous mixtures the dry mixing time may be reduced to 10 seconds. The dry mixing period shall start when all of the mineral aggregates have been charged into the mixer and end when introduction of the asphalt cement begins. After dry mixing, the asphalt cement shall be charged into the mixer in a manner that will uniformly distribute the asphalt over at least ¾ the full length of the mixer. The time required to add the asphalt shall not exceed 15 seconds. Wet mixing shall begin at the introduction of the asphalt cement and continue for at least 30 seconds, or longer if necessary to produce a complete and uniform coating of the particles and a thorough distribution of the asphalt cement throughout the aggregate. The wet mixing period shall end when the discharge gate is opened. The dry and wet mixing times shall be as directed by the Engineer. 405.5.2 Continuous Mixing Plants. Each size of hot aggregate, mineral filler or hydrated lime if needed, and the asphaltic cement shall be accurately proportioned in the quantities required by the job-mix formula. The mixing period shall be determined in accordance with Section 404.13.10.2 and shall be not less than 35 seconds. The mixing time shall be directed by the Engineer, and may be increased above the minimum specified, if necessary, to produce a complete and uniform coating of the particles and a thorough distribution of the asphalt cement throughout the aggregate. 405.5.3 The compaction and mixing temperature range for warm mix and modified binders will be furnished by the supplier.
7/1/2016
405-7
Bituminous Pavements and Base
405.5.3.1 Mixing Temperature. Mixing temperature range for unmodified binders will be determined where the unaged binder has a Viscosity of 0.17 ± 0.02 Pa-s measured in accordance with AASHTO T 316 "Viscosity Determination of Asphalt Binder Using Rotational Viscometer". 405.5.3.2 Compaction Temperature. Compaction temperature range for unmodified binders will be determined where the unaged binder has a Viscosity of 0.28 ± 0.03 Pa-s measured in accordance with AASHTO T 316 "Viscosity Determination of Asphalt Binder Using Rotational Viscometer". 405.5.4 The Contractor is advised that mix design will require gradation design, asphalt binder content design, moisture susceptibility testing, and nuclear gauge or ignition oven calibration. It may also require testing of the blended aggregate once the mixture design is completed. 405.5.5 Production Mixture. Mixture quality testing shall be performed in accordance with Section 404.7.6. When the produced mixture is reheated and compacted within the molding temperature range indicated on the mix design, mixture shall meet the following criteria: 405.5.5.1 Air Voids. Voids shall be 4.0 ± 1.0.percent. The air voids will be calculated from the field determined maximum specific gravity (AASHTO T 209) and the field determined bulk specific gravity (AASHTO T 166). See Section 405.16. 405.5.5.2 VFA. Voids Filled with Asphalt (VFA) shall be between 65 to 78 percent. 405.5.5.3 Binder Content and Voids in the Mineral Aggregate. The Voids in the Mineral Aggregate (VMA) shall be within -0.5 and +2.0 percent of the minimum required for the bituminous mixture. The field measured binder content shall be within ± 0.3 percent of the mix design target. The VMA will be determined using the field determined bulk specific gravity (AASHTO T 166) of the compacted specimens, the field calculated percent aggregate, the job mix formula aggregate bulk specific gravity and the field measured percent binder as determined by one of the following methods: AASHTO T 287 nuclear gauge method; AASHTO T 164 "Quantitative Extraction of Bitumen from Bituminous Paving Mixtures"; or by AASHTO T 308 "Method A-Standard Test Method for Determining Asphalt Content of Hot Mix by the Ignition Method".
Bituminous Mix Designation
Nominal Maximum Particle Size, inches
Type D
Minimum VMA, Percent Design Air Voids, Percent* 3.0
4.0
5.0
⅜
14.0
15.0
16.0
Type C
½
13.0
14.0
15.0
Type X
¾
12.0
13.0
14.0
*Interpolate minimum voids in the mineral aggregate (VMA) for design air voids between those listed.
7/1/2016
405-8
Bituminous Pavements and Base
405.5.5.4 On each follow-up field test, three specimens will be compacted to 50-blows or two specimens compacted at 40 gyrations when gyratory method approved. 405.5.5.5 Production Suspension and Mix Redesign. Should any of the mixture properties specified in Section 405.5.5 or 405.5.6.4 be found outside of the prescribed tolerances, a second test shall be run immediately. Should the second test confirm the findings of the initial test, production of the bituminous mixture will be suspended until adjustments are made and passing test results have been achieved. Repeated instances of non-conformance may result in suspension of production and redesign of the bituminous mixture. 405.5.6 Field Adjustments of Job Mix Formula. 405.5.6.1 Aggregate and Binder. When test results indicate the mixture produced does not meet the specification requirements the Contractor may field adjust the job mix formula as noted herein. Field adjustments may consist of changing the percentages of the aggregate fractions as listed on the approved job mix formula and changing the percent binder as listed on the approved job mix by 0.3 percent or less. Additional fractions of materials or new materials will not be permitted as field adjustments. The Engineer shall be notified immediately when any change is made in the cold feed settings, the hot bin settings, and / or the binder content. Engineer prior approval will be required when the aggregate percentages are adjusted by more than a total of 5.0 percent and / or the binder content are adjusted more than 0.3 percent from the job mix formula. 405.5.6.2 Volumetrics. When a field adjustment is allowed, the Contractor will be permitted to place not more than 750 tons of mixture, once the adjustment is made, to establish new volumetric properties of the mixture, and to verify the mixture meets the specification requirements of Section 405.5.5. The field adjusted job mix formula combined gradation and combined aggregate bulk specific gravity (Gsb) shall be calculated accordingly to reflect any change in the percentages of the aggregate fractions. The maximum theoretical specific gravity of the mixture (Gmm), the bulk specific gravity of the compacted specimens at 50-blow (or at NDesign of 40 gyrations when approved), the VMA, the percent filled (VFA), the dust proportioning (-200/Pbe), and the percent of asphalt binder targets will be established by sampling the material from the roadway after 100 tons have been produced. 405.5.6.3 Specimen Requirements. A minimum of 3 specimens will be compacted to 50-blows (or 2 specimens when NDesign of 40 gyrations is approved). The maximum theoretical specific gravity of the mix, percent asphalt binder of the mix and the cold feed gradations shall be determined. The volumetrics of the field adjusted mix shall be calculated from these test results. The average values of the volumetrics from the 50blow (or NDesign of 40 gyrations) compacted specimens will be used to establish the new volumetric targets of the mix. 405.5.6.4 The new volumetric targets of the mix shall be in compliance with all of the Marshall Mix design requirements of Section 405.5.5. When one or more of the Control Limits are exceeded, the Contractor shall take action to adjust production. When the adjustments to the mixture fail to produce a mix that meets the specification requirements, the production of the mixture will be halted. No mixture will be delivered to the job site until the mixture has been brought within the control limits. 7/1/2016
405-9
Bituminous Pavements and Base
Property
Control Limits
Penalties / Shut Down
Comments
Gradation and Binder Content Control Points Percent Passing JMF sieve:
From JMF:
No.8
±5.0
See Section 405.4.3.4
Gradation used to gauge mix uniformity
No. 200
±2.0
See Section 405.4.3.4
Gradation used to gauge mix uniformity
Binder Content, %
±0.3
See Note 2
See Section 405.4.3.4 & 405.5.5.5 when outside control limits
See Note 2
See Section 405.16
See Note 2
See Section 404.18.1 for 25% unit price reduction application for winter paving when VMA < 13
92 > MD > 96
See Section 405.14 for unit price reduction or removal
Volumetric Control Points VA (Air Voids), % 1
VMA , %
3.0 ≥ VA ≥ 5.0 VMAMin to +2.0 of the VMAMin
Density Control Points Mat Density (MD),%
92 ≤ MD ≤ 96
Notes: 1 2
VMAMin is the minimum VMA required as per Section 405.5.5.3. Shut down after two consecutive failed tests or as per comments
After this procedure has established the field adjusted job mix formula that complies with Section 405.5.5 requirements, the Contractor may continue paving operations using the field adjusted job mix formula. 405.5.6.5 Field Mix Redesign. When a new mix design is required, the Contractor will be permitted to establish the new mix design in the field. The mix shall be designed in accordance with Section 405.3 and shall meet the mix design requirements of Section 405.4. A representative sample of the mix shall be submitted with the new mix design to the Materials Laboratory for mixture verification. The amount of mix submitted for verification shall weigh at least 50 pounds. 405.5.6.5.1 New mix designs established in the field will be approved by the Materials Laboratory. When new mix designs are approved, the Materials Laboratory will assign a new mix number to the mixture.
7/1/2016
405-10
Bituminous Pavements and Base
405.5.6.5.2 No mix is to be placed on the project until the new field mix design is approved by the Engineer. 405.5.6.5.3 To keep accurate records, the original job mix formula will be labeled with a revision number consecutively numbered beginning with (R1) behind the last digit of the job mix formula number to signify that the job mix formula has been field adjusted. 405.5.6.6 Supporting data justifying the need and type of field adjustment shall be submitted to the Engineer. The Engineer will approve all field adjustments. The Contractor must notify the Engineer in writing of the adjustments made, new target values, and any other information required for evaluation of the revised mix. 405.5.6.7 The Contractor shall submit the field adjusted job mix formula to the Engineer in writing within 24 hours. 405.5.7 Safety Requirements. Safety requirements shall be in accordance with Section 404.13.11. 405.5.8 Plant Permitting and Calibration. Plant permitting and calibration shall be in accordance with Section 404.13.12. 405.6 Hauling Equipment. Hauling equipment shall meet the requirements of Section 404.14. 405.7 Plant Laboratory. 404.12.
Plant Laboratory shall be provided in accordance with Section
405.8 Equipment. Equipment for production of bituminous mixture shall be in accordance with Section 404.13. 405.9 Pavers. Pavers, safety edge, notched wedge, screed control, and equipment operation and maintenance shall meet the requirements of Sections 404.15 through 404.15.5.3. 405.10 Automatic Screed Control. The use of automatic screed controls should follow the procedures set forth in Section 404.15.4. 405.11 Rollers. Rollers shall meet the requirements of Section 404.17 and the following. 405.11.1 Trench rollers, vibrators, and other special equipment used for compacting mixtures placed in areas inaccessible to the rollers specified shall be of a weight and design approved by the Engineer. For each piece of compaction equipment proposed for use, the Contractor shall submit a certification of weight or other suitable documentation certifying compliance with specifications. Non-certified equipment will not be permitted to be operated. No direct payment will be made for the cost of complying with this requirement.
7/1/2016
405-11
Bituminous Pavements and Base
405.11.2 After the asphaltic mixture has been spread, struck off, and surface irregularities adjusted, it shall be thoroughly and uniformly compacted by rolling. Rolling shall begin as soon after spreading the mixture as it will bear the weight of the roller without undue displacement. The number of rollers furnished shall be sufficient to obtain the required compaction while the mixture is in a workable condition. Except for projects involving small quantities of mixture, the compacting equipment requirements shall meet specifications set forth in Section 405.13. If equipment breaks down or rolling does not keep up with the spreader, all work will be stopped. The Engineer will have the option of rejecting any pavement not meeting the rolling or density requirements of Section 405.13. If pavement is designated to remain in place, penalties will be assessed for the affected material in accordance to Section 405.14. 405.12 Paving Procedures. Paving procedures shall meet all the requirements in Sections 404.18 through 404.32, except as modified herein. 405.12.1 Lift Thickness Limitations. The thickness of each course shall conform to the typical section in the contract. The Engineer may increase the compacted layer thickness for mixtures when used for full-depth base repair or in areas where the above specified layer thickness is not deemed practical. In these areas the approved compaction methods shall be performed at the proper intervals and duration until there is no further evidence of consolidation. These areas will not be subject to compaction penalties. The Contractor may construct each course in any number of layers within the following lift thickness limitations: Mix Type
Compacted Thickness (inches) Minimum
Maximum
D
1
2
C
1.5
2.25
X
2
4
405.12.2 Spot Wedging and Leveling Course. The Engineer will determine the locations and thickness of spot wedging and the thickness of leveling course to obtain the smoothest possible riding surface. This procedure may result in spot wedging operations over small areas with feather edging at high points and ends of wedge areas. Rigid control of the placement thickness of the leveling course will be required. A leveling course, consisting of a layer of asphaltic concrete of variable thickness used to superelevate curves and eliminate irregularities in the existing base, shall be spread uniformly to the desired profile grade and cross section. The use of an approved finishing machine with automatic screed control will be required on the spot wedge and the leveling course. Bituminous pavement type C mixture shall be used for spot wedging greater than 1 inch. Bituminous pavement type X mixture shall be used for spot wedging greater than 2.25 inches in depth. The type of mixture to be used for the leveling course will be designated in the contract. Surface grades will be established in advance of the Contractor's wedge and level operations to prevent unnecessary interruptions in the work.
7/1/2016
405-12
Bituminous Pavements and Base
405.13 Compaction. Rolling shall be continued until all roller marks are eliminated and before the un-modified mixture cools to 185°F or the modified mixture cools to 200°F, except as otherwise specified. Mat density testing and the associated requirements listed below do not apply for wedge/leveling courses or lift thicknesses less than the minimum compacted thickness for the mix type placed. The final density of the in-place mixture shall be between 92 and 96 percent of the determined daily maximum specific gravity (AASHTO T 209). When a daily maximum specific gravity is not performed, the last computed maximum specific gravity will be used. In some case that might be the design maximum specific gravity. The applicable density will be determined by the Engineer to correspond with the mix design test method. Density will be determined by nuclear methods (ASTM D 2950) or by an approved specific gravity method (AASHTO T 166). 405.13.1 Density Samples. Density samples shall be taken and holes restored by the Contractor and paid for in accordance with Section 404.25.1. 405.14 Compensation for Density Deficiencies. Pavement shall be tested in accordance with this Section and Section 404.25. Density values for each lift of bituminous concrete will be determined. Pavement, which is not compacted to the minimum density requirement specified, shall be removed and replaced. If in the judgment of the Engineer the inadequately compacted pavement would not seriously impair traffic service, penalties may be assessed for low-density results in lieu of the removal and replacement of pavement. Density penalties will be assessed at the Director's option in accordance with this section. 405.14.1 Full Depth Bituminous Pavement Construction, New Real Estate Subdivision and Bituminous Overlays. At the Director's option, penalties for inadequate compaction of pavement will be assessed as follows: Type C and Type X Bituminous Compaction Results (Percent of Field Determined Maximum Specific Gravity, Gmm)
Deduction in Unit Price per Ton
> 97 percent ................................................. 100 percent Reduction or Remove and Replace 97 percent ............................................................................................. 25 percent Reduction 92 to 96 percent ................................................................................................ No Deduction 91 percent ............................................................................................... 5 percent Reduction 90 percent ............................................................................................. 25 percent Reduction < 90 percent ................................................. 100 percent Reduction or Remove and Replace Penalties will be assessed at no less than 100 feet and no more than 500 feet intervals. 405.15 Compensation for Thickness Deficiencies. Thickness penalties will be assessed at the Director's option in accordance with this section. Cores shall be cut in accordance with Section 404.32 and 404.32.1 to determine pavement thickness as modified herein.
7/1/2016
405-13
Bituminous Pavements and Base
405.15.1 New Real Estate Subdivision Bituminous Pavement, Bases and Overlays Construction. If any core measurement is less than the thickness for each material type indicated on the plans, the Contractor will have the option of removing and replacing the pavement at his expense, or will be required to reimburse St. Louis County for the deficiencies in thicknesses noted on the schedule. The choice of alternate penalty under category (4) below will be at the sole discretion of St. Louis County. The reimbursement amount shall be deposited with the Treasurer of St. Louis County. Deficiency in Thickness, inch
Deduction, in Percent of Escrow Amount
0.0 to 0.3
None
Over 0.3 to 0.5
20 Percent Reduction
Over 0.5 to 1.0
40 Percent Reduction
Over 1.0
100 Percent or Remove and Replace
Estimated cost is computed at the rate per square yard of pavement used in determining the amount of the developer’s escrow deposit. When the measurement of any core is deficient in excess of 0.3 inch from the plan thickness for each material type specified, additional cores will be taken at 100 feet intervals parallel to centerline ahead and back of the affected location until the extent of the deficiency has been determined. Penalties will be assessed at 100 feet intervals. The deficiencies and penalties listed herein shall only apply to bituminous pavements mixtures placed within St. Louis County right-of-way. 405.15.2 All Other Full Depth Bituminous Pavement, Base, and Bituminous Overlay Construction. Pavement thickness will be determined in accordance with Section 404.32.2 and compensated in accordance with Section 404.32.1. 405.16 Compensation for Air Void Deficiencies. The percent air voids (VA), computed in accordance with Section 405.5.5.1, and subject to the limits specified in Section 405.6.4, the mix shall be subject to deductions. If the air voids exceed the control limits indicated, penalties shall be assessed in accordance with the following schedule: Deficiency in Air Voids, percent
Deduction, in Unit Price Per Ton
5.0 ≥ VA ≥ 3.0
None
3.0 > VA
See Note 1
Any test below 2.5 percent will be cause for immediate shutdown. Note 1: Shutdown after two consecutive failed tests
405.17 Method of Measurement. Measurement of the mixture placed shall be in accordance with Section 404.30.
7/1/2016
405-14
Bituminous Pavements and Base
405.18 Basis of Payment. 405.18.1 Due to possible variations in the specific gravity of the aggregates, the tonnage used may vary from the proposal quantities and no adjustment in contract unit price will be made because of such variation. 405.18.2 Payment for Pavement Repairs (Blow-ups). Payment for removing and disposing of the broken concrete and for preparing subgrade and aggregate base will be made as provided in contract bid items or in Section 104.3. Payment for furnishing, placing, and compacting the bituminous material replacement material will be at the contract unit bid price for the mixture used. 405.18.3 Wedge and Leveling. The accepted quantities of bituminous material will be paid for at the unit bid price, to the nearest 0.1 ton, for each of the pay items included in the contract. 405.18.4 Interlayer Paving Geotextile. Payment for interlayer paving mat geotextile material will be made for the surface area covered with geotextile, to the nearest square yard. No additional payment will be made for geotextile laps, splices, repair, etc. 405.18.5 Safety Edge and Notched Wedge. No separate payment will be made for shoulder preparation or the construction of the Safety Edge or Notched Wedge. All work associated in the Safety Edge or Notched Wedge construction shall be integral to the pavement work and shall be included in the contract pricing for those pay items. The accepted quantities for Shoulder Backing Material will be paid for at the unit price for each of the pay items included in the contract. No direct payment will be made for fine grading, shaping, compaction, or the addition of water used in performing Shoulder Backing Material.
7/1/2016
405-15
Bituminous Pavements and Base
(This page intentionally left blank.)
7/1/2016
405-16
Bituminous Pavements and Base
Section 406 406.1 Description. driveways.
Joint and Cracksealing Joint and cracksealing asphalt and concrete pavements, curbs and
406.1.1 This item shall consist of the thorough cleaning, drying, and sealing of existing cracks and joints in asphalt pavements, curbs and driveways. 406.1.2 This work shall also include removal of all waste material produced in the joint or crack sealing process. 406.1.3 All pavement joints, both new and existing, and all existing cracks are to be cleaned, dried and sealed within the limits indicated in the contract. 406.1.4 Definition of joint and crack: 406.1.4.1 A joint is defined as any interface to the asphalt pavement or joint made during construction. Examples of interface to the asphalt pavement; manhole, drainage inlet, curb, utility patch, concrete driveway approach, etc. 406.1.4.2 A crack is defined as an opening larger than 1/8 inch. 406.2 Materials. Sealant material shall be in accordance with Section 1057.5, Joint and Crack Sealer, Hot-Poured Elastic Type. 406.3 Equipment. Sealing equipment shall be in accordance with the following: 406.3.1 Air compressors for cleaning of cracks and joints will have the following: 1) Equipped with oil and moisture filters. 2) Pressure at discharge - 100psi minimum. 406.3.2 Air Lance for drying of cracks will have the following: 1) Velocity - capable of 3000 ft/s. 2) Temperature - capable of 2000 deg F. 406.3.3 Melter-Applicator of sealant specifications to include: 1) Double-boiler. 2) Sealant heating range up to 480 deg F. 3) Full-sweep agitator. 4) Accurately calibrated material and heating oil temperature gauges.
3/15/2022
406-1
Joint and Cracksealing
406.4 Construction Requirements. 406.4.1 Preparation of Cracks and Joints. Immediately before installation of the sealant, cracks and joints shall be thoroughly cleaned until all loose material is removed from the sides and upper edges of the space to be sealed. After this cleaning and immediately prior to filling, cracks and joints shall be blown out with compressed air and left completely free of loose pavement, dust, debris, oil and water. All joints and cracks shall be at a minimum cleaned with compressed air and dried utilizing a heat lance (no direct flame will be allowed on the pavement). 406.4.2 Routing of Cracks. Cracks larger than 1/5 inch wide shall be routed. The routed shape will create a squared reservoir. Cutting or routing machine will produce clean flat surfaces on bottom and side edges. 1) Recommended Equipment: Vertical-Spindle Router with sharp carbide-tipped or diamond router bits, Rotary-Impact Router with sharp carbide-tipped router bits, or crack saws on straight cracks and construction joints. 406.4.3 Cleaning of Cracks and Joints. The Contractor shall provide adequate details, explaining and showing the extent of the clean out work he proposes to do at the existing joints and cracks, along with the methods, equipment and construction procedures he intends to employ. It is not intended to limit the method of joint and crack cleaning to the use of compressed air and mechanical brush systems. Other cleaning systems may be necessary to thoroughly clean cracks and joints. 406.4.4 Separating and Blocking Media. At wide joints or cracks with openings in excess of ¾ inch or when voids are evident below these joints or cracks, the Contractor shall provide the labor, equipment and material to install an approved filler material. This material shall be readily compressible, non-shrinkable, non-reactive with the sealant and nonabsorptive, such as extruded butyl or polychloroprene foam rubber see section 1057.12. The blocking medium shall not melt or soften at the pouring temperature of the sealant, shall fit snugly in the reservoir and shall not be stretched during insertion into the joint. Placement of the separating or blocking media, when required, shall be placed with a double-wheeled, steel roller to the depth below the joint surface of the pavement equal to the width of the cleaned joint or as directed by the Engineer. 406.4.5 Rate of Progress. Contractor will have 10 minutes after applying a heat lance to seal the joint. If the time limit is exceeded the area will need to be dried again with the heat lance. 406.4.6 Site Cleanup. The Contractor shall be responsible for the daily cleanup of old blown-out material and debris and for the final cleanup of excess or unused material or debris from the right-of-way within forty-eight (48) hours after the completion of a project site, or as directed by the Engineer. Failure to comply with this specification will result in the suspension of work, the charging of working days while work is suspended, and the application of liquidated damages as specified by the contract if the charging of work days or completion date exceeds the contract or change order amount.
3/15/2022
406-2
Joint and Cracksealing
406.4.7 Traffic Control. The Contractor shall provide, install and maintain temporary advisory signing as required by the most recent edition of the Manual of Uniform Traffic Control Devices (MUTCD) or as directed by the Engineer. The Contractor shall provide protective measures to prevent tracking of sealant material onto private and personal property. Failure to comply with this specification shall result in the suspension of work, the charging of working days while work is suspended, and the application of liquidated damages as specified by the contract if the charging of work days or completion date exceeds the contract or change order amount. 406.4.8 Application of Crack Sealing Material. Hot poured liquid crack sealant material shall not be installed until the cleaned and dried joints or cracks to be sealed have been inspected and approved by the Engineer. The sealant application temperature shall be as recommended by the sealant manufacturer, but the temperature does not exceed the safe heating temperature. The sealant shall not be applied when the following weather conditions exist: 1) In fog or on damp pavement. 2) When the air and pavement temperature in the shade is less than 40°F unless permitted by the Engineer. 406.4.8 The Engineer may suspend and reject work when the joint is not clean, dry or when the sealant material fails to adhere to the crack or joint. 406.4.9 Application of Material The crack and joint seal material shall be applied with an appropriate applicator with a disk attachment specifically designed for this type of work. The applicator shall be operated in such a manner to assure that: 1) Joints shall be filled from the bottom up to within level of the pavement surface, plus or minus ⅛ inch, as shown on the Construction Details when included in the plans, or as directed by the Engineer. 2) Cracks shall be filled to a slightly overfilled condition and then immediately leveled to a concave shape with a U- or V- shaped squeegee to provide a "band-aid" type effect not to exceed ⅛ inch high above the pavement surface and with the edges feathered out to extend no greater than 2 inches on each side of the crack. 3) The procedure for routing, cleaning and sealing longitudinal random cracks will be the same, except the crack reservoir shall be sealed flush rather than providing an over sealed or "band-aid" type effect. 4) Excess or spilled sealant material on the pavement surfaces shall be promptly removed and discarded. Material that remains in the applicator at the end of the day's operations shall be withdrawn and wasted.
3/15/2022
406-3
Joint and Cracksealing
406.4.10 Traffic shall not be permitted over newly sealed pavement joints or cracks until the sealant is cured to a tack free condition or until authorized by the Engineer. When necessary to prevent vehicle or pedestrian tracking, the completed sealant surface shall be treated with one of the following: 1) Dusted with fine sand, Portland cement, or mineral filler. 2) Covered with a biodegradable surfactant with a minimum water content of 80%. 3) Covered with tissue paper. 406.4.11 Crack Sealing Quality Control. 1) Spills or excessive material that exceed the height and width specified shall be removed, the joint or crack re-cleaned and resealed at the Contractor’s expense and approval after engineer’s review. 2) The County will withhold payment, of up to 100%, of the affected areas until excess or spilled sealant is removed to the satisfaction of the Engineer. 3) The Contractor, at his expense, shall reapply sealant to low areas where sealant has settled or where too little material was applied within the height and width specified. 4) The Engineer will check adhesion randomly by pulling up the cooled sealant. The Contractor, at his expense, shall remove, clean, dry and reseal all unbonded areas to the height and width specified. 406.4.12 Method of Measurement. Measurement of individual joints and cracks will not be made. The ordered and accepted cleaning, separating or blocking media, and sealing of pavement joints and cracks will be measured along the centerline roadway surface to the nearest 0.01 mile. 406.4.13 Basis of Payment. The quantity of cleaning and sealing of pavement joints and cracks ordered and accepted, measured as noted above, will be paid for, to the nearest 0.1 mile, at the contract unit price. This shall be full compensation for the furnishing of labor, equipment, materials, tools, personal protective equipment, traffic control, cleanup, providing and placing filler material, drying and resealing, separating or blocking media, and incidentals necessary to clean and seal, as required, all designated asphalt and Portland Cement Concrete pavement.
3/15/2022
406-4
Joint and Cracksealing
Section 407
Tack Coat
407.1 Description. This work shall consist of preparing and treating an existing bituminous or concrete surface with bituminous material in accordance with these specifications, as shown on the plans or as directed by the Engineer. Nighttime lighting requirements shall be in accordance with Section 612.80. 407.2 Materials. All materials shall be in accordance with Division 1000, Materials Details, and specifically as follows: Item
Section
Emulsified Asphalt or Performance Graded Binder
1015
407.2.1 Warnings. Wear and use proper personal protective equipment (gloves, face shields, hearing protection, eye protection, etc.) during all phases of work. Emulsions are sprayed heated and under pressure. Avoid exposure to breathing fumes, vapors and mists. Do not load or mix different classes, types, and grades of bituminous materials in the distributor. Do not apply severe heat to pump packing glands or pump casings. Do not subject emulsion or air above it to open flames, heat or strong oxidants. Avoid contact with the eyes and skin, especially when sampling. Thoroughly wash any affected area immediately. In case of contact with eyes, irrigate thoroughly and seek medical attention immediately. 407.2.2 Allowance for Testing. The Contractor shall make allowance for sampling of tack for quality control testing purposes. 407.2.3 Blotter Material. Aggregate used for sanding tack shall be a fine, granular material naturally produced of a siliceous nature; or fines manufactured from igneous rock, chert gravel, or flint sand. Limestone or Dolomite sands shall not be used. Blotting sand application shall not exceed an application rate of 4 to 6 pounds per square yard when used. 407.3 Equipment. The Engineer will approve an alternative system of application for small or irregular areas. For all other conditions the following equipment is required. 407.3.1 Pressure Distributor. This system shall be, designed, equipped, maintained, and operated such that liquid asphalt at even heat may be applied uniformly at the spray application temperature on variable widths of surface up to 15 feet. The distributor system application rate shall be readily determined and controlled, with uniform pressure ranging from 25 to 75 psi, and with an allowable variation from any specified rate not to exceed 0.02 gal./yd2. 407.3.1.1 Truck. The truck shall be capable of operating at speeds as low as 75 feet per minute when applying bituminous material and at normal roads speeds when transporting bituminous material. The truck shall be cleaned of foreign contaminants and free from hydraulic, fuel, transmission or oil leaks before it is used.
2/1/2017
407-1
Tack Coat
407.3.1.2 Tank. The Contractor shall provide a distributor system that shall have a capacity of not less than 500 gallons. It shall be insulated and equipped with a removable manhole cover, an overflow pipe and a suitable strainer located at the intake or outlet to the pump. A dial gauge plainly visible to the spray bar operator shall be conveniently placed to indicate the contents of the tank at various levels. The tank shall be equipped with baffle plates. A measuring stick, calibrated in no more than 50 gallon increments shall be supplied that is designed and calibrated to read tank contents with or without dipping stick into material, depending on the manufacturer. 407.3.1.3 Heating System. The distributor shall be equipped with an approved heating system to heat the bituminous material. The heating system shall consist of heat flues having sufficient radiation to ensure the rapid circulation of hot gasses of combustion from one or more smokeless burners of the torch type, a circulating device to ensure uniform heating of the materials and a suitable fuel supply tank. 407.3.1.4 Pump. The distributor pump shall be of the rotary pressure type of sufficient size and discharge capacity to apply uniformly the specified amount of bituminous material at the specified width. It shall be driven in the most direct method by a gasoline motor other than the vehicle propelling motor or by other methods approved by the Engineer. The pump motor shall be of sufficient power to operate the distributor pump at the required volume and pressure. If the motor pump is equipped with a transmission, it shall have a governor. Suitable housing or heating jackets shall be provided to enclose the distributor pump and piping in order to retain heat and to ensure a constant even flow of material. 407.3.1.5 Spray Bars. The system shall also include a hand spray bar and nozzle having a suitable length of flexible hose with packed couplings which shall be provided for applying materials at intersections, shoulders and similar locations not accessible by the spray bar. 407.3.1.6 Thermometer. A thermometer having the stem extending into the material or into an approved well shall be placed in suitable position in the tank to give a true average temperature of the contents of the tank. The thermometer well shall not be in contact with a heating tube. Calibration of thermometers should be verified to be within +2% of full scale reading annually. Certification can be accomplished by a qualified laboratory or by comparing stabilized dial readings to the pencil thermometer reading. Replace any thermometer that does not meet the +2% accuracy requirement. 407.3.1.7 Operator’s Platform. A substantial platform for the operator shall be provided at the rear of the distributor. It shall be so located that it will provide a clear view of the operation of the spray bars. 407.3.1.8 Tachometer or Synchronizer. The tachometer shall be readily visible to the operator and have a dial reading registering gallons per minute passing through the nozzle. When a synchronizer is used, a tachometer may be omitted. The synchronizer shall deliver the specified amount of bituminous material on the road surface regardless of the speed of the truck. The distributor shall be equipped with a bitumeter with a dial gauge registering feet of travel per minute and shall be visible by the driver. The distributor shall also be equipped with a digital application rate indicator that indicates the application rate in square yards as the distributor is applying the binder.
2/1/2017
407-2
Tack Coat
407.3.1.9 Distributor Calibration. The Engineer, prior to the distributor system's use, shall approve the calibration of the system, and the Contractor shall furnish all equipment, tools, materials, and assistance necessary to perform the required calibration. The Contractor shall submit the following for review by the Engineer: 1) The make, model and serial number and tank capacity of the distributor. 2) Spray nozzle size, spacing and type, and spray bar width. The distributor shall be provided with a full circulatory system that includes the spray bar. The normal width of application of the spray bar shall be 12 feet with provision for lesser width when necessary. Nozzle and spray setting shall be set in accordance with Section 407.4.3.4. 407.3.1.9.1 Yield Verification. Verification of the use of a computerized distribution system to verify application rates shall be performed at the beginning of the project or no less than once per calendar year. The tank volume must be checked using the dipstick supplied with the truck by the manufacturer, not the pointer gauge on the rear tank. Using a width and distance to spray at least 50 gallons (no more than 75% of the volume of emulsion in the truck be sprayed when performing yield verification), the Contractor will determine the application rate at the beginning of the project to verify the computer application rate is correct. 407.3.1.10 Sampling. Means shall be provided for obtaining samples of the material from the tank or from the piping leading from the tank to the spray bars. 407.3.2 Cleaning Equipment. The mechanical or vacuum sweeper shall be in accordance with Section 412.2.2. Equipment shall also include scrapers, hand brooms, shovels, gaspowered blowers and other equipment as may be necessary to thoroughly clean the base or surface. 407.4 Construction Requirements. 407.4.1 Weather Limitations. Weather limitations shall be in accordance with Section 404.18. 407.4.2 Preparation of Surface. A self-propelled, mechanical sweeper or vacuum sweeper, equipped with a watering system capable of dust suppression shall be used to remove dust and loose material from the pavement surface. Grease and other petroleum distillates, debris or other foreign material shall also be removed from the pavement surface prior to the time the bituminous material is applied. The surface shall be clean and dry at the time of application. 407.4.2.1 Pre-Wetting. Existing surfaces may be pre-wetted with potable water just prior to the emulsified tack coat application. Pre-wetting shall consist of fogging the surface with water using controlled fogging equipment to achieve a uniformly damp condition with no standing water or shiny appearance.
2/1/2017
407-3
Tack Coat
407.4.3 Application. 407.4.3.1 Rate of Application. Emulsion shall be applied uniformly with a pressure distributor to achieve the residual rate (the amount of binder left after water separates from the emulsion) specified in the contract, or as revised by the Engineer to be within a minimum of 0.03 gal/yd2 and a maximum of 0.08 gal/yd2. Uniform application will not have streaks, bare spots, puddles, or other irregular patterns. If the residual rate is not specified in the contract, the Engineer may use the following table as a guide: Application Rate (gal/yd2)***
Existing Pavement Condition
Residual
Emulsion*
New Asphalt1
0.03 to 0.04
0.05 to 0.07
Oxidized Asphalt & Micro-milled surfaces
0.04 to 0.06
0.07 to 0.10
Milled Surface
0.06 to 0.08
0.10 to 0.13
Portland Cement Concrete (PCCP)
0.04 to 0.06
0.07 to 0.10
**
**
Vertical Face 1
New asphalt that is clean and has been opened to traffic 5 calendar days or less. * Rates shown are for slow setting emulsions (SS-1h, SS-1) containing approximately 60 percent bituminous material. Adjust rates downward if greater than 60 percent bituminous material. Measurement of the material will be based on the volume at 60°F using the tables in Section 1015.6.2 for converting the material from the volume at the observed temperature to the volume at 60°F. ** Longitudinal and Transverse construction joints should be treated using a rate that will thoroughly coat the vertical face without running off. *** Use the emulsion application rate appropriate to obtain the desired undiluted rate.
407.4.3.2 Dilution of Asphalt Emulsions. The Contractor shall notify the Engineer of the exact quantity of water in the emulsion supplied. The exact quantity of water shall be indicated on the manufacturer's bill of lading. No additional dilution is allowed. The application of the resulting emulsion shall be such that it will be uniformly spread at the specified residual rate. The tack material shall be properly cured and the tacked surface shall be cleaned of dirt, milling dust, grease and other petroleum distillates and surplus sand before hauling equipment is allowed on the tack and before the next course is placed. When bituminous material is placed by hand methods, a pressurized application system must be used, unless otherwise approved by the Engineer. 407.4.3.3 Performance Graded (PG) Asphalt Binder. Hot applied PG graded asphalt binders may be used as tack coat in lieu of emulsified asphalt. The PG graded binders shall be applied uniformly with a pressure distributor to provide complete coverage of the preceding course or layer. Safety procedures of hot applied asphalt shall be addressed in the Contractor's safety plan. Pre-wetting is not approved for use with sprayed PG binders. A pre-paving meeting shall be held to address all safety procedures and protocols of hot applied asphalt prior to tack coat application.
2/1/2017
407-4
Tack Coat
407.4.3.4 Heating, Circulation and Application Temperatures. The bituminous material shall be heated at the time of application to a temperature in accordance with the limits provided in Section 1015.5, as determined by the emulsion manufacturer, as specified in the contract, or as designated by the Engineer. The emulsion manufacturer shall submit the temperature/viscosity relationship to the Engineer prior to application. An increase of material application temperature to within 20°F of the maximum spray temperature specified in accordance with Section 1015, may be required as the ambient temperature or pavement surface temperatures are below 70°F so that emulsion will achieve proper flow and cure. Prior to applying the emulsion, heat and circulate the material. The following heating and circulating process shall be used: 1) The emulsion shall be slowly heated to within 10°F of the minimum spray temperature. 2) Begin circulating the emulsion in the distributor tank only (100 to 150 gallons per minute) and continue slowly increasing heat to the specified spraying temperature range. 3) Once the desired spray temperature is reached, begin circulation in the distributor bar. 4) Maintain circulation in the distributor’s spray bar for a minimum of 30 minutes prior to tack application. 407.4.3.5 Traffic Controls. Keep traffic off surfaces freshly treated with bituminous material. Provide sufficient warning signs and barricades so that traffic will not travel over freshly treated surfaces. 407.4.3.6 Application Limits and Maintenance. The tack coat shall be applied in such manner as to cause the least inconvenience to traffic and to permit one-way traffic without pickup or tracking of the bituminous material. All exposed tack coat shall be covered with bituminous mixture prior to opening to traffic. Excess blotter sand shall be broomed from the surface before the overlay to ensure a proper bond. The application of tack coat will be limited to 600 feet ahead of the spreading machine. Tack coat shall extend beyond the mat to be placed by 2 to 3 inches at longitudinal joints and transverse joints. 407.4.3.7 Nozzle and Spray Bar Settings. All spray bar nozzles shall be of the same size and type and set to the same angle. Spray nozzles shall be of the opening size required by the manufacturer and appropriate to the material being applied. The angle is measured from the axis of the spray bar and is typically uniformly set between 15 and 30 degrees and the height of the spray bar shall be set to provide a triple coverage (with 4 inch nozzle spacing) or double coverage (with 6 inch nozzle spacing) fan pattern. The frame of the distributor shall be blocked or snubbed to the axle of the truck to maintain a constant spray bar height above the road surface during discharge of the load. An alternate method of maintaining constant spray bar height may be approved.
2/1/2017
407-5
Tack Coat
407.4.3.8 Protection of Appurtenances. The surfaces of sidewalks, curbs, islands, medians, gutters, surface of railings, utility frames and covers, other structures, and pavement not to be resurfaced, and vegetation adjacent to the area being treated shall be protected in such a manner as to prevent their being spattered or marred. Material used for such protection shall be removed and disposed of in a satisfactory manner. Cleaning of unintentionally sprayed appurtenances will be performed at the expense of the Contractor. 407.4.3.9 Contact Surfaces. The contact surfaces of all cold pavement joints, curbs, gutters, manholes and the like shall be neatly painted with emulsion immediately before the adjoining asphalt mixture is placed. 407.4.4 Sampling. The Engineer, with the assistance of the distributor driver, will sample from the distributor daily in accordance with ASTM D 140 and one out of five samples will be randomly selected and tested for specification compliance by the County. Do not take a sample while the hauling vehicle is pumping into the distributor. Do not take a sample without allowing enough time for heating, circulation and thorough mixing of the emulsion. Samples shall be taken during circulation and after one-third and not more than two-thirds of the load has been removed. The Engineer will observe that sufficient material has been drained off through the sampling nozzle to ensure removal of any material lodged there before collecting the sample. 407.5 Method of Measurement. Measurement of emulsion will be made to the nearest 10 gallons after correction to 60˚F. 407.5.1 No measurement of material for sanding tack coat will be made. 407.6 Basis of Payment. The accepted quantities of tack coat will be paid for at the contract unit price. Water fogging, furnishing and applying sand on newly tacked surfaces, surface cleaning, and protection of appurtenances shall be at no expense to the Department, with no direct compensation being made therefore.
2/1/2017
407-6
Tack Coat
Section 408
Prime Coat
408.1 Description. This work shall consist of preparing and treating an existing surface with bituminous material, in accordance with these specifications and in conformity with the lines shown on the plans or established by the Engineer. Nighttime lighting requirements shall be in accordance with Section 612.80. 408.2 Materials. The type and grade of bituminous material will be specified in the contract. Liquid asphalt may be changed one grade by the Engineer during construction at no change in unit price. All material shall be in accordance with Division 1000, Materials Details, and specifically as follows: Item
Section
Type MC Liquid Asphalt
1015
Emulsified Asphalt
1015
408.3 Equipment. Equipment shall be in accordance with Section 407. 408.4 Construction Requirements. 408.4.1 Weather Limitations. Prime coats shall not be normally placed: 1) When either the air temperature or the temperature of the surface on which the mixture is to be placed is below 40°F, 2) On any wet or frozen surface, 3) When weather conditions prevent the proper handling, curing or finishing, or 4) Unless authorized by the Engineer during critical temperature periods below 40° F. 408.4.2 Preparation of Surface. The surface to be primed shall be shaped to the required grade and cross section, shall be free from all ruts, corrugations, segregated material, or other irregularities and shall be uniformly compacted by rolling. The surface shall be firm and slightly damp when primer is applied. Moisture in excess of that stated in Section 304.3.7 will be cause to delay the priming operation. Delays in priming may necessitate reprocessing or reshaping to provide a smooth compacted surface. 408.4.3 Application. Bituminous material shall be applied to the width of the section to be primed by means of a calibrated pressure distributor in a uniform, continuous spread. The application rate shall be as specified in the contract or as revised by the Engineer between 0.2 and 0.5 gallon per square yard. The primer shall be heated at the time of application to a temperature designated by the Engineer in accordance with the limits provided in Section 1015.5, or as specified in the contract. When prime is to be placed by hand methods a pressurized applicator system must be used, unless otherwise approved by the Engineer.
5/1/2010
408-1
Prime Coat
408.4.3.1 The angle of the spray nozzles and the height of the spray bar shall be in accordance with Section 407.4.3.2. 408.4.3.2 There shall be no overlapping of bituminous material. Pools of primer material remaining on the surface after the application shall be removed. As soon as the bituminous material has been absorbed by the surface and will not track, traffic may be routed onto the treated traveled way. Any damage caused to the prime coat due to the Contractor’s equipment or decision to allow traffic on the aggregate base too soon shall be primed again at the Contractor's expense. 408.4.3.3 Furnish and apply blotter material, in accordance with Section 407, to absorb excess asphalt at the Contractor’s expense. All material removed, blotter material and primer, shall be at the Contractor’s expense. 408.4.3.4 The primer shall be properly cured, for a minimum of 12 to 48 hours, and the primed surface shall be cleaned of all dirt and surplus sand before the next course is placed. 408.5 Method of Measurement. Bituminous material will be measured to the nearest 10 gallons in accordance with Section 1015. 408.6 Basis of Payment. The accepted quantities of prime coat will be paid for at the unit bid price for each of the items included in the contract. No direct payment will be made for furnishing or applying any water required for dampening the surface to be primed and furnishing, applying and removing blotter sand and excess prime.
5/1/2010
408-2
Prime Coat
Section 409
Seal Coat
409.1 Description. This work shall consist of an application of heated ground tire modified asphaltic cement followed with an application of graded aggregate surfacing material. The work performed under this contract shall consist of furnishing all labor, equipment, traffic control devices, and materials to construct a single-layer aggregate surface treatment over existing asphaltic concrete pavements. Nighttime lighting requirements shall be in accordance with Section 612.80. 409.1.1 The specific road(s) and their limits to receive seal coat treatment shall be included in the contract documents. The ground tire modified asphalt seal coat shall be constructed in accordance with these specifications and in conformity to the lines, grades, thicknesses, and cross sections shown on the plans, or established by the Engineer. 409.2 Materials. All material shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Sand
1002.2
Aggregate for Sealcoat
1003
Bituminous Materials
1015
Temporary Lane Markers
1048.7
409.3 Design Aggregate and Binder Application Rates. The McLeod mix design method shall be used and all computations (target stockpile gradation, pre-coating amount, application rates of binder and cover aggregate) shall be submitted to the Engineer for approval review prior to the pre-construction meeting. The mix design shall state the application rate for each aggregate type specified in the contract and target Binder Application Rate and operating tolerance. The Engineer, based on a site-by-site evaluation, will determine the changes in application rates within the tolerances specified in Section 409.3.1. Application mix design rates including the operation tolerances and application correction factors shall be within the range of 0.25 to 0.50 gal./yd2. 409.3.1 The binder application rate, after the Engineer makes adjustments to the target rate, shall not exceed the range specified in Section 409.3. The Engineer will use the following correction factors to the mix design binder application rate(s) as follows: Application Correction Factor
Existing Pavement Texture Black, flushed asphalt Smooth, non-porous Slightly porous and oxidized Slightly pocked, porous and oxidized Badly pocked, porous and oxidized
7/1/2015
409-1
Gal/yd2
L/m2
-0.01 to –0.06 0.00 +0.03 +0.06 +0.09
-0.04 to –0.27 0.00 +0.14 +0.27 +0.40
Seal Coat
409.3.2 Asphalt cement containing particulate modifiers may be susceptible to separation of the modifier. Appropriate circulation or agitation in storage shall be provided if separation of the modifier is expected, suspected or if the modified asphalt will be stored at elevated temperature for more than one day before use. 409.4 Sand. Sand shall conform to Section 1002.2, Materials Details. Sand from the Mississippi River or Missouri River basin may be used for blotter material, if needed. 409.5 Equipment. The following equipment or its equivalent will be required. 409.5.1 Distributor. Equipment shall be in accordance with Section 407. 409.5.2 Broom. A vacuum type power broom shall be used for removing loose material from the surface to be treated and for removing loose aggregate after work is completed. The broom shall have a minimum suction area of 150-inch2 and air velocity in the nozzles of 175 mph. The broom must also be equipped with plastic bristles with a positive means of controlling vertical pressure. 409.5.3 Rollers. A minimum of two self-propelled oscillating-type pneumatic-tire rollers shall be required to roll aggregate after spreading. A minimum of three complete passes shall be made. The pneumatic tire rollers shall be self-propelled with smooth-tread pneumatic tires of equal size staggered on the axles at such spacing's and overlaps as will provide uniform pressure to seat the cover aggregate into the bituminous material without fracturing the aggregate particles. The pneumatic-tire rollers shall weigh from 5 to 8 tons, shall be operated at a speed not to exceed 5 mph (440 feet per minute), shall have a minimum contact pressure of 80 psi, and shall have a total compacting width of not less than 5 feet. The Contractor shall provide a manufacturer's chart indicating that regarding tire size, pressure, and loading that the contact pressure established by the Engineer is being met prior to use. 409.5.4 Aggregate Spreader. The aggregate spreader shall be a self-propelled mechanical spreader, equipped with positive controls capable of accurately measuring and uniformly distributing aggregate at a prescribed rate in a single-pass operation over the applied bituminous material. Operation of aggregate spreaders at speeds, which cause aggregate to "roll over" after striking the emulsion-covered surface, will not be permitted. Aggregate spreaders will not be operated on uncovered crumb rubber modified asphalt cement. The Engineer, prior to the aggregate spreaders use, shall approve the calibration of the spreaders, and the Contractor shall furnish all calibrated equipment (including direct reading, top loading scales), material, and assistance necessary. The aggregate spreaders shall be calibrated in accordance with ASTM D5624, in the presence of the Engineer, and before operation on the project. The aggregate moisture content and gradation shall be known and approved before calibration begins. The spreader shall be adjusted until all of the gates are dropping the correct amount of aggregate, plus or minus one pound per square yard of the design application rate in both the transverse and longitudinal directions. 409.5.5 Hauling Equipment. Hauling equipment shall be operated in a prudent manner and at moderate speeds that will not damage the new chip seal or create a hazard to the traveling public. Trucks that transport aggregate shall be legally licensed, in good working condition, have beds that are free from detrimental foreign matter and be equipped with the safety devices required by the United States Department of Transportation. All loads shall be covered with a tarpaulin in accordance with Section 404.14. 7/1/2015
409-2
Seal Coat
409.5.5.1 Haul trucks shall be compatible with the aggregate spreader so that the dump bed will not push down on the spreader when fully raised or have too short of a bed which results in spilling while dumping into the receiving hopper. 409.6 Job Mix Formula. No sooner than 14 calendar days before and no later than the Modified Asphalt Seal coat Pre-Construction meeting, the Contractor shall submit to the Engineer, the mix design(s) and samples from all suppliers furnishing a minimum of the following materials with corresponding Material Safety Data Sheets (MSDS) and Certified Test Reports. Sampling of the material will be under direct supervision of the Engineer. Materials
Amount
Aggregate for Polymer Modified Asphalt Seal coats
50 pounds per each stockpile
Coated Aggregate for Polymer Modified Asphalt Seal coats
50 pounds per each stockpile
Aggregate Bituminous pre-coating
Certification and Test Report for each tanker load
Specified Binder
Certification and Test Report for each tanker load
409.6.1 The Engineer will have no less than 14 calendar days to evaluate the mix design submittals from the date they are received. The mix design shall contain all design computations for application rates and the following information: 1)
Source, binder grade, and certified test results for the pre-coating asphalt cement binder.
2)
Source, binder grade, and certified test results for the ground scrap tire modified asphalt cement binder.
3)
Source, identification of SBS modifier, percent of modifier by mass of binder and certified test results for the binder modifier.
4)
Supplier, certifications, and test reports for the shredded crumb rubber (b) Source, type (formation, etc.), ledge number if applicable, density and, gradation of each aggregate specified.
5)
The certified test results for each aggregate type specified.
6)
Mix Design method and computations.
7)
The loose unit weight of each aggregate type specified.
8)
The amount, type, manufacturer, and application rate of binder material used to precoat the lightweight aggregate as specified in the contract documents.
7/1/2015
409-3
Seal Coat
9)
The amount, type, manufacturer, and application rate of liquid anti-strip material used with binder material to pre-coat the lightweight aggregate as specified in the contract documents.
10) The percent, type, manufacturer, and design target modified binder application rate and operating tolerance in gallons per square yard for each aggregate type as specified in the contract documents. 11) The amount, type, manufacturer, and application rate of liquid anti-strip material used with the modified binder as specified in the contract documents. 12) The aggregate application rate, pounds per square yard for each aggregate type as specified in the contract documents. 409.6.2 The application rates shall not vary from the mix design by more than the following amounts: Material
Tolerance
Asphalt Binder
± 0.02 gal./yd2 or as per Section 409.3.1
Aggregate
± 10 percent of the design target application rate
409.7 Quality Control. The Contractor is responsible for the quality control sampling and testing. The Contractor shall furnish to the Engineer, for each aggregate type (and source) specified in the contract, test results for soundness, wear, deleterious substances, sieve analysis, and crumb rubber modified asphalt rubber content and binder properties from a certified testing laboratory no later than the pre-construction meeting. The Contractor shall notify the Engineer with 24 hours of pre-coating aggregate operations. 409.7.1 Aggregate Stockpiles. All sampling, testing, and reporting submittals to the Engineer are to be at the Contractor’s expense. The Contractor's AASHTO accredited laboratory shall sample stockpiles in accordance with ASTM D 75 and perform Sieve Analysis Tests in accordance with ASTM C 136 from representative samples of the first 500 tons or less stockpiled at each approved site and for every 1,500 tons produced. Material type, source name, referenced test method, results, and dated laboratory manager signature shall be on test reports provided to the Chief Materials Engineer within 3 calendar days of sampling. 409.7.2 Bituminous Materials. Only bituminous materials from sources that provide quality control test results and certifications from an AASHTO approved laboratory, for each tanker load of material used on the project may be used. Supplier name, plant location, grade of cement and batch number is to be included on all test reports. Test reports and certifications shall be provided to the Engineer before material is applied on the job site. 409.7.3 Application Rates. The Contractor shall provide the Engineer daily reports of the aggregate application rate and crumb rubber modified asphalt cement application rate. At the end of daily production the Contractor and the Engineer will determine the surface yardage applied for that day and agree to that daily quantity before start of production the next day.
7/1/2015
409-4
Seal Coat
409.7.4 Reduction in Payment. Failure to provide test reports to the Engineer as required will result is suspension of payment until all test reports are submitted. Test reports that indicate failing gradations shall cause the work to cease until the Contractor provides the Engineer assurances that the problem has been resolved. No suspension of workdays will be granted during this suspension other than for those weather-related. 409.8 Construction Requirements. 409.8.1 Test Strip. A test strip 500 feet long and the width of one lane shall be conducted on a contract site using the methods and equipment that will be used during full production. A test strip shall be provided for projects that exceed 100,000 yd2 of each aggregate type specified in the contract documents. Test strips shall be performed after spreader and distributor calibration is approved, on a non-holiday weekday and no sooner than 48 hours prior to the anticipated start date. The test strip will be evaluated for 24 hours after placement and will be subject to approval from the Engineer before any further production. The Engineer may allow the distributor to be calibrated during the test strip. However, if the distributor fails to achieve proper calibration the contractor shall make the appropriate adjustments and another test strip will be performed. The test strip will be evaluated in accordance with Section 409.7. If unsatisfactory, the test strip shall be removed and another strip placed for evaluation at the Contractor's expense. 409.8.2 Weather Limitations. Seal coat damaged by rain during the first 24 hours after completion shall be resealed at the Contractor's expense. Bituminous material shall not be applied on a wet surface and shall not be applied: 1) When either the pavement or air temperature is below 70°F (temperatures shall be obtained in accordance with MoDOT Test Method TM 20) 2) When the air temperature is above 100°F. 3) Within one hour of sunset. 4) Before June 1 or after September 30. 5) When other weather conditions would prevent the proper construction of the sealcoat. 409.8.3 Preparation of Surface. Immediately before applying the modified asphalt cement, any loose material, grease, and other petroleum distillates, dirt, clay, or other objectionable organic or inorganic materials shall be cleaned and removed from the surface to be sealed. Cleaning shall be performed by sweeping, flushing, or other means necessary to remove all objectionable material from the pavement surface and shall be in compliance with all Federal, State, and local ordinances. The Contractor shall use an industry-approved acrylic sealer for oil spot treatments that cannot be removed by water blasting or other Engineer approved methods. Water in cracks shall be allowed to thoroughly dry before the application of the modified asphalt cement material. Material removed from the surface shall not be mixed with cover aggregate. The surface to be treated shall be clean and dry as approved by the Engineer.
7/1/2015
409-5
Seal Coat
409.8.4 Protection of Utility Appurtenances. The Contractor shall be responsible for furnishing and placing masking materials over all sewer, utility and traffic control device covers and inlet grates located in the roadways to be treated. All such materials shall be removed and disposed of after the surfacing material has cured. Utility covers shall then be cleaned to their pre-surfacing condition. All aggregate swept (mechanically, by traffic, or by rain) into curb and grated inlets, storm, sanitary and combination sewer manholes or inlets and utility valve boxes shall be removed at the Contractor's expense and to the satisfaction of the Engineer. 409.8.4.1 Existing Manholes and Inlets. Any damaged manhole frame, cover, inlet sill or lid, or any damaged brickwork, resulting from the Contractor's operations, shall be replaced or repaired. Prior to final acceptance of the project, the Contractor will be responsible for obtaining and submitting to the Engineer an acceptance letter or other suitable documentation indicating satisfactory repair, by the appropriate sewer district, for all storm and sanitary structures within the construction area. No direct payment will be made for compliance with this provision. 409.8.4.2 Adjustment of Utilities. The Contractor is advised that St. Louis County Department of Transportation Operations Division, the Missouri Department of Transportation (MoDOT) (signals and lighting), gas and water utility jurisdictions have existing valve boxes or other utility appurtances that may need adjustment to grade or relocation. The Contractor shall be responsible for contacting the appropriate utilities at least 5 full working days, but not more than 10 working days to avoid delays in making necessary adjustments, providing the street names and specific date's construction will be performed. The Contractor is also advised that he is responsible for making any required adjustments to existing water service valves. No direct payment will be made for these items and the cost shall be incidental to other items bid. 409.8.5 Application of Modified Asphalt Cement. The modified asphalt cement shall be applied by means of a pressure distributor in a slow, uniform, continuous spread, without missing or overlapping, at a truck speed consistent with the placement of the cover aggregate. Unless otherwise specified, the polymer modified asphalt shall be applied to one-half the width of the surface at a time, with the center lap of the application placed at the lane line of the traveled way and kept as narrow as practicable. The adjacent lane shall be left open to traffic. Modified asphalt binder shall not be applied at a distance greater than it can be immediately covered by aggregate within one minute after modified binder application or as approved by the Engineer if field conditions warrant. The modified asphalt cement shall be applied within the temperature range specified in Section 1015.3.2.5. 409.8.6 Irregular Areas. Cul-de-sacs, intersections, turn lanes and other irregular areas shall not have modified cement applied in an area greater than it can be immediately covered by aggregate within five minutes after modified binder application or as approved by the Engineer if field conditions warrant. 409.8.6.1 If the sealcoat is to be placed on a newly applied bituminous surface, the placing of the sealcoat will not be permitted until the underlying bituminous course has cured a minimum of 30 calendar days, or as directed by the Engineer.
7/1/2015
409-6
Seal Coat
409.8.6.2 The application rate of polymer crumb rubber modified asphalt cement for the chip seal shall be within the limits in Section 1015.3.2.5. A minimum of 200 gallons of crumb rubber modified asphalt cement shall remain in the distributor tank at all times except for the last application on the project. The modified asphalt binder should be uniformly applied through the pressure distributor at a temperature specified in Section 1015.3.2.5. The temperature used for spraying at a given spray bar pressure should not be that which causes fogging or foaming when the asphalt cement leaves the spray bar. 409.8.6.3 The angle of the spray nozzles between 15 and 30 degrees, fan nozzle width and the 12-inch spray bar height shall be set to provide a triple coverage fan pattern and shall be approved by the Engineer. 409.8.6.4 To insure uniform application of the polymer modified asphalt cement at the beginning of each distributor load, a portion of the roadbed surface shall be covered with building paper. The area covered by the building paper shall be in accordance with ASTM D 6380, Class S, Type IV with a minimum weight of 50 lb./100 ft.2 and used at the starting point for each distributor load or each part of a load after a temporary delay. If the cut-off is not positive on the distributor, the use of paper shall be required at the end of each spread. For the next application, the leading edge of the paper is placed within ½ inch of the cut off line of the previously laid treatment. The paper shall be removed and disposed of in an approved manner. The distributor shall be moving forward at proper application speed when the spray bar is opened. A hand spray shall be used to apply asphalt necessary to touch up all spots missed by the distributor. Any skipped areas or deficiencies shall be corrected. Junctions of spreads shall be carefully made to insure a smooth riding surface. The application of asphalt on adjacent Portland cement concrete or bituminous pavements, curbs, bridges, or any areas not specified to be sealed shall be avoided. The Contractor shall immediately clean up any such spills to the satisfaction of the Engineer. 409.8.6.5 From 4 to 6 inches of the centerline edge of the initially treated lane shall be left uncovered with aggregate to allow for an overlap of asphalt binder when the remaining half of the surface is treated. The Contractor will be required to remove the excess material occurring as a result of dual application of product along construction seams. 409.9 Application of Cover Aggregate. Operations shall proceed in such a manner that modified asphalt cement material will not be permitted to chill, set up, dry or otherwise impair retention of the cover aggregate. Spreading shall be accomplished in such a manner that the tires of the trucks or aggregate spreader at no time contact the uncovered and newly applied bituminous material. Application of cover aggregate shall take place no more than one minute after application of the heated modified asphalt cement. The cover aggregate shall be spread by means of a self-propelled mechanical spreader accurately measuring and uniformly spreading the aggregate. All portions of the surface not covered by mechanical spreaders shall be hand applied such that the entire surface will be uniformly covered. Light hand brooming may be necessary to distribute excessive aggregate. 409.9.1 Cover Aggregate Application Rate. The quantity of cover aggregate to be used may not exceed 27 lb./yd2 for Trap Rock or 10 lb./yd2 for coated Haydite, but will depend on the application rate determination method and actual specific gravity of the material used.
7/1/2015
409-7
Seal Coat
409.9.1.1 Application Rate Determination Method. The McLeod design method, computations, and exact rate shall be determined in the Contractor's submitted mix design and as approved by the Engineer. The calibrated scale used to determine the application rate shall be able to measure weight to the nearest 0.1 pound. The application rate design computations shall be submitted to the Engineer for review no later than at the pre-construction meeting. 409.9.1.2 Material Invoices and Scales. Material invoice tickets indicating weight delivered, weighed in accordance with Section 304.4.3, shall be submitted to the Engineer for each load used. All scales used to weigh materials incorporated into St. Louis County Department of Transportation projects must display a current inspection sticker from the Missouri Department of Agriculture approved private scale firm. These stickers are valid for one year, and then the scales must be re-inspected. The Contractor should be aware that the Engineer will not make payment for materials weighed on scales that do not display a current inspection sticker. 409.9.1.3 Aggregate Moisture. exceed 2.0 percent by weight.
The moisture content of the aggregate shall not
409.9.1.4 Aggregate Placement. Spreading shall be accomplished in a continuous manner, without stopping between trucks, and in such a manner that the tires of the trucks or aggregate spreader at no time contact the uncovered and newly applied crumb rubber modified asphalt cement. All portions of the surface not covered by mechanical spreaders shall be hand applied so that the entire surface will be uniformly covered. Light hand brooming may be necessary to distribute excessive aggregate. Previously used (sweeping) aggregates will not be permitted. 409.10 Aggregate Rolling. Rolling shall begin immediately behind the spreader and shall consist of at least three complete coverages with the pneumatic tire roller. Initial rolling shall consist of one complete coverage and shall begin immediately behind the spreader. Initial rolling shall be completed within 15 minutes of the time that the aggregate was spread. Aggregate shall not be spread more than 1,000 feet ahead of completion of initial rolling operations. The second roller shall be used for the remaining complete coverages to smooth and adequately seat the aggregate. Rolling shall continue until a smooth, thoroughly compacted surface is obtained. All rolling shall be completed the same day that the cover aggregate is applied. Rolling shall proceed in a longitudinal direction, beginning at the outer edges of the treated surface and working toward the center. Each pass by the roller shall overlap the previous pass by one-half the width of the front wheels. 409.11 Brooming. After the embedded aggregate has set, the surface shall be lightly broomed before opening to unrestricted traffic flow. Sweepers will not be allowed on the pavement until treatment has cured eight (8) hours. All loose aggregate shall be removed from the pavement, driveways and side streets using a power broom with light pressure, or a hand broom within 24 hours after initial surface treatment. Subsequent brooming the following three days may be directed by the Engineer to ensure that the surface is free of loose aggregate that could cause vehicle damage. Pavement surfaced on a Friday will be swept on Saturday. Roads that are not swept within 24 hours of initial treatment, to the Engineer’s approval, will cause sealcoat application operations to cease and working days to be charged until all sweeping operations are complete. Maintenance of the surface shall include distribution of aggregate over the surface to absorb any free crumb rubber modified asphalt cement, to cover any area deficient in cover aggregate, and to prevent the formation of corrugations. Clean sand may be used in lieu 7/1/2015
409-8
Seal Coat
of cover aggregate to blot any excess of crumb rubber modified asphalt cement that comes to the surface. Generally, the surface maintenance shall be confined to the cooler hours of the day and shall be conducted so as not to displace embedded material. The surface shall be free of excess aggregate at the time of acceptance of the work (Final Inspection). 409.11.1 Excess Aggregate Disposal. Excess aggregate, which in the opinion of the Engineer is not salvable and which interferes with drainage, shall be removed and disposed of by the Contractor at the Contractor’s expense. A Final Inspection will not be held until all utility valve boxes and storm, waste, or combination inlets have been cleaned of aggregate or binder from the sealcoat operation and approved by the Engineer. 409.12 Traffic Control and Safety. In addition to the requirements of Section 107.5.1, the Contractor shall submit to the Director a complete schedule of his intended operations, listing by street names his schedule of operations so that County forces will have an opportunity to perform any preparatory work that may be required. If this preparatory work is not completed before the Contractor moves into an area, the Engineer may postpone the Contractor's work in that area until such a time that the preparatory work is completed. No reimbursement will be made for any inconveniences or time lost because of the postponement. 409.12.1 Traffic Control Maintenance. The Contractor shall maintain traffic control signs until all loose aggregate has been removed. The Contractor's supply trucks shall observe the traffic controls. 409.12.2 Traffic Control Approval. In all cases, the Contractor shall notify the Engineer, sufficiently in advance of operations, in order to provide for suitable inspection of the preparation work performed by the Contractor. In no case will the Contractor be permitted to begin operations without prior approval by the Engineer. 409.12.2.1 The traffic control device and locations shown on the traffic control standard drawings are for pictorial purposes and approximate quantities only and are not to be taken as the actual quantities and locations of the devices. The quantities and locations of these devices shall be as approved by the Engineer. Payment shall be made at the contract unit price bid for each of the pay items included in the contract. 409.12.3 No traffic shall be permitted on the sealcoat until all rolling has been completed. On roads where the posted speed limit is above 25 mph, the Contractor shall control traffic by means acceptable by the Engineer. The Contractor’s supply trucks shall observe these traffic controls. The Contractor will be required to cover existing speed limit signs with "20 MPH" plates until the roadway has had its' final sweeping application. 409.12.4 Traffic Control Sign Placement. The beginning and end of the work zone shall have the following signs posted: "Flagger Ahead", "Fresh Oil", "Loose Stone", "Travel at Own Risk", and "Road Construction Ahead". All side streets shall have "Road Construction Ahead" signs placed as directed by the Engineer and all signs shall conform to Section 1063 Construction Signs. All signs shall be installed on permanent holding frames, one-foot above ground and shall remain in place at each job site until all sweeping operations are complete. Signs shall be safely installed so as to not block vehicle or pedestrian line of sight and shall be resistant to wind gusts.
7/1/2015
409-9
Seal Coat
409.12.5 Flaggers. When traffic cannot be detoured, flaggers, equipped with 2-way handheld radios and in accordance with Section 612.30.2, shall assist traffic and pilot cars through the project in a manner that provides safety for the traveling public, workers, and equipment while imposing minimal interruption of the work. When applying sealcoat to Arterial roads and intersections, lanes shall be coned off for safety and traffic control during daylight hours. Cones shall conform to Section 616.3.1. 409.12.6 Worker Safety. Safety precautions shall be used at all times during progress of the work. Workers shall be equipped as required by the Manual on Uniform Traffic Control Devices (MUTCD). 409.12.7 Resident Notification. The Contractor shall be responsible for prior notification of residents regarding access restrictions and for no parking on streets during sealcoat operations. In cases where on-street parking exists, the Contractor shall furnish and install "No Parking" notices a minimum of 24 hours in advance of sealcoat operations. All such signs shall clearly indicate the duration of the parking restriction. 409.12.8 Rush-hour restriction on required road sections will be stated in the contract documents and will be enforced. No sealcoat work will be permitted on these roadways from 7:00 a.m. to 9:00 a.m. and from 4:00 p.m. to 6:00 p.m. on weekdays. 409.12.9 Temporary Lane Markers. Temporary lane markers shall be supplied and installed by the Contractor in accordance with Section 620.70. 409.12.10 Permanent Striping. The County will apply permanent paving striping and markings after completion of sealcoat operations. 409.13 Basis of Acceptance. The Engineer, based on the following criteria, will evaluate sealcoat. Any of the following may be grounds for rejection: 1) During normal traffic operations, the presence of any loose stone that may be picked off the surface by vehicles. 2) During normal traffic operations, the presence of dusts that are a nuisance to adjoining properties or impairs visibility. 3) During normal traffic operations, the presence of any bleeding or moderate tracking. 4) Transverse or longitudinal construction joints from the chip seal application that are not straight and uniform and create a bump or poor riding joint. 5) An asymmetric appearance seen in a chip seal surface characterized by longitudinal grooves or ridges in the surface. 6) A surface not having complete aggregate coverage with holes or failures in the surface.
7/1/2015
409-10
Seal Coat
409.14 Method of Measurement. 409.14.1 Measurement of ground-tire modified asphalt cement, to the nearest 10 gallon, will be made at the job site as specified in Section 1015.6. 409.14.2 Measurement of cover aggregate will be made in accordance with the applicable requirements of Section 304.4 and be computed to the nearest square yard. At the end of daily production the Contractor and the Engineer will determine the surface yardage applied for that day, compare the computed weight of aggregate and modified binder with the inplace amount, and agree to that daily quantity before start of production the next day. Final measurement of the completed surface will not be made except for authorized changes during construction, or where appreciable errors are found in the contract quantity. Appreciable error shall be defined as ± 2 percent of the total contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. 409.15 Basis of Payment. 409.15.1 The accepted quantities of sealcoat will be paid for at the contract unit price for each of the pay items included in the contract. No direct payment will be made for traffic control or placing and removing "No Parking" signs. No additional payment will be made for: Quality Control Testing; removing and replacing test strips; supplying, applying and removing sand blotter material; general clean-up; quality control sampling, testing and reporting; mix design; and other incidentals necessary to complete and warrant the job as specified herein. No separate payment will be made for pre-coating aggregate. The quantity of crumb rubber modified asphalt cement for payment purposes will be the actual gallons (measured or computed) of material used. All work involving the sealcoat work performed under this contract shall be compensated for through the contract prices bid for each of the pay items included in the contract. Reduction in payments in accordance with Section 409.7.4 will be made in the pay period represented by the un-submitted test report. 409.15.2 Traffic Control Devices in accordance with Section 612 of the Department's Specifications will consist of furnishing, constructing and maintaining traffic control and safety devices as directed by the Engineer, shown on the plans or included in the construction contract, addendums or specifications. Directional Barricades shall be approved and used as directed by the Engineer at no additional cost. Directional Barricades shall be NCHRP 350 compliant. Opening to traffic does not constitute acceptance of the work. The accepted quantities for furnishing, installing, maintaining, and removing the contract traffic control devices specified will be paid for at the contract unit prices for each item in the contract.
7/1/2015
409-11
Seal Coat
(This page intentionally left blank.)
7/1/2015
409-12
Seal Coat
Section 410
Micro-Surfacing
410.1 Description. 410.1.1 This work shall consist of the application of micro-surfacing material to asphaltic pavement surfaces. The micro-surfacing shall consist of a mixture of quick set cationic natural or synthetic latex modified asphaltic emulsion, mineral aggregate, Portland cement, setcontrol additives, and water. The micro-surfacing material shall be properly transported, proportioned, mixed, and evenly spread on the asphaltic pavement surface in strict accordance with the plans, these specifications and as directed by the Engineer. In some cases, more than one lift may be required to obtain the specified thickness. Nighttime lighting requirements shall be in accordance with Section 612.80. 410.1.2 The cured micro-surfacing shall have a uniform and homogeneous appearance, substantially fill all cracks, and adhere firmly to the existing surface. The mix shall be capable of being spread in varying thickness cross-sections (wedges, wheel path depressions, scratch courses and surfaces) which, after curing and initial traffic consolidation, resists compaction throughout the entire design tolerance range of bitumen content and varying thickness to be encountered. The end product shall maintain a friction resistant surface (high wet friction coefficient) throughout the service life of the micro- surfacing. 410.1.3 The mix is to be a quick-traffic system, meaning that it will be able to accept traffic after a short period. The completed mixture shall be such that the micro-surfacing mixture has proper workability during lay down and will permit straight running traffic on ⅜ inch thick microsurfacing within one hour after placement at 75°F or greater and 50 percent or lower relative humidity. Micro-surfacing shall be placed without the occurrence of bleeding, raveling, separation or other distress. 410.1.4 Work shall be performed in accordance with the current edition of "Recommended Performance Guidelines for Polymer-Modified Micro-Surfacing", A143 (revised) published by the International Slurry Surfacing Association (ISSA), and ASTM D 6372 Standard Practice for Design, Testing and Construction of Micro-Surfacing, with the modifications specified herein. 410.1.5 Pre-construction Meeting. 410.1.5.1 The Contractor or listed subcontractor shall be experienced and familiar with the application of micro-surfacing. 410.1.5.2 At least 14 calendar days before work is started, the Contractor shall meet with the Engineer in a pre-construction meeting. The Contractor shall submit to the Engineer for approval, during the pre-construction meeting, both a completed mix design, complete as directed in Section 410.4.1. If the Contractor has not performed Micro-Surfacing for the County within the last calendar year, a list of at least 3 projects of Micro-Surfacing, completed by the Contractor or listed subcontractor within the last 24 months. The project list shall show: 1) The name of the project,
9/1/2023 /1/2010
410-1
Micro-Surfacing
2) Name of the project owner, 3) Address and telephone number of an appropriate party to contact, 4) The year of completion, 5) The total square yards completed. This information shall be completed for each project. 410.1.5.3 The Contractor shall submit to the Engineer, during the pre-construction meeting, a typed bar chart schedule for the work, listing the dates and number of contract work or calendar days on which streets, roadways or other locations are to be paved for approval by the Engineer. The Contractor shall provide a traffic control plan (if not included in the plans) that indicates type of signing, spacing of signing, flaggers, channelizers and other traffic control items in accordance with the current edition of the Manual on Uniform Traffic Control Devices (MUTCD). Directional Barricades shall be approved and used as directed by the Engineer at no additional cost. Directional Barricades shall be NCHRP 350 compliant. Local, County, State and Federal laws and ordinances shall be obeyed. No additional cost will be granted for compliance with local ordinances. In addition, issues regarding safety, local events and ordinances, additional traffic control and access by public services shall be discussed. 410.1.5.4 The Contractor shall present samples of materials, laboratory reports and calibration reports as required by these specifications to the Engineer. The Contractor shall furnish three copies of all certifications to the Engineer. 410.1.5.5 The Contractor shall employ operators, foremen and other personnel directly involved in the micro-surfacing placement that each have a minimum of 3 years of experience in the application of micro-surfacing. If the Contractor's personnel have less than three years individual experience with the placement of micro-surfacing, the Contractor may submit a request to the Engineer detailing a formal training program that the personnel have received. 410.1.5.6 A "Notice to Proceed" for the work will be issued to the successful bidder on or before the first of May. No "Notice to Proceed" will be granted until all the above mix design, samples of materials, laboratory reports, calibration reports, personnel experience and project experience information is submitted to the Engineer. Work will commence on a date mutually agreeable to both the Contractor and the Department, and will be completed within the assigned working days from the date of "Notice to Proceed". Liquidated damages will be assessed at a rate of the prescribed rate for each calendar day that items of work under this contract remain uncompleted. 410.1.6 Street Closure. The Contractor will be required to request in writing to the Director, 14 calendar days in advance of work, to close a section of road(s) to apply Micro- Surfacing. If approved by the Director, the closure time limits and closed road(s) length will be stipulated and strictly enforced.
9/1/2023 /1/2010
410-2
Micro-Surfacing
410.2 Materials. 410.2.1 Synthetic or Natural Latex Modified Asphalt Emulsion. 410.2.1.1 Emulsified Asphalt. The emulsified asphalt shall be a quick-traffic, natural or synthetic latex modified grade CSS-1h (cationic) emulsified asphalt conforming to the requirements specified in AASHTO M 208 (ASTM D 2397) or as modified herein. The cement-mixing test shall be waived for this emulsion. The quick set emulsified asphalt grade CSS-1h shall be modified with at least 3 percent approved Natural or Synthetic Latex solids, based on asphalt weight. The use of synthetic latex shall be used with porphyry aggregate and the use of natural latex shall be with slag aggregate. 410.2.1.2 Polymer Modifier. The approved synthetic or natural latex polymer modifier shall be milled or blended into the asphalt or emulsifier solution prior to the emulsification process. The range of synthetic or natural latex solids content shall be from 3.0 percent to 5.0 percent synthetic or natural latex solids by weight of binder (asphalt) within the emulsion. The minimum amount required shall be determined by the laboratory performing the mix design. The asphalt emulsion manufacturer shall certify that each load of emulsion contains the amount of synthetic or natural latex solids as specified in the mix design. 410.2.1.3 Additives. An approved set-control agent shall be added in such a quantity as to produce a one-hour set and shall not vary more than ± 1.0 percent of the quantity specified in the mix design. 410.2.1.4 Residual Binder Content. The emulsified asphalt residual binder content shall be 6.0 to 9.0 percent as measured by the weight of the dry aggregate or as directed by the Engineer. The residual asphalt content shall have a tolerance of ± 0.5 percentage from design and shall not be outside the 6.0 to 9.0 percent limit. Each Bill of Lading for emulsified asphalt shall be accompanied with certified test reports from each batch. The certified test reports shall be submitted to the Engineer prior to use of the emulsion. 410.2.1.5 The emulsified asphalt quick-set synthetic or natural latex modified CSS-1h shall comply with following requirements when sampled in accordance with ASSHTO T40 (ASTM D 140) and shall comply with the requirements Section 1015. 410.2.1.6 The polymer modified emulsified asphalt shall be so formulated that when the paving mixture is applied with the relative humidity at not more than 50 percent and the ambient air temperature of at least 75°F, the paving mixture will sufficiently cure so that uniformly moving traffic can be allowed in one hour. Additional curing time may be required at locations such as driveways, intersections and where sharp turning movements may take place or where vehicles may accelerate sharply. 410.2.2 Mineral Aggregate. 410.2.2.1 The mineral aggregate shall meet Section 1002.1 or as directed by this provision and shall be composed of 100 percent crushed, clean and durable particles such as crushed Porphyry or air cooled blast furnace steel slag (ACBFS) at proportions acceptable by the Engineer to achieve the desired gradation. The mineral aggregate shall be identified by the material type (for ACBFS, the type of steel produced shall be
9/1/2023 /1/2010
410-3
Micro-Surfacing
included), producer's name and location (steel mill if ACBFS) and production dates. The individual aggregates shall be reasonably uniform in gradation and other qualities; shall be uniformly blended with designated proportions using calibrated cold feeds with controlled feeders into a separate stockpile prior to use; and the proportion shall not change from that used for the mix design during the course of placement. The aggregate shall be free of cemented or conglomerated lumps and shall not have any coatings or injurious material. 410.2.2.2 Aggregate shall be screened prior to loading into trucks or the paving machines. 410.2.2.3 ACBFS stockpiles shall be aged for a period of at least 6 months in duration. Age period determination starts over if any new material is added to the pile during the aging period. 410.2.2.4 The aggregate supplied shall be tested in advance of the mix design submittal by the Contractor. The Contractor shall provide the test results to the Engineer with the mix design for review. Aggregate used for this project shall be sampled in accordance with AASHTO T2 (ASTM D 75) and conform to the following requirements when tested in accordance with the specified test methods: Test
Method
Requirement
Sand Equivalent (without mineral filler)
ASTM D 2419
65 minimum b
Abrasion Resistance after 500 revolutions *
ASTM C 131
30 percent maximum
Moisture content of Aggregate
ASTM C 566
as tested
Sieve Analysis (individual and combined)
ASTM C 136
See Section 410.2.2.5
Material Passing No. 200 Sieve
ASTM C 117
as tested
Soundness of Aggregates by use of Sodium Sulfate (or Magnesium Sulfate), 5 cycles
ASTM C 88
15 (25) percent maximum
Aggregate Bulk Specific Gravity (individual and combined)
ASTM C 127
as tested
Unit Weight of Aggregate
ASTM C 29 (AASHTO T 19)
as tested for bulking effect
b
* On parent aggregate before crushing
See Section 410.5.2.2.2. for production tolerance
410.2.2.5 A stockpile(s) of aggregate shall be dedicated for this project. Each stockpile shall be accepted based on the average of five combined samples, tested for gradation according to ASTM D 75 (AASHTO T 2). If the average of the five combined samples test within gradation tolerances (including mineral filler), then the Engineer will accept the materials. Rejected stockpiles of material may not be reworked or blended. Stockpile/production tolerances are applied to the job mix (target) gradation; the
9/1/2023 /1/2010
410-4
Micro-Surfacing
stockpile gradation bands shall be within the grade specified below percent passing limits specified for each sieve and shall be within the gradient band. The Engineer will also reject the stockpile or any production gradation test report if the percent passing goes from the high end to the low end of the range for any two consecutive sieve screens. Aggregate Stockpile/production tolerances are established from the following gradation: Sieve Size
ISSA Type II Grade PERCENT PASSING
Stockpile / Production Tolerances (Percent)
⅜ inch
100
No. 4
90-100
±5
No. 8
65-90
±5
No.16
45-70
±5
No. 30
30-50
±5
No. 50
18-30
±4
No. 100
10-21
±3
No. 200
5-15*
±2
*includes mineral filler 410.2.2.5.1 ACBFS stockpiles shall be tested by the Contractor's laboratory in accordance with Illinois Department of Transportation Test Procedure 202- Leachate Determination in Crushed Slag Samples prior to ACBFS delivery to the designated project site stockpile and shall meet the following requirements for a slag material: 1) No observable color darker than HUE 10Y (Rock Chart-Geological Society of America) 2) If A. passes, test the pH level in accordance with AWWA (15 days) or an approved equal. The pH shall be between 6.5 and 10.0 (The meter should be accurate to ± 0.05 units at 77°F). 410.2.3 Mineral Filler. 410.2.3.1 The Portland cement mineral filler shall be any recognized brand of non-air entrained Type I Portland cement that is free from lumps or foreign matter. The amount of mineral filler needed shall be determined by the laboratory mix design and will be considered as part of the mineral gradation requirement. The mineral filler shall be between 1.0 percent and 3.0 percent by the weight of dry aggregate. The laboratory mix design percentage of mineral filler can be increased or decreased up to 1 percent when directed by the Engineer as the micro-surfacing is being placed if it is found to be necessary for better consistency or set times. The percentage of Type I Portland cement shall be indicated on the mix design. Once production is started any changes in cement brand must be approved in advance by the Engineer. The Contractor will include any changes in cement brand in the daily control log. When the tolerance is
9/1/2023 /1/2010
410-5
Micro-Surfacing
applied to the mix design percentage, the percentages shall fall between 1.0 and 3.0 percent by the weight of dry aggregate. 410.2.4 Water. 410.2.4.1 The water shall meet the requirements of Section 1070, be potable, free of harmful soluble salts, and shall be added in an amount to provide proper consistency. Total water is the moisture taken from the aggregate, the pre-wet water and the water from the emulsion. The total mix design water optimum, maximum and minimum percentage shall be specified in the mix design. When the pre-wet water percentage is applied, it shall not exceed 9.0 percent during production. 410.2.5 Set-Control Agent. 410.2.5.1 To improve workability, a set-control agent that is approved by the Engineer, and will not adversely affect the micro-surfacing, shall be used. The amount of set- control agent, brand name and manufacturer must be included as part of the mix design and be certified compatible with the other components of the mix. This additive shall allow the Micro-Surfacing mixture to cure sufficiently so that normal traffic is permitted in one hour after placement of the Micro-Surfacing mixture, without damage to the new surface. 410.2.6 Polymer Modifier. 410.2.6.1 A polymer based modifier approved by the Engineer, that consists of synthetic or natural Latex shall be milled or blended into the asphalt emulsion. The amount, brand name and supplier of natural latex must be included in the mix design. A blend of natural and synthetic latex is not permitted. The Contractor shall use only one type of polymer modifier with the one corresponding aggregate type during the contract. 410.3 Application Rate. 410.3.1 Micro-surfacing material shall be applied in 2 lifts of 15 lb./yd2 per lift of the dry mass of the combined mineral aggregate on the Arterial Road System (ARS). 410.3.2 Micro-surfacing material shall be applied in one lift of 18 lb./yd2 of the dry mass of the combined mineral aggregate on the County Road System (CRS). 410.3.3 The application rate shall be corrected in accordance with Section 410.4.5 at no additional cost to the County. 410.3.4 Wheel Rut Depression micro-surfacing shall be applied at a rate specified in Section 410.13. 410.4 Composition of Micro-Surfacing Mixtures. 410.4.1 Mix Design. At least 14 calendar days before micro-surfacing placement commences or no later than the time of the pre-construction meeting, the Contractor shall submit to the Engineer for approval, a signed and dated laboratory report of tests and a proposed mix design. The laboratory must be experienced in the design of Micro-Surfacing, recognized by International Slurry Surfacing Association (ISSA) Technical Response
9/1/2023 /1/2010
410-6
Micro-Surfacing
Committee, and approved by the Engineer in advance of the mix design submittal. The recommended percentages of each individual material required shall be shown in the laboratory report. 410.4.2 Source of Each Individual Material. (brand name, manufacturer and recommended percentages or applicable units): 1)
2)
3)
Emulsion a)
Emulsifier;
b)
Natural Latex;
c)
Liquid Asphalt;
d)
Other modifiers;
e)
Water.
Aggregate a)
Target Gradation;
b)
Target Sand Equivalent;
c)
Abrasion Resistance;
d)
Soundness;
e)
Bulk Specific Gravity;
f)
Unit Weight;
g)
IDOT T-202 ACBFS Test report (for ACBFS aggregate only).
Mineral Filler a)
4)
9/1/2023 /1/2010
Cement Type.
Field Simulation Tests a) Cure Time; b)
Wet Cohesion;
c)
Wet Stripping Test;
d)
Wet Track Abrasion Loss (include machine type);
e)
Lateral displacement;
f)
Classification Compatibility;
410-7
Micro-Surfacing
5)
6)
g)
Trial Mix Time at 77°F and 100°F;
h)
Marshall Stability and Flow;
i)
Bulking Effect.
Interpretations of Results and Determination of a Job Mix Formula a)
Mix designs for each mix time at 77°F and 100°F with:
b)
Percentage of Mineral Filler (minimum and maximum);
c)
Percentage of Water, including aggregate moisture (minimum and maximum);
d)
Percentage of Mix Set Control additive;
e)
Percentage of Synthetic or Natural Latex (minimum);
f)
Percentage of Modified Emulsion (minimum);
g)
Target percentage of Residual Content of Modified Emulsion.
Signature and Date a)
Laboratory Manager Name, signature and date;
b)
Contractor designated representative name, signature and date.
Adjustments of water and set-control agent by the Engineer may be required during construction based on field conditions. The Engineer shall approve the design mix and all micro-surfacing materials and methods prior to use and shall designate the proportions to be used within the following limits: Latex Emulsified Asphalt Residue
6.0 percent to 9.0 percent by dry weight of aggregate
Mineral Filler
1.0 percent to 3.0 percent by dry weight of aggregate
Latex-based Modifier
3.0 percent minimum synthetic or natural Latex solids based on weight of binder (asphalt and rubber)
Total Water a
Percent based on dry weight of aggregate, as designed, with specified operating tolerances
Set-control Agent
As needed; Engineer approved system to provide one hour set
a
9/1/2023 /1/2010
Total Water shall include water content from aggregate, from the emulsion and mixing (pre-wet) water added.
410-8
Micro-Surfacing
410.4.3 Compatibility of the aggregate, polymer-modified emulsion, mineral filler and other additives shall be verified by the mix design. The mix design shall be performed by a laboratory capable of performing all of the current applicable International Slurry Surfacing Association (ISSA) tests at one location. The Engineer, in advance of the mix design submittal, shall approve the mix design laboratory. The mix design shall be made with the same aggregate sources(s), blend, gradation, and synthetic or natural latex-modified binder that the Contractor will be using on the project. The Engineer may disqualify any mix design submitted by any laboratory whose capability or experience with Micro-Surfacing cannot be verified. The proposed Latex-modified Micro-Surfacing mixture to be used for this project shall conform to the requirements specified when tested in accordance with the following tests: ASTM TEST
DESCRIPTION
REQUIREMENT
ASTM D 1559 AASHTO T 245 (modified)1
Marshall Stability and Flow1
1,800 lb. minimum and 6 to 16 units
D 3910
Cure time
1 hour maximum
ISSA TEST TB 139
Wet Cohesion: 30 minutes (set time)
12 kg-cm minimum (Normal)
60 minutes (traffic time)
20 kg-cm minimum (Or near spin, spin or Solid spin)
TB 114
Wet Stripping
Pass (90 percent minimum)
TB 100
Wet Track Abrasion One hour soak, loss
50 g/ft2 maximum
Six day soak, loss
75 g/ft2 maximum
ISSA TB 147, Method A
Lateral Displacement by LWT
5 percent, Maximum
ISSA TB 144
Classification Compatibility by the use of SchulzeBreuer
11 Grade Points, Minimum (AAA, BAA)
TB 113
Mix Time @ 77°F
TB 113
Mix Time @ 100°F 1
9/1/2023 /1/2010
Controllable to 120 seconds minimum Controllable to 45 seconds minimum
Air drying of the mixture at 70°F to 77°F for three days before reheating and placing the materials in the test molds is permitted.
410-9
Micro-Surfacing
410.4.4 The mix design report shall be reported on the testing laboratory's letterhead, signed by a manager of the laboratory that performed the tests and shall show the results of each of the required tests compared to the specification values. The Contractor name, St. Louis County Project Name and Number, date and time of collection and location of sample collection shall be noted on the report. Any test values out of specification shall be clearly noted. The report shall clearly state a recommendation of the proportions of the mineral aggregate, mineral filler, water (minimum and maximum, free water not to exceed 9 percent), set-control additive (minimum and maximum), and asphalt solids (target extraction) content (minimum and maximum) within project limits, based on the dry weight of the mineral aggregate. The contract and corrected aggregate spread rate shall also be included in the report. The laboratory shall also report the quantitative effects of moisture content on the unit weight of the mineral aggregate (bulking effect- weight of dry aggregate per volume of moist aggregate). 410.4.5 The minimum dry mass per unit area is based on a bulk specific gravity (BSG) of 2.65. In the event that crushed steel slag aggregate is used as a part of the blended aggregate, or as the entire aggregate, the BSG of the final aggregate blend shall be determined and shown as part of the mix design criteria. If the BSG is different from 2.65 by more than 0.05, the above minimum masses shall be adjusted by dividing the specified unit mass by 2.65 and multiplying by the new BSG, e.g., for a new BSG = 3.15 and a specified unit mass of 15.0 lb./yd2, the new minimum would be 3.15[15.0/2.65] = 17.8 lb./yd2. These adjusted values shall be designated on the mix design and shall apply in the field. These adjusted values shall be designated on the mix design and shall then be applied in the field. 410.4.6 The mix design will further show recommended changes in Type I Portland cement, water and additive proportions for high temperature weather conditions by reporting proportions of materials required for mix time with materials heated to 100°F. This elevated temperature mixing report will not be required for nighttime application. 410.4.7 All of the component materials used in the mix design shall be representative of the materials to be used on the project. Once the proportions of materials to be used are approved by the Engineer, no substitutions of other materials will be permitted, unless the materials proposed for substitution are first tested and a laboratory report is submitted for design approval by the Engineer as specified above. Substituted materials shall not be used until the Engineer approves the mix design for those materials. 410.4.8 The job mix (target) gradation shall be within the gradation band for the desired type. After the target gradation has been submitted and approved (this should be the gradation that the mix design is based on), the percent passing of each sieve shall not vary more than the stockpile tolerance specified in Section 410.2.2.5 for each individual sieve, and still remain within the gradation band. The percent passing shall not go from the high end to the low end of the range for any two consecutive screens. 410.5 Material Sampling and Testing Quality Control Responsibilities. 410.5.1 The Contractor shall submit to the Engineer samples from all suppliers furnishing a minimum of the following materials with corresponding Material Safety Data Sheets (MSDS) sheets. Materials that appear on the Missouri Department of Transportation's (MoDOT) approved Product Approval List (PAL) will not require pre-approval sampling, with the exception of the mineral aggregate. The stockpiled aggregate is to be sampled by the
9/1/2023 /1/2010
410-10
Micro-Surfacing
Engineer in the presence of the Contractor after the supplier’s stockpile meets the requirements of Section 410.2.2.5. Materials to be submitted and the quantity required are: 1 gallon of the synthetic or natural latex modified asphaltic emulsion in plastic quart containers 100 pounds of combined micro-surfacing mineral aggregate in bags not to exceed 35 pounds 35 pounds of each parent mineral aggregate 6 pounds of non-air entrained Type I Portland cement mineral filler (with supplier label) 410.5.2 Quality Control. The Contractor is responsible for production quality control sampling and testing. The Contractor shall be responsible for scheduling all laboratory mix sampling and testing, and for furnishing all test results to the Engineer. The final project report shall indicate "FINAL REPORT" in the remarks area of the report. A semi-final inspection shall not be conducted until the Engineer receives all test reports. The report formats shall be as follows: 410.5.2.1 Emulsion. 410.5.2.1.1 The Contractor shall provide material certification and quality control test results for each batch of emulsion used on the project. A bill of lading shall be supplied for each tanker load. All material certifications and quality control test results shall include: 1) Supplier Name; 2) Plant Location; 3) Project Name and Number; 4) Emulsion Grade; 5) Batch Number; 6) Residual Asphalt content; 7) Minimum Synthetic or Natural Latex content percent; 8) The emulsion must meet all requirements of this specification. 410.5.2.2 Aggregate. Aggregate shall be sampled from the Micro-Surfacing machine. 410.5.2.2.1 The Contractor shall run gradation tests in accordance with AASHTO T 11 and AASHTO T 27 as per Section 410.5.2.2. Companion samples shall be provided upon the request of the Engineer. The quality control tolerances for the job mix formula are listed in Section 410.2.2.5. The Contractor's approved laboratory representative, in the presence of the Engineer, shall take a minimum of one
9/1/2023 /1/2010
410-11
Micro-Surfacing
representative aggregate sample every day of production. Determine the gradation (including mineral filler), sand equivalence and moisture content. 410.5.2.2.2 The Contractor shall determine the Sand Equivalent according to AASHTO T 176 for each aggregate gradation test at the stockpile site. Quality Control tolerance is ± 7 of the value established in the mix design (65 minimum). 410.5.2.2.3 The Contractor shall determine the moisture content daily. The stockpile shall have a minimum moisture content of 2.0 percent. 410.5.2.2.4 Report the results to the Engineer the same day the sample is taken. Each aggregate sample should have a minimum weight of 25 pounds and shall be sampled from five locations around the machine bin using a sand thief or other approved device. 410.5.2.3 Production Asphalt Content. 410.5.2.3.1 Calculate and record the percent residual asphalt content of the mixture from the equipment counter readings, randomly, a minimum of three time per day of production. The quality control tolerance is ± 0.5 percent for a single test and the average daily asphalt content is ± 0.2 percent from the job mix formula. The residual asphalt content and asphalt temperature shall also be reported on the Contractor's daily report and verified by the Engineer. 410.5.2.4 Production Aggregate Quality. 410.5.2.4.1 The sampling and testing of the latex-modified Micro-Surfacing aggregate by the Contractor's approved laboratory will result in a report submitted to the Chief Materials Engineer by facsimile, to the attention of the Chief Materials Engineer at (314) 615-1190, within 24 hours after aggregate sampling. A companion sample shall be provided to the Engineer with the submitted test report when requested. The report shall be included in the Contractor's daily report. The report shall contain the following information:
9/1/2023 /1/2010
1)
Project name and number;
2)
Sample street name and address;
3)
Date sampled;
4)
Sampling and testing personnel names;
5)
Laboratory name and address;
6)
Material type;
7)
Source name;
8)
Referenced test method, specification limits and results for each test (gradation, moisture and sand equivalent);
410-12
Micro-Surfacing
9)
Dated laboratory manager signature shall be on all test reports provided;
10)
Failure to comply with this requirement shall result in the immediate stoppage of work. Failure of a test report may require removal of material placed or nonpayment for the area represented by the test, as directed by the Engineer. Payment for each authorized test report will be made at a contingent unit price of;
11)
Test Report on aggregate: $200 per test report;
12)
If the Engineer determines that the material is to be left in-place, a reduction of payment for gradation outside the production tolerance will result in the reduction of the contract price in accordance with Section 410.5.3.
410.5.3 Schedule of Price Reduction for Micro-Surfacing. 410.5.3.1 Failing aggregate gradations will result in a contract price reduction for work performed for that day. 410.5.3.1.1 The contract price for Micro-Surfacing will be reduced by 1 percent for each 1 percent passing outside the production tolerance requirements for the No. 4 sieve, No. 8 sieve, and No. 16 sieve. 410.5.3.1.2 The contract price for Micro-Surfacing will be further reduced by 1 percent for each 0.1 percent passing outside the production requirements for the No. 200 sieve. Laboratory testing report shall be in accordance with Section 410 4.4 of this provision and will determine: 410.5.3.2 Tests on Mineral Aggregate: Sieve Analysis, Sand Equivalent, Moisture Content as per Section 410.2.2.4 and spread rate. 410.5.3.3 Failing residual asphalt content will result in a contract price reduction for work performed for that day. The Contract price for Micro-Surfacing will be reduced by 1 percent for each 0.1 percent passing outside the ± 0.5 percent from the target established in the mix design. 410.5.3.4 Failing Sand Equivalent will result in a contract price reduction for work performed for that day. The Contract price for Micro-Surfacing will be reduced by 1 percent for each 1 percent passing outside the ± 7 percent tolerance of the value established in the mix design (65 minimum). 410.5.3.5 Failing aggregate application spread rate that exceeds ± 2 lbs./yd2 of the adjusted contract spread rate for work performed for that day, will result in a shut-down of the Contractor’s operations. The Contractor shall adjust placement operations as necessary to maintain production tolerances before placement the next workday. 410.5.4 Copies of all material load tickets and certified test reports shall be given to the Engineer prior to use of the material on the project. A certified analysis (test report) of each emulsified asphalt batch shall accompany each shipment of emulsion to the Contractor, and the exact residual asphalt cement content of each tanker shall be plainly marked on the load tickets.
9/1/2023 /1/2010
410-13
Micro-Surfacing
410.5.5 The Contractor shall furnish to the Engineer a daily aggregate moisture determination for the stockpile before placing the Micro-Surfacing. The Contractor shall notify the Engineer one business day in advance of when any new stockpiled aggregate material is ready for sampling and testing. 410.5.5.1 The Engineer shall perform the initial moisture content and gradation tests for each new stockpile. Sampling and moisture content shall be re-tested by the Contractor on delivery of new aggregate to the stockpile or if weather conditions have changed the aggregate moisture content appreciably. Aggregate moisture will be accounted for in determining the aggregate/bitumen ratio to be used during placement. 410.5.6 The Contractor shall provide 3 copies of a daily control log, electronic and/or hard copies, kept in accordance with ISSA Technical Bulletin No. 107, Micro-Surfacing Contact Log Form or an Engineer approved equal, to the Engineer before start of the next day's production. The log shall contain: 1)
Date, weather and air temperature at start up and completion;
2)
County Project Name and Job Number;
3)
Beginning and Ending Street name or address for the day’s work;
4)
Length, width and total area covered for that day;
5)
Control Settings, Calibration values, percent residue in emulsion;
6)
Head Pulley Counter Readings at beginning, end and total;
7)
Percent and Quantity (weight/sacks) of each material (aggregate, emulsion, water, mineral filler);
8)
Changes in material source;
9)
Production Application Rate of pounds of dry aggregate;
10)
Daily asphalt production spot check and temperature reports of emulsion;
11)
Asphalt emulsion bill of Lading/Certification;
12)
Calibration forms;
13)
Aggregate Test Report (Gradation, moisture and Sand Equivalent);
14)
Contractor's authorized signature and date.
9/1/2023 /1/2010
410-14
Micro-Surfacing
410.6 Material Sampling and Testing Quality Assurance Responsibilities. 410.6.1 Aggregate. 410.6.1.1 Initial Stockpile gradation and moisture content sampling and testing will be conducted by the County per each stockpile site. No material shall be used from unapproved stockpiles. 410.6.2 Asphalt Emulsion. 410.6.2.1 Shipments may be sampled and tested at random by the County. 410.7 Mixing Equipment. The machine shall be specifically designed and manufactured to lay micro-surfacing. The machine shall be maintained in satisfactory working condition at all times to ensure a high-quality product. 410.7.1 The material shall be mixed by an automatic sequenced, self-propelled microsurfacing mixing machine, which shall be a continuous flow mixing unit, able to accurately deliver and proportion the aggregate, emulsified asphalt, mineral filler, control setting additive and water to a revolving multi-blade twin shafted pugmill and discharge the mixed product on a continuous flow basis. The machine shall have sufficient storage capacity for aggregate, emulsified asphalt, mineral filler, control additive and water to maintain an adequate supply to the proportioning controls. 410.7.2 If used, the self-loading machine shall be equipped to allow the operator to have full control of the forward and reverse speeds during applications of the Micro-Surfacing material and be equipped with opposite-side driver stations to assist in alignment. The self- loading device, opposite-side driver stations, and forward and reverse speed controls shall be original equipment manufacturer design. 410.7.3 Belt Feeder. The aggregate feed to the mixer shall be proportioned using a chain dragged belt feeder that shall be equipped with a working revolution counter or similar device so that the amount of aggregate used may be determined at any time. The belt feeder shall be operated with an adjustable cut-off gate. The height of the gate opening shall be readily determinable. The belt delivering the aggregate to the pugmill shall be equipped with a device to monitor the depth of aggregate being delivered to the pugmill. Said device for monitoring depth of aggregate shall automatically shut down the power to the aggregate belt feeder whenever the depth of aggregate is less than the target depth of flow. A second device shall be located where it will monitor movement of the aggregate belt by detecting revolution of the belt feeder. The device for monitoring no flow or belt movement, as may be the case, shall automatically shut down the power to the aggregate belt when aggregate belt movement is interrupted. This second device will not be required where the aggregate delivery belt is an integral part of its' drive chain. To avoid erroneous shutdown by normal fluctuation, a delay of 3 seconds between sensing and shutdown of the operation will be permitted. 410.7.4 Positive Displacement Pump. A positive displacement type pump shall proportion the emulsion. The pump shall be equipped with a functional revolution counter or similar device so that the amount of emulsion used may be determined at any time.
9/1/2023 /1/2010
410-15
Micro-Surfacing
410.7.5 Calibration of Mixer-Spreader Truck. The delivery rate of mineral aggregate and emulsion per revolution of the aggregate feeder shall be calibrated at the appropriate gate settings for each mixer-spreader truck used on the project. Individual volume or weight (mass) controls for proportioning each material to be added to the mix shall be provided. Each material control device shall be calibrated and properly marked. They shall be accessible for ready calibration and so placed that the Engineer may determine the amount of each material used at any time. The calibration shall demonstrate that the delivery rates of dry aggregate and emulsion residue are within the recommended percentages stated in the laboratory mix design. The procedures for calibration of micro-surfacing equipment shall be as recommended by the current edition of ISSA publication MA-1 "ISSA Inspector’s Manual" and supplemental procedures as specified by the County. 410.8 Calibration-Run. 410.8.1. The Contractor's equipment shall be checked and verified for the following volumetric consistency in the presence of and subject to the approval of the Engineer at least once per calendar year and prior to application of test strip and verified every 90 days. The documentation shall include an individual calibration of each material at various settings, which can be related to the machine metering devices. 410.8.1.1 No machine will be allowed to work on the project until the calibration has been completed and approved by the Engineer. 410.8.1.2 The Contractor shall provide digital scales, calibrated by a State Department of Agriculture approved commercial calibration company to weigh materials. The Contractor will be required to re-verify equipment every 90 days or re-calibrate equipment when a significant material change is made and approved by the Engineer. 410.8.2 Aggregate Belt Feeder. The aggregate feed to the mixer shall be equipped with a revolution counter or similar device so that the amount of aggregate used may be determined at any time. 410.8.2.1 The aggregate belt feeder shall deliver aggregate to the pug mill with such volumetric consistency that the deviation for any individual aggregate delivery rate checkrun shall not exceed 2.0 percent of the mathematical average of three runs of at least 50 counts of the rock belt counter or 2,000 pounds in duration each. This shall be applied for at least three gate-opening settings. The Contractor shall provide the Engineer with a daily total of aggregate used, in pounds. 410.8.3 Mineral Filler. The mixing machine shall be equipped with a cement (fines) feeder that provides an accurate metering device or method to introduce a predetermined proportion of mineral filler into the mixer at the same time and location that the aggregate is fed. 410.8.3.1 The fines feeder shall be delivered with such consistency that the deviation for any individual cement feeder delivery rate check-run shall not exceed 2.0 percent of the mathematical average of three runs of at least 10 counts or 2 pounds of the fines feeder counter per sample. The Contractor shall provide the Engineer with a daily total of mineral filler used, in pounds.
9/1/2023 /1/2010
410-16
Micro-Surfacing
410.8.4 Emulsion Pump. The positive displacement-type shall be equipped with a revolution counter or similar device so that the amount of emulsion used may be determined at any time. 410.8.4.1 The emulsion pump shall deliver emulsion to the pugmill with such volumetric consistency that the deviation for any individual delivery rate check-run shall be within 2.0 percent of the mathematical average of three runs of at least 75 counts of the rock belt counter or 100 pounds or 12 gallon each in duration. The Contractor shall provide the Engineer with a daily total of emulsion used, in pounds and gallons. 410.8.5 Water Pump. The water pump shall deliver water to the pugmill with such volumetric consistency that the deviation for any individual delivery rate check-run shall be within 2.0 percent of the mathematical average of three runs per setting of at least 75 counts of the rock belt counter or 100 pounds or 12 gallons each in duration. The Contractor shall provide the Engineer with a daily total of water used, in gallons. 410.8.5.1 The Contractor shall then determine, for each machine: 1) The aggregate feed gate setting, to nearest ⅛ inch; 2) The average desired production rate of dry aggregate per minute and include this in the calibration report; 3) The aggregate delivery belt setting in counts per minute; 4) The mineral filler delivery rate in pounds per minute; 5) The mineral filler delivery feeder setting in counts per minute; 6) Check the mineral filler in the final mixture by determination of the mineral filler delivered per count of the aggregate belt; 7) Set the mineral filler feeder to provide the appropriate number of counts per minute; 8) The emulsion delivery rate in pounds per count of the rock belt counter; 9) The emulsion delivery rate in pounds per minute. 410.7.5.2 Calibration Verification 90-Day. 1) The Contractor shall set the material delivery system to the appropriate settings for the job mix formula; 2) Follow Section 410.7, except only perform one test, for each vehicle; 3) If the delivery rate for any material differs from the rate shown on the approved calibration by more than ± 4 percent, a new calibration is required.
9/1/2023 /1/2010
410-17
Micro-Surfacing
410.7.5.3 Calibration Report. contain the following information:
9/1/2023 /1/2010
The initial and verification calibration reports shall
1)
All calibration worksheets, graphs and computations signed and dated by the designated company representative;
2)
County Project Name and Number;
3)
Company Name;
4)
Contact Person;
5)
Truck Type, Serial Number and Make;
6)
Mix Design Number;
7)
Calibration Date;
8)
Verification Date;
9)
Primary source, type and percent Emulsion as specified in the approved job mix formula;
10)
Product, type, source and percent of mineral filler as specified in the approved job mix formula;
11)
Dry Aggregate source, gradation, supplier and delivery rate, pounds (kilograms) per count;
12)
Gate Opening, to nearest ⅛ inch, to deliver the required rate of Dry Aggregate;
13)
Counts per minute of the aggregate belt at required Gate Opening;
14)
Pounds per minute of Mineral filler;
15)
Counts per minute of Mineral filler counter;
16)
Delivery Rate of Mineral Filler per Count of the aggregate belt counter;
17)
Summary;
18)
Emulsion Delivery Rate (Fixed), pounds per count;
19)
Aggregate Gate Opening to nearest ⅛ inch;
20)
Aggregate Belt Speed Setting count per minute;
21)
Mineral Filler Speed Setting mineral filler count per minute;
22)
Company Representative’s signature and date following this statement;
410-18
Micro-Surfacing
23)
"I certify that the calibration and mix design information used to determine these mix unit settings are based on the actual materials and mix design to be used on this project.";
24)
Engineer approval signature and date
410.8 Emulsion Storage. 410.8.1 The emulsion storage located immediately before the emulsion pump shall be equipped with a device which will automatically shut down the power to the emulsion pump and aggregate belt feeder when the emulsion level is lowered sufficiently to expose the pump suction line. 410.8.2 A temperature-indicating device shall be installed in the emulsion storage tank at the pump suction level. The device shall indicate temperature of the emulsion and shall be accurate to within 5°F. The maximum temperature of emulsion contained in the mixerspreader truck emulsion storage tank shall be 120°F. In cases where cool, damp weather conditions are prevalent or nighttime work is performed, this maximum temperature may be increased to 140°F as directed by the Engineer. 410.9 Mixing and Spreading Equipment. 410.9.1 Equipment. All equipment, tools, and machines used to perform this work shall be maintained in satisfactory working order at all times. Hand squeegees, shovels, traffic control equipment and other support and safety equipment shall be provided if necessary to perform the work. 410.9.1.1 The micro-surfacing shall be mixed in pugmill mixers of adequate size and power for the type of micro-surfacing to be placed. 410.9.2 The Micro-Surfacing machine shall be designed and manufactured to lay Microsurfacing and be equipped to proportion the mineral aggregate, Type I Portland cement mineral filler, water, set-control additives and emulsified asphalt by weight, to a revolving multiblade dual mixer, and discharge the thoroughly mixed product. The machine shall have sufficient storage capacity for mineral aggregate, emulsified asphalt, Type I Portland cement mineral filler, water, and set-control additive to maintain an adequate supply to the proportioning controls. The machine shall be self-propelled and be operated in that manner. All rotating and reciprocating equipment on mixer-spreader trucks shall be covered with metal guards. The paddles or augers shall be designed and operated so all fresh mix will be agitated and to create a turbulence or laminar flow to prevent the mixture from setting up in the box, causing side build-ups and lumps. 410.9.3 The mixing machine shall be equipped with a water pressure system and a nozzle type spray bar, in good working condition, to provide a uniform water spray to dampen the surface when required, immediately ahead of and outside the spreader box. No free-flowing water shall be present.
9/1/2023 /1/2010
410-19
Micro-Surfacing
410.9.4 The mixer-spreader truck shall not be operated unless all low-flow and no-flow devices and revolution counters are in good working condition, functioning and all metal guards are securely in place. All indicators required by these specifications shall be visible while walking alongside mixer-spreader truck. 410.9.5 Mineral aggregate feeders shall be connected directly to the drive on the emulsion pump. The drive shaft of the aggregate feeder shall be equipped with a revolution counter that is in good working condition and reads to the nearest one-tenth of a revolution of the aggregate delivery belt. 410.9.6 The identification number of mixer-spreader trucks shall be at least 2 inches in height and located in the front and rear of the vehicle. 410.9.7 At least 2 operational spreader trucks shall be available at the job during the spreading operation. 410.9.7.1 Individual volume or weight controls for proportioning each material and used in material calibrations shall be provided and properly marked. 410.9.8 When construction is being performed under traffic, all equipment, including loading vehicles and supply trucks will be required to operate in a single lane on which the microsurfacing is being applied. The Contractor’s equipment for micro-surfacing shall be operated in such a manner which will permit traffic to move safely and expeditiously through and around the work area. 410.10 Spreader Boxes. 410.10.1 The micro-surfacing mixture shall be spread by means of one of the following controlled spreader box configurations conforming to the following requirements: 410.10.1.1 Full Width Spreader Box. The full width spreader box shall be capable of spreading a traffic lane width and shall have strips of flexible rubber seals or similar material on each side of the spreader box. The box shall be in contact with the pavement to positively prevent the loss of micro-surfacing from the ends of the box and shall be equipped with devices to adjust thickness or grade of the surface. All spreader boxes over 7.5 feet in application width shall have baffles, reversible motor driven twin- shafted paddles or spiral augers, to insure uniform application on super-elevated sections and shoulder slopes. Spreader box skids shall be maintained in such a manner as to prevent transverse chatter (wash boarding), tearing, or shoving in the finished mat or the mat adjacent to the box. The rear seal shall have flexible and adjustable strike-off blades that shall make close contact with the pavement, shall be designed and operated to achieve a uniform consistency that provides a free flow of material to the rear strike- off without causing skips, lumps, or tears in the finished surface. The spreader box shall have suitable means provided to side shift the box to compensate for variations in the pavement geometry. 410.10.1.1.1 A secondary rubber strike-off shall be provided to improve surface texture. The secondary strike-off shall have the same leveling adjustments as the spreader box.
9/1/2023 /1/2010
410-20
Micro-Surfacing
410.10.1.2 Wheel Path Depression (Rut) Box. The wheel path depression box shall be designed as a double chambered box with adjustable screeds to regulate depth and shall be either 5 or 6 feet in width. Hydraulic augers set at a 45-degree angle ("V") shall move the mixed material from the rear to the front of the filling chamber. The augers shall push the larger aggregate into the center, deeper section of the wheel path depression and send the fine material toward the edges of the pass to act as a mastic and for feathering down the longitudinal joint along the wheel path. 410.10.1.3 Spreader Box Maintenance. The micro-surfacing spreader box in use shall be clean at the start of each work shift. The box shall be cleaned as needed or as directed by the Engineer to prevent excessive broken micro-surfacing from accumulating on the spreader box and adversely affect surface texture during application. A rubber squeegee shall be attached to the adjustable metal plate at the rear of the spreader box, behind the second strike-off, to texture the surface. All strike-off blades (rubber and steel) shall be cleaned or replaced at any time problems with cleanliness and longitudinal scouring occur. 410.11 Material Stockpiling and Storage. 410.11.1 Aggregate Storage. If the mineral aggregates are stored or stockpiled, they shall be handled in such a manner as to prevent segregation, mixing of the various material, and contamination with foreign materials. The grading of aggregates proposed for use and as supplied to the mixing plant shall be uniform. Suitable equipment of acceptable size shall be furnished by the Contractor to work the stockpiles and prevent segregation and excessive breakdown of mineral aggregates. The aggregate shall be passed over a ⅜ inch scalping screen, provided by the Contractor, immediately prior to transfer to the micro-surfacing mixing machine to remove oversize material. 410.11.1.1 The Contractor's material and equipment may be stored at designated areas within a Department’s Operation facility, as directed by the Engineer. Equipment and materials shall not be stored on the public road right-of-way. 410.11.2 Asphaltic Material Storage. The asphaltic material storage shall be ample to meet the requirements of the plant. All equipment used in the storage and handling of asphaltic material shall be kept in a clean condition at all times and shall be operated in such a manner that there will be no contamination with foreign matter. The storage stability test may be waived provided the asphalt emulsion storage tank at the project site has adequate provisions for circulating the entire contents of the tank, and provided satisfactory field results are obtained. 410.12 Construction Methods. 410.12.1 Weather Limitations. 410.12.1.1 The micro-surfacing mixture shall not be spread when: 1) The pavement or air temperature are below 60°F and falling, but may be applied when both the pavement and air temperature are above 50°F and rising; 2) There is a forecast of temperatures (as per the National Weather Service) below 40°F within 24 hours of completion of the work;
9/1/2023 /1/2010
410-21
Micro-Surfacing
3) Pavement is wet, when raining or other weather conditions prolong the opening to traffic beyond one hour. 410.12.1.2 The Engineer may allow the Contractor to proceed with micro-surfacing when the relative humidity exceeds 80 percent and the Contractor accepts responsibility for following the specified set time and construction specifications. 410.12.2 Seasonal Limitations. The micro-surfacing mixture shall not be constructed before April 15th or after September 15th without written approval of the Engineer. 410.12.3 Test Strip. After approval of the Contractor's mix design and stockpile gradations but no sooner than 48 hours prior to the requested production application of the MicroSurfacing mixture the Contractor shall place a test strip. At a contract street location established by the Engineer, the Micro-Surfacing mixture will be placed to demonstrate the compatibility of the modified emulsion and the mineral aggregate under field conditions. This test strip shall also be used to demonstrate mix uniformity and compliance of the mix to the requirements of proportioning of the asphalt, mineral aggregate, mineral filler, polymer modifier, set-control agent and water. 410.12.3.1 The test strip shall be at least 500 feet in length, and the width of one lane and shall consist of the application courses specified in the contract. The test strip shall be conducted at the same time of day or night the full production will be applied. 410.12.3.2 The test strip shall be performed in the presence of the Engineer and a Department Materials Testing Laboratory representative, at least 48 hours prior to the Contractor's intended start-up date. All equipment used shall be calibrated before placement of the test strip. The Engineer shall evaluate the test strip 24 hours after it's' placement to determine that the mix design and materials are acceptable. 410.12.3.3 A new test strip shall be performed when the test strip is deemed unacceptable, a change in the mix design become necessary or as directed by the Engineer. The establishment of a test strip will be considered incidental, however the approved test strip will be measured and paid for in accordance with the contract provisions for the actual square yards of micro-surfacing placed. 410.12.3.4 Failure of the test strip shall require the Contractor to completely remove the test strip with no compensation for the labor, equipment, or material to place, remove or properly dispose of the failed test strip. Method or equipment substitutions used and approved by the Engineer in the test strip, shall be used in field production. 410.12.4 Resident Notification. The Contractor shall be responsible for prior notification of residents for no parking on streets during micro-surfacing operations. Temporary "No Parking" signs noting the time and date of construction activity shall be provided and installed by the Contractor at maximum intervals of 100 feet and visible within the Right-of- Way, 24 hours in advance of work. Should the work not occur on the specified day, a new notification will be distributed by the Contractor. The Contractor shall distribute letters of notification (to residents) with the phone number of their representative who has authority for correction of concerns that residents may have. Signs shall be removed and disposed of by the Contractor at the end of the operation on that street. No additional compensation will be allowed for delays or inconveniences when parked vehicles are encountered.
9/1/2023 /1/2010
410-22
Micro-Surfacing
410.12.5 Surface Preparation. Immediately prior to placement of the micro-surfacing mixture, the Contractor shall furnish the proper labor, equipment, materials, and small tools to clean the pavement thoroughly and remove all vegetation, loose materials, dirt, mud and other objectionable material that may prevent adhesion of the micro-surfacing to the existing pavement surface and then pre-wet with a light mist as required. This also includes removal of any vegetation in the curb line. The Contractor shall use an industry-approved acrylic sealer for oil spot treatments that cannot be removed by water blasting or other Engineer approved methods. An Engineer approved power broom shall be used in advance of the micro-surfacing operation. The broom shall have plastic bristles, an approved suction area and enough air velocity in the nozzles to pick up and remove the above debris. A power blower shall immediately precede the slurry lay down unit. The Contractor shall remove any debris, vegetative or non-vegetative, blown onto private property, sidewalks, or driveways in a manner approved by the Engineer. The Engineer shall approve the surface preparation prior to surfacing. No dry aggregate either spilled from the lay-down machine or existing on the road, will be permitted. In multiple-pass systems, the first lift shall be swept free of loose material immediately prior to placing the second lift. 410.12.5.1 Potable Water used in pre-wetting the surface ahead of the spreader box and shall be applied at such a rate that the entire surface shall be damp and free of ponding or free-flowing water. 410.12.5.2 Protection and Cleaning of Appurtenances. Utility covers, manholes, grated inlets, curb inlets and traffic device covers located in the roadway to be paved shall be protected from coverage by the micro-surfacing and referenced for prompt location and cleaning following application. The Contractor shall be responsible for providing adequate traffic control, covering, locating, removing, and cleaning of these items following the micro-surfacing application operation. The methods used to protect, reference, locate and clean shall be submitted by the Contractor and shall be subject to approval by the Engineer. All such materials shall be removed and properly disposed of by the Contractor after the surfacing material has cured. The above items shall be cleaned to their presurfacing condition or as directed by the Engineer. 410.12.5.3 Thermoplastic and Paint Striping and Marker Removal. All existing Thermoplastic and Paint pavement striping, stop bars and turn arrows in conflict with the micro-surfacing paving operation shall be completely removed as directed by the Engineer and paid for in accordance with items contained in this contract. 410.12.5.3.1 Tack Coat. The areas where striping and markings have been removed shall be lightly coated with 0.05 gal./yd2 CSS-1h Tack (ONE PART EMULSIFIED ASPHALT AND THREE PARTS WATER) before placement of the micro-surfacing on those areas. The tack shall be allowed to cure sufficiently before the application of micro-surfacing. The cost of this work is incidental and shall be included in the square yardage cost of micro-surfacing. 410.12.5.3.1.1 The Engineer may require additional tack on surfaces to be covered by micro-surfacing that are extremely dry, raveled, concrete or brick, prior to microsurfacing. Tack shall be applied evenly at a rate of 0.05 to 0.10 gal./yd2 with a standard distributor.
9/1/2023 /1/2010
410-23
Micro-Surfacing
410.12.5.4 The Engineer shall approve all surface preparation prior to application of the micro-surfacing. 410.12.5.5 Disposal of Waste Materials. 410.12.5.5.1 The Contractor shall remove and properly dispose of waste materials daily, in a manner approved by the Engineer, after the surfacing material has cured. 410.12.6 Spreading and Stability of Mixture. The surface may be pre-wetted by water fogging ahead of the spreader box when road conditions require. The rate of fogging shall be adjusted during the day based on pavement temperature, humidity, surface texture and dryness of the pavement. The micro-surfacing shall be homogeneous during and following mixing and spreading. It shall be free of excess water or emulsion and free of segregation of the emulsion and aggregate fines from the coarser aggregate. A sufficient amount of materials shall be carried to all parts of the spreader at all times so that complete coverage is obtained. Overloading the spreader box shall be avoided. No lumping, balling, or unmixed aggregate shall be permitted. Under no circumstances shall water be sprayed directly into the lay-down box during application of micro-surfacing. 410.12.6.1 The mixture shall be uniform and homogeneous after spreading on the surfacing and shall not show separation of the emulsion and aggregate after setting. Streaks, such as those caused by oversized aggregate, shall be avoided. If excess streaking develops, the job will be stopped by the Engineer until the Contractor can demonstrate that the occurrence has been eliminated. Excessive streaking is defined as: 1) More than 4 drag marks greater than ½ inch wide and/or 4 inches long; or 2) 1 inch to 3 inches long in any 30 square yard area. 3) No transverse ripples or longitudinal streaks in excess of ¼ inch will be permitted when measured by placing a 10-foot straight edge over the surface. 410.12.6.2 Inaccessible Areas (Handwork). Micro-surfacing to be spread in areas inaccessible to the spreader box shall be surfaced using approved hand squeegees to provide complete and uniform coverage. If necessary, the area to be hand worked shall be lightly dampened with potable water prior to mix placement. Care shall be exercised to leave no unsightly appearance from handwork. The same type of finish as applied by the spreader box shall be required. Unless otherwise directed by the Engineer, all handwork shall be completed in the first pass for multiple-pass operations. 410.12.6.3 Micro-surfacing shall not be applied over steel expansion plates or bridge decks, unless directed by the Engineer. Micro-Surfacing application, when approaching railroad tracks, shall end at the railroad right-of-way and shall not be allowed to enter the track area itself.
9/1/2023 /1/2010
410-24
Micro-Surfacing
410.12.6.4 Excess Material. All excess material that overruns in gutters, on curbs, inlet tops, or on sidewalks shall be removed immediately or squeegeed back onto the surface. All excess material removed from any non-paved area and from the ends of each job site shall be removed immediately and disposed of by the Contractor in a manner approved by the Engineer. Discolored curbs, inlets and sidewalks shall be immediately cleaned and flushed before the material sets. Any set material left in place will be removed by sand blasting, by the Contractor, at the Contractor’s expense and as directed by the Engineer. 410.12.6.5 Work at Intersections. Work at intersections shall be done in stages, or blotter materials shall be used, to allow crossing and turning movements. The blotting material shall be the same aggregate used in the micro-surfacing and shall be removed by the Contractor when designated by the Engineer. Regardless of the method chosen by the Contractor and approved by the Engineer, no marred or streaked sections in excess of that defined in Section 410.12.6.1 will be allowed. 410.12.6.6 Pneumatic Rolling. If a section of pavement or shoulder is not going to be exposed to traffic within 48 hours, it shall be compacted with a pneumatic tire roller after curing. The pneumatic-tire rollers shall weigh from 5 to 8 tons, shall be operated at a speed not to exceed 5 mph, shall have a minimum contact pressure of 80 psi and shall have a total compacting width of not less than 5 feet. The Contractor shall provide a manufacturer's chart indicating that regarding tire size, pressure, and loading that the contact pressure established by the Engineer is being met prior to use. 410.13 Wheel Path Depressions (Ruts). 410.13.1 When wheel path depressions have a cross section that is deformed 1 inch or more, the individual wheel paths shall be first filled utilizing a wheel path depression (rut) box before the final surface course is placed. 410.13.1.1 When required on the plans or as directed by the Engineer, but before the final surface course is placed, preliminary micro-surfacing material shall be required to fill ruts, utility cuts, depressions in the existing surface, etc. Wheel path depression spread rates will vary with depression depth. Maximum single application for wheel path depressions shall be ¾ inch in depth, or 30 lb. per yd2 as directed by the Engineer. Greater depths may require multiple applications in each depression. 410.13.1.2 Wheel path depression repair shall be constructed with a slight crown to permit initial traffic compaction of the micro-surfacing. Generally, the depression should be crowned by ⅛ to inch ¼ per 1 inch of wheel path depression to allow for compaction under traffic. Excessive crowning (over-filling) shall be avoided. 410.13.1.3 At least 24 hours of traffic compaction shall be allowed on freshly filled wheel path depressions before additional lifts are applied. 410.13.2 If rutting peaks extend more than ½ inch above the existing pavement, they should be milled down at or just below existing pavement surface prior to rut filling if directed by the Engineer and shall be tacked in accordance with Section 410.12.5.3.1.
9/1/2023 /1/2010
410-25
Micro-Surfacing
410.14 Rate of Application. The complete aggregate spread rate shall be no greater or no less than 2 lb./yd2 of the target application rate. The application rate is based upon the weight of combined dry mineral aggregate in the mixture. 410.14.1 Irregular surfaces or pavements with wheel path deformations of less than ½ inch shall require two full width box applications of micro-surfacing. Two lifts of 15 lb./yd2 of the dry mass of the combined aggregate will be required on the Arterial Road System (ARS). 410.14.1.1 Micro-surfacing material shall be applied in one lift of 18 lb./yd2 of the dry mass of the combined mineral aggregate will be required on the County Road System. An additional lift shall be placed at intersections or cul-de-sacs as directed by the Engineer. 410.14.2 Adequate means shall be provided by the Contractor to protect the microsurfacing from damage by traffic until such time that the mixture has cured sufficiently so that the micro-surfacing mixture will not adhere to and be picked up by the tires of vehicles. 410.15 Seams and Joints. 410.15.1 No excess buildup, uncovered areas, or unsightly appearance shall be permitted on longitudinal or transverse joints. The Contractor shall provide suitable spreading equipment to produce a minimum number of longitudinal joints throughout the project. Half passes and odd width passes will be used only in minimum amounts. If half passes are used, they shall not be the last passes of any paved area. Any damage to, or irregularities in, the microsurfacing shall be repaired by the Contractor and at the Contractor's expense, as directed by the Engineer. All repairs are to be made with a paver box, except those designated as handwork areas. 410.15.1.1 Any necessary longitudinal or transverse joints in underlying layers shall be constructed in accordance with Section 404.19.2.1. 410.15.2 Whenever possible the longitudinal joints shall be placed on the lane lines, staggering the underlying joints by allowing a maximum of 3 inches for overlap of the longitudinal lane line joints. The Engineer may permit the Contractor to use other patterns of longitudinal joints, if such patterns will not adversely affect the quality of the finished product. 410.15.3 Longitudinal joints common to two driving lanes, shall not overlap more than 3 inches. The resultant joint shall present an elevation difference between driving lanes that is less than ¼ inch when measured by placing a 10-foot straight edge over the joint and measuring the elevation drop off. If the Engineer determines that this is exceeded or that the seam is rough enough to cause a noticeable effect on steering of an automobile, the seam shall be removed, and new micro-surfacing patch shall be applied by the Contractor. No additional payment shall be granted for this repair.
9/1/2023 /1/2010
410-26
Micro-Surfacing
410.16 Workmanship. 410.16.1 Edge Lines and Joints. Edge lines and joints shall be uniform and parallel, radial or perpendicular with the centerline of the roadway. Lines at and through intersections and tapers shall be kept straight and uniform in appearance. The Contractor shall use roofing paper to mask off the start or end of streets to provide straight lines. The Engineer may require the Contractor use a string line or other methods to achieve this. Edge lines should not vary by more than 2 inches horizontal variance in any 100 feet of length. 410.16.2 Micro-surfacing material required to repair deficiencies due to unsatisfactory workmanship, as determined by the Engineer, shall not be paid for but shall be entirely at the Contractor's expense. 410.16.3 Adjustments to utility covers, manholes, grated inlets, curb inlets and traffic device covers located in the roadway shall meet the requirements of Section 604.20. 410.17 Patching. 410.17.1 Patching of damaged micro-surfacing surface shall be made with any of the above described methods. The patch repair shall be made in the same direction as the paver was traveling. 410.18 Method of Measurement. Although all materials are required to be measured for quality control purposes, the method of measurement for the bid item "Latex Modified Microsurfacing", complete and acceptably in place, including any multiple passes or courses will be made to the nearest square yard. Linear measurements to determine the square yardage of surface area shall be made to the nearest one foot. Measurement of individual passes or courses will not be made. At the end of daily production, the Contractor and the Engineer will determine the surface yardage applied for that day and agree to that daily quantity before start of production the next day. Final measurement of the completed surface will not be made except for authorized changes during construction, or where appreciable errors are found in the contract quantity. Appreciable error shall be defined as ±2 percent of the total contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. 410.19 Basis of Payment. 410.19.1 The accepted quantity of latex-modified asphalt emulsion Micro-Surfacing as provided above in the Method of Measurement, shall be paid for at the contract unit price per square yard for Latex Modified Micro-surfacing. This contract price shall include full compensation for furnishing all labor, materials, tools and equipment for: calibration of equipment; record keeping; quality control sampling, testing and mix design; for preparation of the road surface; for supplying, installing and removing temporary "No Parking" signs; for supplying Digital Distance Measuring Instruments, for transporting, mixing, applying, blotting (furnishing, placing and removal of material), general clean-up; and other incidentals necessary to complete and warrant the job as specified herein. No additional payment will be made for multiple test strips or removing and replacing test strips. Reduction in payments in accordance with Section 410.5.3 will be made in the pay period the deficient test report is received by the Engineer.
9/1/2023 /1/2010
410-27
Micro-Surfacing
410.19.2 Traffic Control Devices in accordance with Section 612 will consist of furnishing, constructing, and maintaining traffic control and safety devices as directed by the Engineer, shown on the plans or included in the construction contract, addendums or specifications. Directional Barricades shall be approved and used as directed by the Engineer at no additional cost. Directional Barricades shall be NCHRP 350 compliant. Opening to traffic does not constitute acceptance of the work. The accepted quantities for furnishing, installing, maintaining and removing the contract traffic control devices specified, will be paid for at the unit prices bid for each item in the contract.
9/1/2023 /1/2010
410-28
Micro-Surfacing
Section 412
Pavement Surfacing and Texturing
412.1 Description. This work shall consist of improving the profile, cross slope, and surface texture of the existing pavement to the depths indicated on the plans by mechanical surfacing and texturing methods. Nighttime lighting requirements shall be in accordance with Section 612.80. 412.2 Equipment. The surface planing or grinding equipment used to surface and texture the roadway pavement will be a self-contained power unit, self-propelled and capable of remaining, in one pass, a combined thickness of 2 inches or more of asphaltic concrete pavement and ½ inch or more of Portland cement concrete pavement. The equipment shall have sufficient power, traction, and stability to maintain an accurate depth of cut and cross slope and shall be capable of accurately and automatically establishing profile grades along each edge of the machine by referencing from the existing pavement by means of a traveling reference or from an independent grade control. An automatic system for controlling cross slope at a given rate will be incorporated into the machine and a manual system shall provide for a uniformly variable depth of cut while the machine is in motion to allow for flush cuts at obstructions in the pavement. The speed of the machine shall be variable in order to leave the desired pattern; however, the forward speed of the planning or grinding equipment in relation to the turning speed of the cutter drum shall remain constant. Unless otherwise allowed, the machine will be equipped with an integral loading and reclaiming means to immediately remove material being cut from the surface of the roadway and discharge the cutting into a vehicle, all in one operation. Adequate backup equipment (mechanical sweeper, loader, water truck, etc.) and adequate personnel will be provided to ensure that all cuttings are removed from the street surface daily. A dust control and/or abatement system will be incorporated into the machine. A smaller grinding machine or other approved equipment with or without integral loading and reclaiming means will be required in areas inaccessible to the mainline machine or adjustment to the curb or other obstructions. 412.2.1 Hauling Equipment. Trucks used for hauling surfaced material shall have tight, metal beds. Each truck shall be equipped with a securely fastened cover of suitable material of such size as to completely cover the loaded bed. 412.2.2 Sweeper. A self-propelled, mechanical sweeper or vacuum sweeper equipped with a watering system capable of dust suppression shall be in operation at all times. The sweeper must also be equipped with plastic bristles with a positive means of controlling vertical pressure. This equipment shall be capable of rendering a clean surface free of asphalt or concrete cuttings, dirt, or dust and capable of sustaining temporary pavement striping as applied for traffic control. Breakdown of this cleaning equipment will be considered cause for suspension of the surfacing and planing operation.
9/1/2023
412-1
Pavement Surfacing and Texturing
412.3 Surfacing and Texturing. The required pavement texture shall be a series of discontinuous longitudinal striations spaced approximately ½ inch apart. Individual striations shall be 4 to 8 inches in length, spaced so as to produce a uniform overall grid pattern. The depth of the striations shall be 1/8 to 3/16 inch as directed by the Engineer. The Contractor will be required to perform a test section so as to demonstrate his ability to operate and maintain the machine in the desired pattern. If a broken or worn tooth is to be replaced in a row of teeth, then all teeth in that row must be of equal height. 412.3.1 The Portland cement concrete pavement shall be surfaced and textured while controlling the elevation of each end of the milling cutter to follow the existing longitudinal profile. The depth of cut shall be as required to produce a uniform texture across the width of the pass, eliminating cross-slope irregularities due to such causes as wear in the wheel tracks. 412.4 Construction Methods. The pavement surface shall be removed to the depth, width, grade, and cross section as shown on the plans, or as directed by the Engineer. When Portland cement concrete pavement is to be surfaced and textured while controlling the elevation of each end of the milling cutter to follow the existing longitudinal profile the depth of cut will be as required to produce a uniform texture across the width of the pass, eliminating cross slope irregularities due to such causes as wear in the wheel track. 412.4.1 The roadway pavement surface shall be removed and planed around and over manholes, utility valves, and drainage appurtenances within the limits of the work as directed by the Engineer. Any damage to manholes, utility valves, or drainage appurtenances by the removal and planning operation shall be the responsibility of the contractor to correct. After removal of existing material around manholes, utility valves and other appurtenances in the driving lane, the Contractor shall place a temporary wedge of bituminous material at a slope no steeper than 1 inch in 4 feet around the appurtenance. Bituminous wedges shall be removed prior to resurfacing. No direct payment will be made for compliance with the specification. 412.4.2 The Engineer may require that the pavement planing operations be referenced from an independent grade control in those areas where he deems this type of control to be appropriate. For this type of operation, the independent grade control shall be established and maintained by the Contractor in a manner acceptable to the Engineer, and the final position of same shall be acceptable to the Engineer. 412.4.3 In the event the entire pavement width along a section of highway has not been planned to a flush surface by the end of a work period resulting in a vertical or near vertical longitudinal face exceeding 1½ inches in height at the centerline and 2 inches at the shoulder or curb and gutter, this longitudinal face shall be sloped in a manner acceptable to the Engineer so as not to create a hazard to traffic using the facility during periods when construction is not in progress. All transverse faces that are present at the end of a working period will be tapered utilizing Type C Bituminous or SP 125 material to avoid creating a hazard for traffic. Vertical faces along a cross street at an intersection that are present at the end of a workday shall be tapered to the planed depth by the addition of Type C Bituminous or SP 125 material placed to provide a smooth riding surface. In either case the transitional asphaltic material shall be removed before the final course is placed.
9/1/2023
412-2
Pavement Surfacing and Texturing
412.4.4 When the Contractor is required to construct butt joints at overlay termini on existing Portland cement concrete and bituminous streets and at any other location, the dimensions of the joint and other construction details shall be in accordance with the standard butt joint detail included with the plans. The Contractor will be required to use a surfacing and/or grinding machine meeting the requirements of Section 412.12. 412.4.5 The loose material resulting from the operation shall be disposed of at sites obtained by the Contractor and approved by the Engineer in writing, in accordance with provisions of Section 203.2.16.1. Unless otherwise specified on the plans, the material shall become the property of the Contractor. Effective measures shall be taken to suppress dust during cutting loading and pavement cleaning operations. Cuttings shall be removed immediately and disposed of promptly. Before the prepared surface is opened to traffic it will be thoroughly cleaned of all loose material. 412.4.6 Temporary striping will be placed by mechanical means. Temporary striping will be placed at the end of each day's operation, the completion of the site and as directed by the Engineer to properly reestablish and maintain traffic throughout the project limits. The placing of temporary striping will normally be completed before twilight. During night operations positive traffic control will be maintained by use of reflective material on channelizes or barricades as directed by the Engineer. Unless otherwise directed, temporary striping layout will match the existing markings on the roadway prior to surfacing and texturing operations. No direct payment will be made for compliance with this provision. 412.5 Surface Smoothness. The depth of cut shall be controlled during surfacing and texturing so as to prevent the introduction of bumps or depressions into the existing pavement exceeding ⅜ inch 10 feet. The surface at the edges of adjacent passes shall be matched within plus or minus ⅛ inch. If a broken or worn tooth is to be replaced in a row of teeth, then all teeth in that row must be of equal height. 412.6 Removal of Cuttings. Effective measures shall be taken to prevent the generation of dust during cutting, loading, and pavement cleaning operations. Cuttings shall be removed immediately behind the texturing equipment and disposed of by the Contractor in accordance with the provisions of Section 203.2.16.1. Before the textured surface is opened to traffic, the surface shall be cleaned thoroughly of all loose material that would create a hazard, a nuisance, or would be redeposited into the surface texture. 412.7 Method of Measurement. The quantity of pavement surfacing and texturing including the removal and disposal of cuttings shall be by the computed number of square yard (square meters) on the site. This item will include longitudinal profiling, paved shoulder correction and cross slope correction as established by the Engineer. Butt joints, where shown on the plans or where so designated by the Engineer, will be paid by computed quantity as established by the Engineer. Type C Bituminous or SP 125 material used to taper joints, as herein described, will be paid to the nearest ton and will include tar paper, installation, compaction and removal prior to paving.
9/1/2023
412-3
Pavement Surfacing and Texturing
412.8 Basis of Payment. Pavement surfacing and texturing, by designated depth, will be paid for at the unit bid price per square yard. Butt joint, where designated, will be paid for at the unit bid price per square yard. In either case the unit bid price shall be considered full compensation for removing all material to the depth shown, texturing the paved surface, loading, hauling and satisfactory disposal of cuttings and debris and for all labor, tools, equipment, manipulation, and incidentals needed to complete the work.
9/1/2023
412-4
Pavement Surfacing and Texturing
Section 413
Asphaltic Concrete Incorporating Reclaimed Asphaltic Pavement or Shingles (RAP or RAS)
413.1 Description. This work shall consist of using Reclaimed Asphalt Pavement (RAP) or Reclaimed Asphalt Shingles (RAS) as a component material that shall be combined with new mineral aggregates, mineral filler and asphalt cement prepared in a stationary plant to be used for base, wedging, leveling and surface courses of pavement. The combined mixture shall meet the grading requirements, within specified tolerances, of the job mix formula (JMF). The mixture shall be placed on a prepared aggregate base or underlying course in conformity with the lines, grades, thicknesses, and typical cross sections shown on the plans. 413.1.1 Unless otherwise stated, specification section references are from the version, in effect at the time of this contract, of the St. Louis County Standard Specifications for Road and Bridge Construction and its' supplements. All applicable provisions of Section 404 Superpave Asphaltic Concrete Pavement, Section 405 Bituminous Pavements and Base, shall apply except as altered herein. These mixes will be identified as Hot Mix Asphalt (HMA). 413.2 Materials. All materials shall conform to Division 1000, Materials Details and specifically as follows: Item
Section
Performance Graded Asphalt Binder
1015
Coarse Aggregate
1002.1
Fine Aggregate
1002.2
Mineral Filler
1002.3
Salvage Asphalt
203, 412
413.2.1 The Engineer will designate the grade and amount of asphalt cement after examination of the reclaim (RAP or RAS) and new mineral aggregates the Contractor proposes to furnish. The right is reserved by the Engineer to designate the asphalt cement grade at the time the job mix formula is tested and approved. 413.3 Reclaim. The reclaim RAP shall be processed or crushed to a maximum size of ¾ inch square sieve. Scalping off of occasional oversize chunks without further reduction will be permitted. The removal and any further reduction operations shall be performed in such a manner as to minimize aggregate fracture in the RAP. The reclaim RAS shall be reduced to a nominal size (100 percent) passing the ⅜ inch sieve.
7/1/2015
413-1
Asphaltic Concrete Incorporating Reclaimed Asphaltic Pavement or Shingles (RAP or RAS)
413.3.1 Deleterious Substances. 413.3.1.1 RAS shall consist of waste from a shingle manufacturing facility or postconsumer shingles that contains no harmful quantities of asbestos in accordance with guidelines provided by the Environmental Protection Agency (EPA). The manufacturer shall provide test results or Certification for Bulk Sample Analysis, known as Polarized Light Microscopy, when post-consumer shingles are used, to certify RAS materials are free of asbestos. This test (or certification) shall be performed at the rate of one test (certification) per year minimum and for every 10,000 tons stockpiled after processing. The blending of tear-off materials from roofs (post-consumer asphalt shingles) will not be allowed to be performed with manufacturing shingle waste and shall be stockpiled separately. RAS shall be stockpile separately from other materials. RAS shall contain: 1) No more than 1.5 percent by total weight of wood particles, and 2) Shall contain no more than 3.0 percent by total cumulative weight of extraneous waste materials, including, but not limited to: dirt, nails, wood, insulation, roofing paper, metal flashings, coal tar epoxy, rubber materials, paper, plastic, brick, tar, waterproofing materials, and other materials detrimental to the reclaimed RAS asphalt pavement. For post-consumer RAS, the manufacturer shall provide a supplier certification that contains "The Reclaimed Asphalt Shingle (RAS) materials stockpiled contain no harmful quantities of asbestos in accordance with current guidelines provided by the EPA" with the submitted mix design. The Contractor shall be aware that asphalt plant emissions could be effected and shall comply with Federal, State and local ordinances. 413.3.1.2 RAP material shall consist of waste material from milling of asphalt pavement that can include material from aggregate sealcoat and micro surfacing projects. RAP material, after coating removal, shall be in accordance with Section 1002 for deleterious and other foreign material. 413.4 Stockpiling Reclaimed Material. The RAP and RAS shall be stockpiled in accordance with Section 1001.11. No haul units or loading equipment shall be permitted to operate on the reclaim stockpile. Equipment used to charge the bituminous mixing plant bins shall be operated so as to prevent contamination and consolidation of the RAP and RAS. Regardless of the method of storage and handling, the RAP and RAS shall be kept free of all contaminants. Each approved RAP or RAS stockpile shall require a separate mix design. The Contractor shall ensure that the approved stockpile size is adequate for each project. Stockpiles shall be identified by two classifications: 1) A Class 1 RAP or RAS stockpile shall consist of salvaged RAP or RAS (manufactured shingle waste) from one source only and may be processed into a single stockpile. 2) A Class 2 RAP or RAS stockpile shall consist of salvaged RAP or RAS (post-consumer asphalt shingles) from multiple sources. The RAS binder content, gradation, and specific gravity of the aggregate will be determined by extraction of the binder in accordance with AASHTO PP 78.
7/1/2015
413-2
Asphaltic Concrete Incorporating Reclaimed Asphaltic Pavement or Shingles (RAP or RAS)
The RAP binder content of shall be determined in accordance with AASHTO T 164 or other approved method of solvent extraction. A correction factor for use during production may be determined for binder ignition by burning a sample in accordance with AASHTO T 308 and subtracting from the binder content determined by extraction. The gradation on the aggregate reclaim from the RAP shall be performed by either extraction (AASHTO 319) or binder ignition (AASHTO T 308). The aggregate specific gravity shall be determined by performing AASHTO T 209 and calculating the Gse to use in lieu of Gsb as follows: Gse =
100 - Pb 100 - Pb Gmm Gb
413.4.1 Fractionating RAP or RAS. When Class 2 RAP or RAS is used for Superpave, the Class 2 RAP or RAS shall be screened over a No. 4 deck screen and separated into 2 stockpiles (Plus No. 4 and Minus No.4). Class 2 RAP or RAS used for bituminous pavements may be processed as Class 1 material into a single stockpile. No stockpiled RAP or RAS material will be incorporated into any HMA prior to testing and approval by the County. The Contractor may blend the RAS with sand when required to avoid conglomeration of RAS particles. 413.4.2 All RAP material shall be tested in accordance with AASHTO T 327, "Method of Resistance of Coarse Aggregate Degradation by Abrasion in the Micro-Deval Apparatus". The RAP coating shall be removed by either extraction (AASHTO T 319) or binder ignition (AASHTO T 308) methods. A correction factor for use during production may be determined for binder ignition by burning a sample in accordance with AASHTO T 308 and subtracting from the binder content determined by extraction. The material is to be tested in the Micro-Deval apparatus at the frequency of one test for every 1,500 tons stockpiled. The percent loss shall not exceed 22 percent. 413.5 Composition of Mixture. The RAP or RAS, the virgin mineral aggregates, including required mineral filler, and asphalt binder shall be combined in such proportions that the composition by weight of the recycled mix is within the range for the appropriate HMA specified in the contract. The recycled mixture shall comply with the applicable HMA Composition of Section 404 and 405, except as altered in this Section 413. 413.6 Job Mix Formula. When a representative quantity of RAP or RAS has been placed in the stockpile, the Contractor shall obtain in the presence of the Engineer, samples of asphalt binder, minus ¾ inch sieve RAP or RAS, and the proposed new aggregate fractions for tests. The samples shall be of the size designated by the Engineer and shall be submitted to the Laboratory at least 45 days before producing the mixture on the project. The Contractor shall also submit for the Engineer's approval, a job mix formula for the recycled mixture to be supplied for the project. The job mix formula shall include the type and sources of all materials and shall state a definite percentage for RAP or RAS and each new aggregate fraction. For post-consumer RAS, the manufacturer shall provide, with the mix design, a supplier certification that contains: "The Reclaimed Asphalt Shingle (RAS) materials stockpiled contain no harmful quantities of asbestos in accordance with current guidelines provided by the EPA". No sampling of RAS or verification of mix design will be performed without this certification.
7/1/2015
413-3
Asphaltic Concrete Incorporating Reclaimed Asphaltic Pavement or Shingles (RAP or RAS)
413.6.1 The maximum amount of RAP or RAS will be permitted provided JMF requirements and environmental regulations of other agencies can be met. The Engineer may adjust the quantities as necessary to obtain the required characteristics of the mixture. The percentage of reclaim, new mineral aggregates, new mineral filler, and asphalt cement to be used will be designated by the Engineer at the time the job mix is approved. During manufacturing, the RAP or RAS proportions shall not be adjusted to achieve the required mix volumetric requirements. When unsatisfactory results or other conditions make it necessary or should a source of material be changed, a new JMF may be required. 413.6.1.1 Wearing Surface Courses. When only RAP is used in the mixture, a maximum of 20.0 percent by weight of the total mixture will be permitted in wearing surface courses. When only RAS is used in the mixture, a maximum of 5.0 percent by weight of the total mixture will be permitted. 413.6.1.2 Subsurface Base Courses. When only RAP is used in the mixture, a maximum of 25.0 percent by weight of the total mixture will be permitted in subsurface base courses. When only RAS is used in the mixture, a maximum of 5.0 percent by weight of the total mixture will be permitted. 413.6.1.3 Combination of RAP and RAS. When RAP and RAS recycled materials are used in combination, the RAS will be limited to a maximum of 2 percent of the total RAP allowed. This 2 percent of RAS would be deducted from the total RAP allowed. So the maximum amount RAS and RAP in a wearing surface would be 2 percent RAS and 18 percent RAP. The maximum amount RAS and RAP in a base course would be 2 percent RAS and 23 percent RAP. 413.6.1.4 Virgin Binder Modification. With binder modification, the Contractor is allowed up to a 10 percent increase in RAP content. When the percentage of RAP is greater than specified in Section 413.6.1.1 or 413.6.1.2 but less than 10 percent, select virgin binder one grade softer than normal (e.g., select a PG 58-28 if a PG 64-22 would normally be used). Binder adjusted for traffic speed and traffic level, first change the base binder than adjust the high temperature grade of the binder (e.g., a PG 70-22 would become a PG 64-28). In any circumstances, if the quantity of virgin binder is less than 70 percent by mass of the total RAP or RAP/RAS binder, the grade of the virgin binder shall be determined by following the recommendation from AASHTO M 323 Appendix X1 Procedures for Developing a Blending Chart. The computations shall be submitted with the mix design for Engineer review. 413.7 Gradation Control. The gradation of the RAP or RAS will be determined when the JMF is approved. The gradation of the RAP or RAS on the approved JMF shall be used along with gradation of the new mineral aggregates and mineral filler. During production, the gradation of the aggregates will be determined in accordance with AASHTO T 27 from samples taken from the hot bins on batch-type or continuous mixing plants or from the composite cold feed belt on drum mix plants. These gradations, along with RAP or RAS gradations, will be used as a gradation control.
7/1/2015
413-4
Asphaltic Concrete Incorporating Reclaimed Asphaltic Pavement or Shingles (RAP or RAS)
413.8 Equipment. A drum mix plant with modifications for the addition of recycled material may be used. The modifications for the addition of this material shall meet the approval of the Engineer. The drum mix plant and the proportioning of recycled material shall comply with Section 404.13.13.1, Drum Mix Plants. 413.8.1 Batch or continuous mixing plants shall comply with Sections 404.13.10.1 and 404.13.10.2, except as hereinafter provided. A separate cold feed shall be provided for the RAP or RAS. Vibrators may be required on the RAP or RAS feed gate if continuous proportioning is used. The RAP or RAS may be introduced through a dryer or may be introduced into the mixing unit of the plant immediately after proportioning. Regardless of the method of introduction to the mixing unit, the RAP or RAS shall be accurately proportioned by weight or volume within 2 percent of the quantity of RAP or RAS required. 413.9 Construction Requirements. The recycled mixture shall comply with the requirements of Sections 404.18 through 404.25.1.5. 413.10 Method of Measurement. Section 404.30 shall govern. 413.11 Basis of Payment. Section 404.31 shall govern.
7/1/2015
413-5
Asphaltic Concrete Incorporating Reclaimed Asphaltic Pavement or Shingles (RAP or RAS)
(This page intentionally left blank.)
7/1/2015
413-6
Asphaltic Concrete Incorporating Reclaimed Asphaltic Pavement or Shingles (RAP or RAS)
Division 500
RIGID PAVEMENT
9/1/2023
500-1
Rigid Pavement
(This Page Intentionally Left Blank)
9/1/2023
500-2
Rigid Pavement
Standard Specifications for Road and Bridge Construction Division 500 - Rigid Pavement Section
Description
Revision Date
501......Ready-Mixed Concrete .............................................................................................9/1/2023 502......Portland Cement Concrete Pavement ....................................................................3/15/2022 503......Bridge Approach Slab...............................................................................................2/1/2017 504......Concrete Approach Pavement .................................................................................1/1/2016 505......Reinforced Concrete Pavement ...............................................................................1/1/2016 506......Blank....................................................................................................................................... 507......Strength of Concrete Using the Maturity Method .....................................................1/1/2016 508......Subdivision Concrete Replacement .........................................................................9/1/2023 509......Portland Cement Concrete Base (formerly Section 309) .........................................9/1/2023
9/1/2023
500-3
Division 500 - Index
(This Page Intentionally Left Blank)
9/1/2023
500-4
Division 500 - Index
Section 501
Ready-Mixed Concrete
501.1 Description. This specification covers ready-mixed concrete manufactured, delivered, and conveyed to the point of placement on the job site in a freshly mixed and unhardened state as herein specified. Contractor ready-mixed concrete shall consist of a mixture of Portland cement, supplementary cementitious materials, fine aggregate, coarse aggregate, and water combined in the proportions specified for the various classes of concrete. Admixtures for the purpose of entraining air, retarding or accelerating the set, tinting, and other purposes may be added as specifically required or permitted. 501.2 Materials. All materials shall be in accordance with Division 1000, Materials Details, as specified in the contract documents and specifically as follows: Item
Section
Coarse Aggregate
1005.2
Fine Aggregate
1005.3
Lightweight (Low Mass Density) Aggregates
1005.4
Optimized Aggregate Blend Guidelines
1005.5
Combine Aggregate Gradation Requirements
1005.6
Silica Fume
1016
Ground Granulated Blast Furnace Steel Slag
1017
Fly Ash for Concrete
1018
Portland Cement
1019
Concrete Admixtures
1054
Concrete Tinting Material
1056
Water
1070
501.2.1 Fibers. Macro-synthetic fibers are manufactured from virgin polyolefins (polypropylene and polyethylene) and shall comply with ASTM C 1116.4.1.3 and Section 505.2.3. 501.2.2 Storage. Storage facilities satisfactory to the Engineer shall be provided at the batching plant to permit proper sampling, handling, testing, and control of materials prior to and during use. 501.2.3 Concrete used in sidewalks, steps, medians, median strips, and paved approaches will require the use of coarse aggregate that does not exceed the chert limits specified in accordance with Section 1005.2.6.
9/1/2023
501-1
Ready-Mixed Concrete
501.3 Quality of Concrete. The proportions of Portland cement, supplementary cementitious material, fine aggregate, and coarse aggregate for ready-mix concrete shall be as specified by the Engineer within the applicable limits of the specifications for the class of concrete designated in the contract. Aggregate Proportions. Aggregates in Class B, (curb and gutter) mixes must be proportioned to have a minimum of 55 percent coarse aggregate by weight of the total coarse and fine aggregate, unless an optimized gradation is submitted. Aggregates in mixes with macro-fiber must be proportioned to have no less than 45 percent, but no more than 55 percent coarse aggregate by weight of the total coarse and fine aggregate. Aggregate in seal concrete mixes shall be proportioned to have no less than 45 percent, but no more than 55 percent fine aggregate by weight of the total coarse and fine aggregate. Aggregates in all other mixes must be proportioned to have a minimum of 60 percent coarse aggregate by weight of the total coarse and fine aggregate unless an optimized gradation is submitted. The Contractor shall submit a mixture designed by absolute volume methods or an optimized mix design method such as Shilstone method or other recognized optimization method. Aggregate Gradations. Optimized will refer to aggregate gradations that produce lower water demands, as well as improved workability and finishing characteristics. When optimized aggregate gradations are used, the final grading shall conform to the blending and combined (coarseness, workability, 0.45 power curve, cohesion and workability retained) aggregate requirements of Sections 1005.5 and 1005.6. Unless otherwise specified in the contract documents, the nominal maximum size of coarse aggregate shall not exceed three-fourths of the minimum clear spacing between reinforcing bars, one-fifth of the narrowest dimension between sides of forms, or one-third the thickness of slabs or toppings. The nominal maximum size of coarse aggregate used in seal concrete shall not exceed three-fourths of an inch. The target and allowable gradation range of each fraction shall be included. The Engineer assumes no responsibility for the volume of concrete produced or furnished for the work. 501.3.1 Mix Design. All concrete material used within County right-of-way shall have a mix design submitted, reviewed, and approved by the Chief Materials Engineer. Mix designs shall be prepared in accordance with the appropriate sections of ASTM C 94, ASTM C 192, ACI 211.5R-01, ACI 301, and ACI 318 Chapter 5. When the Contractor submits alternative mix designs and tests results, the Contractor shall provide the Engineer documentation as follows: 1) That an American Concrete Institute (ACI) Certified Concrete Field Testing Technician, Grade I, or approved equal, has been used to: a) Measure temperature, slump, self-consolidating concrete properties (slump flow, visual stability index, and J-ring values), air content and wet unit weight of trial batch; b) Cast a minimum of nine 4" x 8" (or six 6" x 12") cylinders from the trial batch, three for each opening compressive strength, three 4" x 8" (or two 6" x 12") cylinders for 7-day compressive strength, and three 4" x 8" (or two 6" x 12") cylinders for 28-day compressive strength;
9/1/2023
501-2
Ready-Mixed Concrete
c) Cast cylinders as specified otherwise in the contract documents and; 2) That an American Concrete Institute (ACI) Certified Concrete Strength Testing Technician, or approved equal, has been used to: a) Perform compression testing and report the required compressive strengths. 501.3.1.1 Required Information. The Contractor shall submit to the Engineer the following in no less than 14 days in advance of the pre-production trial batch. The mix design shall be designed at the absolute volume of each component (rounded to the nearest 0.01) plus the volume of the target entrained air content specified, be reported to the nearest 0.01, and should add up to 27.10 ± 0.05 cubic feet per cubic yard. If more than one production facility is proposed for use, the information shall be submitted for each facility. Aggregate physical properties testing shall not be more than 1 year old. The concrete mix design shall include the following information: 1) Letter of transmittal identifying proposed concrete mixtures to be furnished, the County project for which it is submitted, and method used to select proportions, signed and dated by the person that prepared the submittal and the person selecting the mixture proportions. a) Certification of compliance that all of the materials proposed for work meet the requirements of the contract documents. 2) Manufacturer name, plant identification, and corresponding email or mailing address. 3) Manufacturer quality control representative name and email or mailing address. 4) Manufacturer mix design designation. 5) Mixture identification by class. 6) Specified minimum compressive strength (f’c) that is applicable for class, in psi. 7) Exposure class, in accordance with ACI 318 Chapter 4. 8) Documentation of compressive strength test records used to determine standard deviation in accordance with ACI 318. These records shall not be greater than 24 months old and shall be collected over a period of not less than 60 days. 9) Required average compressive strength (f’cr), psi. Determination of required average compressive strength (f’cr) of proposed mixture shall be based on ACI 318 Chapter 5 and reported to the nearest 50 psi.
9/1/2023
501-3
Ready-Mixed Concrete
10) Documentation that proposed concrete proportions will produce an average compressive strength f’cr that shall include field strength test record, 10-30 compressive strength test records (tested at 28-days or at the test age specified for f’c), or trial mixtures that represent materials, slump, self-consolidated concrete properties, air entrainment and conditions to those expected during placement. Strength tests with water to cementitious ratio below design are not acceptable. 11) Intended placement method(s): a) Buckets; b) Chutes and Belts; c) Buggies; d) Pumps; e) Tremies; f) Spreader or Belt Placer. 12) Source, type, and specific gravity (to the nearest 0.01) of Portland cement. 13) Source, type (class, grade, etc.), and specific gravity to the nearest 0.01 of each supplementary cementitious material, if used. 14) Vendor, name, amount, and type (Class) of admixtures (fibers, pigments, air entraining, water reducer, accelerator, etc.). a) Identify location of admixture addition if not made at the batching facility. 15) Source, class, type (formation, river source, etc.), applicable ledge number, and gradation of the aggregates used. 16) Saturated-surface-dry specific gravity (to the nearest 0.001) and absorption (to the nearest 0.1 percent) of each fraction in accordance with AASHTO T 85 for coarse aggregate and AASHTO T 84 for fine aggregate, including raw data. 17) Dry-rodded unit weight of each coarse aggregate fraction in accordance with AASHTO T 19 to the nearest whole number. 18) For optimized mixtures, the percent of each aggregate component to the nearest 0.1 percent. 19) Source of water and ice (i.e., Missouri American, well, etc.). a) Non-potable water source requires evidence of satisfactory use at the time of plant calibration in accordance with Section 1070 Water. 20) Wet unit weight of concrete mixture to the nearest 0.1 pounds per cubic foot.
9/1/2023
501-4
Ready-Mixed Concrete
21) Lightweight concrete only: a) Equilibrium density of concrete mixture to the nearest whole pounds per cubic foot in accordance with ASTM C 567; b) Oven-dry loose unit weight of lightweight aggregate to the nearest 0.1 pound per cubic foot. 22) Batch weight of each cementitious material to the nearest 5 pounds per cubic yard. 23) Batch volume of each chemical admixture to the nearest 0.1 fluid ounces per cubic yard. 24) Batch weight of each dry admixture (i.e., fiber, color pigments) in incremental units (sacks, bags, or tins) and to the nearest 0.1 pounds per cubic yard. 25) Batch weight of each aggregate to the nearest 10 pounds per cubic yard. 26) Batch weight of water to the nearest 5 pounds per cubic yard. a) 1 gallon of water @ 60°F is equal to 8.328 pounds. 27) Target water to cementitious ratio (w/cm) where water includes batch water, aggregate surface moisture and water in the admixture (at dosages greater than ½ gallon per cubic yard), but excludes the absorption water of the aggregate. Target water to cementitious ratio shall be reported to the nearest 0.01 and not: a) Be less than 0.28; b) Exceed the Section 501.5 specified maximum less 0.03 (i.e., if the specified maximum w/cm is 0.43, then the target w/cm shall not exceed 0.40); and c) Vary by more than ±0.03 of the approved mix design value during production. 28) Water-soluble chloride-ion (Cl) content for each ingredient or for the hardened concrete by weight of cement, in percent (for prestressed or reinforced concrete only). 29) Latex Modified concrete only: a) Standard density, unit weight in pcf. b) In-place density of plastic concrete, pcf.
9/1/2023
501-5
Ready-Mixed Concrete
30) Self-Consolidating Concrete only: a) Visual Stability Index (VSI) of Self-Consolidating Concrete (SCC) (AASHTO T 351). i) Visual Stability Index rating shall be reported in accordance with Table 1 of AASHTO T 351. b) Slump Flow of Self-Consolidating Concrete (AASHTO T 347). i) Slump flow, to the nearest 0.25 inch. ii) T50 time, to the nearest second. c) Passing Ability of Self-Consolidating Concrete by J-Ring (AASHTO T 345) i) J-Ring Δheight, to nearest 0.25 inch. ii) The slump flow difference between inside the ring and outside the ring, to the nearest inch. d) Stability. Except for lightweight concrete, the stability of the concrete shall be determined in the laboratory prior to approval of the SCC mixture using test method ASTM C 1610, reporting the static segregation to the nearest 0.1 percent. 501.3.1.2 Mix design(s) submitted for approval shall be within the limits specified for: 1) Minimum cement content; 2) Maximum amount of water (and admixture, if applicable) that achieves maximum slump; 3) Slump (except for self-consolidating concrete); 4) Target entrained air content; 5) Nominal Maximum Aggregate size; 6) Fresh Concrete Unit Weight (wet); 7) ±3 pounds per cubic foot of Equilibrium density (when specified for Lightweight concrete only), not to exceed maximum when tolerance is applied; 8) For self-consolidating concrete: VSI, Slump Flow, T50, J-Ring Flow, and static segregation. Static segregation test not required for lightweight concrete.
9/1/2023
501-6
Ready-Mixed Concrete
501.3.1.3 Contractor Materials for Mix Design. The proportions for any mixture of materials obtained from established and County-approved commercial sources may be obtained by the Contractor from the Engineer upon request. If the Contractor desires to ascertain the mix for a certain combination of aggregates obtained from commercial sources before construction work starts, the Contractor shall advise the Engineer in writing of the specific source of materials which he desires to use, and the Engineer will supply the mix for each combination of coarse and fine aggregates for which a specific request is made. Admixtures used in combination shall be compatible with one and other and result in a uniform mixture. Dosage of admixtures may vary. A range of dosages shall be allowed which will permit obtaining the specified physical properties of plastic and hardened concrete. If mix design information is desired for bidding, requests for such information may be made to the Director, Department of Transportation. The County will not specify admixture quantity unless specified in the contract documents. 501.3.1.4 Contractor Request for County Mix Design Review. The Contractor shall make the request as far in advance of the letting as possible to allow the Engineer sufficient time to furnish a reply. The Contractor shall allow the Engineer up to 28-days to furnish a reply. The mix set by the Engineer will be based upon the materials designated by the Contractor as intended for use in the work. The Contractor shall notify the Engineer at least 5 days in advance of a proposed material source change. Materials source changes not approved and that are incorporated in the work will result in the concrete being rejected by the Engineer. If sources of supply are changed, the mix may be revised if necessary. Any costs due to delays caused by the submittal of mix designs which do not meet specification requirements will be the responsibility of the Contractor. 501.3.1.5 Early Opening of Pavement. Alterations in the pavement mix design may be allowed at the discretion of the Engineer to accommodate the early opening of the roadway. Proposals for pavement mix modifications to accomplish accelerated strength gain of the concrete shall be submitted to the Engineer ten days prior to the intended pour date for review and approval. 501.3.1.6 Ordering Responsibility. The Contractor is responsible for ordering concrete from the manufacturer that will ensure timely, uniform delivery of material to the job site. 501.3.1.7 Production Notification. Manufacturing plant inspection is typically required for concrete quantities at or above 50 cubic yards. The plant shall certify loads when the quantity produced is less than 50 cubic yards and inspection is not performed. Whenever production is made for the Department, the Contractor or utility shall notify the Engineer by 2:30 pm the business day before the day of production with the manufacturing plant name, class or designation of the concrete mix, amount of concrete to be batched, special air, slump or admixture requirements and batching time. Failure to notify the Engineer may result in reduction of payment, complete rejection, or removal and replacement of the material placed. 501.3.1.7.1 Load Certification of Compliance. The concrete producer shall provide a Certificate of Compliance for each truckload of concrete when inspection is not performed. The Certificate of Compliance shall verify that the delivered concrete is in compliance with the mix design and shall include:
9/1/2023
501-7
Ready-Mixed Concrete
1) Name of the ready-mix concrete producer and plant location; 2) Name of the Contractor; 3) Date; 4) County / Federal Project Number; 5) Bridge Number (when applicable); 6) Time concrete was batched; 7) Truck number; 8) Quantity of concrete in this load; 9) Running total of this concrete mix batched on this day for this project; 10) Type of concrete (County Mix Designation Number); 11) Cementitious Materials (Portland cement, ground granulated blast furnace slag, fly ash, silica fume, others) including brand, type and production mill and production power plant for fly ash using County Standard Abbreviations; 12) Admixture brand and product name using County Standard Abbreviations; 13) Aggregate sources using state DOT Ledge / Pit identification; 14) Admixture brand and quantity batched in oz./100 wt. or oz./(cy) for: a) Air-entraining admixtures; b) Water reducing admixtures; c) Other admixtures; 15) Total Water (Batch Water + Free Moisture) (gal./lbs.); 16) The water available to add in gallons; 17) Mix Design Water Target (CY’s) - Total water (gallons). 501.3.1.7.2 Certificate Responsible Representative. The Certificate of Compliance shall be signed by a responsible representative of the concrete producer, affirming the accuracy of the information provided. 501.3.1.7.3 Certificate Minimum Requirements. For commercial concrete, the Certificate of Compliance shall include, as a minimum, the batching facility, date, and quantity batched per load.
9/1/2023
501-8
Ready-Mixed Concrete
501.3.1.8 Field Adjustment of Approved Mix Design. During the conduct of work, the Engineer reserves the right to require the Contractor to order the producer to change the proportions if conditions warrant, producing a satisfactory mix. If any changes are made to the mixture proportions, material source or materials that are outside the limits specified below, the revised proportions shall be submitted for review and shall demonstrate a compressive strength equal to or exceeding the current required average compressive strength established by job records. Any changes made shall also be within the limits specified in the contract documents and shall be made at no additional compensation to the Contractor. Mix Design Changes Requiring Resubmittal* Mix Design Element
Tolerance (±)
Water to cementitious material ratio (w/cm)
0.03
Total water content, percent
5
Coarse aggregate (weight per cubic yard), percent
10
Fine aggregate (weight per cubic yard), percent
10
Supplementary cementitious material content, percent
5
Admixture (as originally dosed), percent
25
Unit Weight, pounds per cubic foot
5
* When tolerance is applied, the element value shall not be outside specification limits. 501.3.1.9 Mix Design Re-Submittals. To keep accurate records, the original job mix design will be labeled with a revision number consecutively numbered beginning with (R1) behind the last digit of the job mix design number to signify that the job mix design has been field adjusted. Supporting data justifying the need and type of field adjustment shall be submitted to the Engineer. The Engineer will approve all field adjustments. The Contractor must notify the Engineer in writing of the adjustments made, new target values and any other information required for evaluation of the revised mix. The Contractor shall submit the field adjusted job mix design to the Engineer in writing at least 24 hours in advance of revised mix use.
501.3.2 Classification of Fine Aggregate. For simplicity of design, the various fine aggregates are grouped into four classes, and a minimum cement factor has been established for each class. Classification of Fine Aggregates Class A
Unit Weight (pounds per cubic foot)
Description
Minimum
Maximum
All sand, except manufactured sand
109
-
All chert and river sand
106
108
Glacial sand
-
108
B
9/1/2023
501-9
Ready-Mixed Concrete
C
All chert and river sand
101
105
D
Sand which is produced by the process of grinding and pulverizing large particles of aggregate, or which contains more than 50 percent of material produced by the reduction of coarser particles. Manufactured sand produced from limestone or dolomite shall not be used in Portland cement concrete for driving surfaces such as bridge decks, pavements, and shoulders.
-
100
501.3.2.1 Concrete used in sidewalks, curb ramps, steps, medians drive approaches and driveways will require the use of lignite-free sand, in accordance with Section 1005.3.5, Lignite-Free Material. 501.3.3 Minimum Cementitious Requirements. The quantity of cementitious material used in any cubic yard of concrete shall be the cementitious content in pounds per cubic yard of concrete as determined from a summation of the absolute volumes of all the ingredients and, when air-entrained concrete is specified, the volume of air. Type I/II or Type IL PortlandLimestone cement shall typically be used unless specified otherwise in the contract documents. The total cementitious requirements in pounds per cubic yard of concrete for the various classes of sand are noted in the following charts:
9/1/2023
501-10
Ready-Mixed Concrete
Minimum Cementitious Requirement (Pounds per Cubic Yard) Class of Sand
Class A-1 Concrete
A
600
B
640
C
-
D
-
MSD Class A
Class B Concrete
Class B-1 Concrete
Class B-2 Concrete
Class MB-2 Concrete
Seal Concrete
545
620
729
600
660
583
650
759
620
695
605
670
774
640
715
640
705
814
660
735
As Per MSD Standards
Minimum Cementitious Requirement (Pounds per Cubic Yard) Class of Sand
Pavement Concrete (PCCP)
MPCCP
VES PCCP*
HE PCCP*
A
588
570
850
700
B
602
585
850
700
C
602
585
850
700
D
602
585
850
700
* Type I/II Portland cement. For VES PCCP mix design with Type III cement, the minimum cementitious required is 650 lbs./cy.
501.3.3.1 MSD-A Concrete. Refer to the most recent edition of "Standard Construction Specifications for Sewers and Drainage Facilities" published by the Metropolitan St. Louis Sewer District for cement requirements of Class MSD-A concrete. Type I/II cement shall typically be used unless concrete will be used for sanitary or combined sewers for which Type II cement will be required. 501.3.3.2 Modified Concrete. 501.3.3.2.1 Modified concrete shall use at least two supplementary cementitious materials in accordance with this specification. Modified concrete may be used in-place of each class of concrete. In no case shall modified concrete use less than 15 percent fly ash or Ground Granulated Blast Furnace Slag (GGBFS) when used as supplementary cementitious material replacement of up to 50 percent of the total cementitious material. Modified mixtures shall include the "M" designation before the mix designation (i.e., B-2 modified would be named MB-2).
9/1/2023
501-11
Ready-Mixed Concrete
501.3.3.3 Supplementary Cementitious Material. When permitted, fly ash, GGBFS, and silica fume may be used in the production of Portland cement concrete. The quantity and permissible uses of fly ash will be determined by the Engineer. An adjustment in the design mix proportions will be required to correct the volume yield of the mixture. The maximum cement content will be required for Portland cement - fly ash mixtures, Portland cement silica fume mixtures, Portland cement GGBFS mixtures, and Portland cement-fly ashGGBFS silica fume mixtures regardless of class of concrete specified. Silica fume shall meet the requirements of Section 1016. GGBFS shall meet the requirements of Section 1017. Fly ash shall meet the requirement of Section 1018. 501.3.3.4 Seal Concrete. The use of an ASTM C 494 Type D water reducing-retarding and ASTM C 494 Type S and CRD-C 661-06 anti-washout admixtures are required for underwater placement. Seal concrete not placed underwater shall have a minimum slump of 6 inches at the time of placement. Use of supplementary cementitious materials are permitted up to the limits specified in Section 501.3.5.4. For concrete to self-consolidate underwater under its buoyant weight, seal concrete shall be within a slump range of 6 to 9 inches at the time of placement and shall not receive the cement reduction in accordance with Section 501.3.3.4. Test mixes are advised. Underwater placement of seal concrete shall be in accordance with ACI 304, unless superseded by the standard specifications. 501.3.4 Unit Weight. For aggregates with a nominal maximum size of 1½ inches or less, the aggregate weight per cubic foot shall be determined in accordance with AASHTO T 19 using the rodding method. For self-consolidating concrete the unit weight shall be determined in accordance with AASHTO T19, except that the concrete shall be filled in one lift and not consolidated. Unit weight is reported to the nearest whole pound per cubic foot. 501.3.5 Minimum Performance Requirements. 501.3.5.1 Minimum Design Compressive Strength Requirements. Concrete classes shall meet the following minimum f’ c (28-day design compressive strength) requirements in pounds per square inch (psi) as determined in accordance with ASTM C 39: Minimum 28-day Design Compressive Strength (f’c), psi Class A-1 Concrete
MSD Class A Concrete
Class B / C&G and STR Concrete
Class B-1 Concrete
Class B-2 and MB-2 Concrete
PCCP and MPCCP Concrete
VES and HE PCCP Concrete
Seal Concrete
6,000
Per MSD
3,000
4,000
4,000
4,000
4,000
3,000
501.3.5.1.1 Acceptable Results. Unless specified otherwise in the contact documents, individual strength tests of concrete must meet or exceed the minimum 28-day compressive strength (f’c). An individual strength test shall be the average strength of two 6 inch x 12 inch or three 4 inch x 8 inch specimens.
9/1/2023
501-12
Ready-Mixed Concrete
501.3.5.1.2 Unacceptable Results. Concrete that does not meet the requirements of Section 501.3.5.1.1 shall require the Contractor to submit documentation to the Engineer of what steps are to be taken to improve compressive strength results. Further concrete placement shall not be permitted until the Engineer reviews and approves the Contractor submittal. Concrete in the area represented by the failed molded strength specimens shall be subject to removal and replacement or reduction in pay in accordance with the contract documents. 501.3.5.2 Supplementary Cementitious Limitations. Coal fly ash, ground granulated blast furnace steel slag (GGBFS), and silica fume shall not be used outside the limits allowed herein unless specified otherwise in the contract documents. Concrete shall not exceed the following percent limits of supplementary cementitious by weight of mix design total cementitious content: Supplementary Cementitious Material Limitations
Cementitious Material
Test Method
Percent Allowed based on Total Cementitious materials by weight* Minimum
Maximum
Fly Ash
ASTM C 618
15
25
Slag
ASTM C 989
15
30
Silica Fume (MB-2 mix)
ASTM C 1240
6
8
Silica Fume (Remaining mixes)
ASTM C 1240
4
8
Total of fly ash or other pozzolans, slag, and silica fume
---
40‡
Total of fly ash or other pozzolans and silica fume
---
35‡
* The total cementitious material also includes ASTM C 150, C 595, C 845, and C 1157 cement. Replacement shall be made on a pound for pound basis. The maximum percentage listed above shall include: a) Fly ash or other pozzolans in Type IP blended cement, ASTM C 595, or ASTM C 1157; b) Slag used in the manufacture of an IS blended cement, ASTM C 595, or ASTM C 1157; c) Silica fume, ASTM C 1240, presented in a blended cement. ‡ Fly ash or other pozzolans and silica fume shall constitute no more than 25 and 8 percent, respectively, of the total weight of the cementitious materials.
501.3.5.3 Maturity Testing Requirement. In addition to the mix design, a maturity curve shall be required for any very early strength (4 to 6 hour opening) concrete pavement mix. A maturity curve is optional before the application of any high early strength (24 to 48 hour opening) concrete pavement mixes and for all other mixes intended to have structural forms removed or a structure be placed into service in 3 days (72 hours) or less after placement. The maturity curve shall be developed in accordance with Section 507. 501.3.5.3.1 Maturity Curve Expiration Time Limit. A maturity curve may be transferred to other projects for a period of 1 year from the original approval date or the last field verification date provided that no material sources, admixtures, batch weights, and aggregate gradations have changed, and satisfactory results are obtained during production and placement.
9/1/2023
501-13
Ready-Mixed Concrete
501.3.5.4 Unit Weight Requirement. Unit weight for lightweight concrete shall not exceed ±3 pounds per cubic foot of that approved in the mix design. Unit weight for all other concrete shall not exceed ±5 pounds per cubic foot of that approved in the mix design. 501.3.5.4.1 Unacceptable Results. When a concrete mix design does not meet the requirements of Section 501.3.5.5 the Contractor shall submit to the Engineer documentation of what steps are to be taken to improve unit weight results. Further concrete mix placement shall not be permitted until the Engineer reviews and approves the Contractor submittal. 501.4 Sampling. The Contractor shall afford the Engineer all reasonable access, without charge, for the procurement of samples of fresh concrete at the manufacturing and placement sites to determine conformance of this specification. Sampling of fresh concrete shall be in accordance with AASHTO R 60, except that for central or truck mixed concrete, the entire sample for testing slump, self-consolidating concrete properties (when mix is approved for use), temperature, unit weight, air content, and for molding compressive strength specimens, may be taken at one time after approximately one cubic yard of concrete has been discharged instead of at two or more regular intervals during the discharge of the entire batch. Acceptability of the concrete for slump, selfconsolidating concrete properties, temperature, unit weight, air content, and, when applicable, strength requirements will be determined by tests on these samples. Slump, self-consolidating concrete properties, air-content, temperature, and unit weight tests shall be made at the time of placement at the option of the Engineer as often as necessary for control checks and acceptance purposes, and always when strength specimens are made. Pumped Concrete. The quality of the concrete being placed in the pavement or structure shall be measured at the placement end of the pipeline. Appropriate correlation sampling and testing at both the truck discharge and point of final placement shall be employed to determine if any changes in the slump, air content, and other significant mixture characteristics occur. When sampling at the end of the placement line, great care must be taken to assure that the sample is representative of the concrete going into the placement. The Contractor shall provide safe a sampling area at the placement end of the pipeline for the Engineer before placement begins. Correlation tests should be determined, as a minimum, at the beginning, middle, and toward the end of a pour. The Engineer will evaluate situations such as size of pour, changing weather conditions, changes in conveyor length, changes in pumping boom configuration or pipe angles, and changes in batch proportions when determining frequency of correlation tests. Concrete shall not be allowed to free fall into the tester's container. The handling of the sample shall not result in changes in concrete properties. 501.4.1 Preliminary Sampling. Initial slump, self-consolidating concrete properties, temperature, unit weight or air entrainment checks may be made from a single sample taken after discharge of not less than one-quarter of a cubic yard. All other practices of AASHTO R 60 shall be retained. If measurement of slump, self-consolidating concrete properties, temperature or air content falls outside the limits specified, address as indicated in the following:
9/1/2023
501-14
Ready-Mixed Concrete
501.4.1.1 Upper Limit Exceeded. If the measured slump, self-consolidating concrete properties, temperature, unit weight or air content or any combination is greater than the specified upper limit, a check test shall be immediately made on a new sample. In the event the check test fails, the concrete shall be considered to have failed the requirements of the specification and shall be rejected. 501.4.1.2 Lower Limit Exceeded. If the measured slump, self-consolidating concrete properties, temperature, unit weight or air content or any combination is less than the specified lower limit, the Contractor may make adjustments in accordance with Section 501.11.8, as appropriate. If the sample of the adjusted concrete fails, a check test shall be made immediately on a new sample of the adjusted concrete. In the event that the check test fails, the concrete shall be considered to have failed the requirements of the specification and shall be rejected. 501.4.2 Acceptance Strength Testing. Specimens for strength testing shall be molded and cured in accordance with ASTM C 31 and tested in accordance with ASTM C 39. Selfconsolidated concrete cylinders shall also be made in accordance with ASTM C 31, except that the concrete shall be placed in one lift and not consolidated. Light tapping of the sides of the self-consolidated concrete cylinders with an open hand is permitted. A strength test shall be the average of the strengths of at least three 4 by 8 inch or at least two 6 by 12-inch cylinders made from the same sample of concrete and tested at 28 days or at the age designated for determination of f’c. 501.4.3 Informational Purposes. The Engineer may make additional cylinders to perform strength tests for informational purposes at 7 days or at other time intervals as specified in the contract documents. The Engineer may also make additional cylinders for field cure specimens to monitor curing procedures or early age strength for opening to traffic, form removal and reshoring. Specimens shall be stored as near as possible to the structure and protected in a manner similar to the structure until they are transported for testing. 501.4.4 Sampling and Testing Pumped Concrete. The first load shall be sampled and tested at the truck chute and the point of pump discharge. The difference of slump and entrained air between the truck and the pump shall be checked at a frequency as determined by the Engineer to ensure specification compliance at the point of pump discharge when the following changes take place: 1) A significant change in vertical elevation of the boom or discharge end of the pump takes place; 2) A significant change in the distance concrete is pumped; or 3) When a different pump is used. When there is a decrease in air or slump between the reading at the truck and the reading at the pump use these correction factors to determine specification compliance. Actual sampling and testing frequencies shall be determined at the pre-paving meeting.
9/1/2023
501-15
Ready-Mixed Concrete
501.4.5 Quality Control Practices, Test Methods and Reporting. Quality control testing equipment shall be provided in good working order, maintained, and calibrated in accordance with AASHTO requirements. Practices, test methods, sampling, testing, and reporting shall be performed by the Engineer. When testing and reporting are performed other than by the Engineer: 1) The agency must meet the requirements of ASTM C 1077; and 2) Site sampling and testing of concrete shall be performed by either an ACI or MoDOT certified concrete field testing technician. The reports shall also list any part of the test method not performed by the testing agency. The minimum rate of concrete sampling and testing at the time of placement shall be as follows: 501.4.5.1 Inspection and Testing. Required Plant Tests. Unless otherwise designated in the Contract documents, the Engineer will randomly perform sampling and testing of each design mix for proportioning, air content, temperature, slump, self-consolidating concrete properties (slump flow, visual stability index, and J-ring values), unit weight and compressive strength specimens shall be performed at the plant, or at a location approved by the Engineer, to control the production of a mixture. The manufacturer shall conduct testing for self-consolidating concrete properties. Self-consolidating concrete properties that fail to meet specification requirements shall be rejected for use. Required Field Tests. Unless otherwise designated in the Contract Documents, the Engineer will randomly sample and test concrete at the point of placement for each design mix for air content, temperature, slump, self-consolidating concrete properties (slump flow, visual stability index, and J-ring values), and compressive strength specimens. The Engineer will cast, store, and test specimens for 28-day compressive strengths.
9/1/2023
501-16
Ready-Mixed Concrete
501.5 Consistency. The quantity of mixing water in the concrete shall be considered the net quantity after proper allowance has been made for absorption by the aggregate. The slump and water to cementitious ratio (w/cm) ratio of the concrete shall be within the following limits for the respective classes of concrete. The concrete shall be uniform in consistency and contain the minimum quantity of water required to produce the designated slump. Water shall not be added in transit. The slump of concrete mixes will be determined in accordance with AASHTO T 119. The quantity of mixing water in the concrete shall be considered the net quantity after proper allowance has been made for absorption by the aggregates and water contribution of water-reducing admixture(s), and chloride and non-chloride accelerators. For MSD Class A concrete slump limitations see Section 501.5.1. The production w/cm shall not be less than 0.25. Slump and w/cm shall not exceed the following limits:
Class of Concrete A-1
Maximum W/CM
Maximum Slump (Inches)d 3½
MSD A
Air Entrained
Non-Air Entrained a
0.43
0.50
In accordance with MSD current specifications
B
4
0.50
0.55
B-1
4
0.43
0.50
B-2
4
0.43
----
M-Class
4
0.43
----
Pavement
4
0.43
----
High Early or Very Early Pavement
6
0.40
---
Self-Consolidated
b
0.40
---
Seal
c
0.43
a
Concrete with entrained air content less than or equal to 3.0 percent See Section 501.3.3.7 requirements. c See Section 501.5.1.1.1 requirements. d See Section 501.16.4 requirements, addition of water reducing admixture for allowable slump increase. b
501.5.1 Form Finishing. For all other concrete struck off by hand or vibratory screed and placed between vertical formwork, the slump and mixing water content of the concrete, when placed in the work, shall not exceed the specified w/cm ratio and other limits specified herein. When hand finishing method is used and when tested in accordance with ASTM C 143, the slump at the time of placement: 1) Shall not be less than 2½ inches and 2) Shall not exceed the limits specified in Section 501.5.
9/1/2023
501-17
Ready-Mixed Concrete
501.5.1.1 Self-Consolidating Concrete. Self-consolidating concrete is a flowable mixture that does not require mechanical vibration for consolidation. Self-consolidating concrete mix designs may be developed for VES PCCP, Class A1 and precast concrete items. The maximum allowable horizontal flow measured from the point of placement is 30 feet, unless specified otherwise in the contract documents. Vertical free-fall shall not exceed 15 feet. The slump requirements shall not apply. The Contractor is allowed to use a viscosity modifying admixture approved by the Engineer. When the contract documents indicate self-consolidating concrete, the following properties shall be tested daily, or until in compliance, in accordance with ASTM C 1611 so that at the time of placement the following additional requirements are met. Consolidation is typically not necessary for SCC. However, the Contractor shall have internal vibrators as required in Section 502.3.7 Vibrators on site in case internal vibration is needed due to delays in placement or the concrete has a lower than expected slump flow and has to be placed to prevent the formation of a cold joint. In addition to unit weight, entrained air content, temperature, and compressive strength tests, the following tests will be required: 501.5.1.1.1 Slump-Flow Requirements. Determine the workability of the concrete by performing a slump flow test every 15 minutes until the slump flow reaches the target slump flow less 5.0 inches. From the slump loss flow curve, determine the cutoff time at the lower tolerance range value. Ensure that the anticipated mixing, transit, and placement times do not exceed the allowable cut-off time. The slump flow ranges and production tolerances when tested in accordance with AASHTO 347 shall be as follows: 1) Cementitious content 600 to 650 pounds per cubic yard: 21 to 24 inches. 2) Cementitious content 651 to 750 pounds per cubic yard: 24 to 27 inches. 3) Cementitious content greater than 750 pounds per cubic yard: 27 to 30 inches. 4) Tolerance. a) For slump flow less than or equal to 22 inches, the tolerance is ±1½ inches; b) For slump flow more than 22 inches, the tolerance is ±2½ inches; 501.5.1.1.2 Visual Stability Index. The visual stability index as tested in accordance with AASHTO T351 shall be a maximum of 1. 501.5.1.1.3 T50 Test. The T50 test, in accordance with AASHTO T 347 shall be no less than 2 seconds and no more than 7 seconds with a variance not to exceed 3 seconds between batches. 501.5.1.1.4 J-Ring. When tested in accordance with AASHTO T 345 the difference in slump flow and J-Ring flow shall not exceed 2 inches. 501.5.1.1.5 Stability. The stability of the concrete shall be determined in the laboratory prior to approval of the SCC mixture using test method ASTM C 1610. Concrete mixtures shall have a maximum static segregation (segregation factor) of 15.0 percent. This test is not applicable for lightweight concrete.
9/1/2023
501-18
Ready-Mixed Concrete
501.5.1.1.6 Retesting. If the measured slump flow, visual stability index, or J-Ring values fall outside the limits specified, a check test will be made. In the event of a second failure, the Engineer may refuse to permit the use of the batch of concrete represented. 501.5.2 Slip Form Finishing. An approved ASTM C 494 Type D water-reducing retarding admixture shall be included for slip form paving when specified by the contract documents, when the Contractor is permitted to by the Engineer, or when hot weather conditions exist. When slip form method is used, the target slump at the time of placement shall be 2¼ inches. When tested in accordance with ASTM C 143, the slump shall be within the operating tolerances as follows: 1) Shall not be less than 1½ inches, and 2) Shall not exceed 3 inches. 501.5.3 New Subdivision Pavement. The Contractor may use up to three approved concrete plants to produce subdivision pavement. Mix design, materials, proportions and admixtures shall be approved for use and be of the same for all plants used unless permitted otherwise by the Engineer.
501.5.4 MSD Requirements. When specified in the contract, all concrete and proportioning not specified herein shall conform to the "Standard Construction Specifications for Sewers and Drainage Facilities" of the Metropolitan St. Louis Sewer District (MSD), unless otherwise directed. 501.5.5 Macro Fiber-Reinforced Concrete. Macro Fiber-reinforced concrete slump shall be within the permissible range for a period of 30 minutes starting either on arrival to the job site or after the permitted slump adjustment, whichever is later. Macro Fiber-reinforced concrete shall be free of fiber balls at the time of placement. 501.5.6 Unacceptable Results. Concrete with a measured slump, entrained air, or water to cementitious ratio outside the specified limits is unacceptable and shall be wasted at the Contractor’s expense. 501.5.7 Mud Balls. Concrete discovered to contain mud balls shall be discarded. Aggregate bins at the manufacturing plant shall be reviewed for contamination. Bins or Stockpiles with aggregate containing mud balls shall be emptied and replaced with new material. 501.6 Measurement of Material. The cementitious materials and aggregates for concrete shall be measured by weight. The weights of coarse and fine aggregates to be used will be calculated from the proportions approved by the Engineer. Batches that do not contain the proper quantities or type of material specified in the mix design shall be wasted at the Contractor's expense. 501.6.1 Weighing Hoppers. Weighing hoppers shall be so constructed that there will be no attachments that might affect the free movement of the weighing mechanism. Weighing hoppers shall discharge completely and there shall be no accumulation of tare materials. Weighing and batching equipment shall be supported on a firm foundation. If necessary, the weighing hopper shall be protected against the wind.
9/1/2023
501-19
Ready-Mixed Concrete
501.6.2 Scales. Scales for weighing aggregate, hydraulic cement or cementitious materials may be either the beam-type, the springless dial type, or electronic, digital weight, meter type, and shall be of standard make and design. Scales shall be designed as an integral unit of the batching plant and shall be of rugged construction to withstand the usage for which they are intended. Scales shall be housed or otherwise protected against the effect of wind in a manner approved by the Engineer. 501.6.3 Hydraulic cement shall be weighed on a scale separate and distinct from the scale or scales used for weighing other materials. Supplementary cementitious materials shall be measured in the same manner and with the same accuracy as hydraulic cement. Supplementary cementitious materials may be weighed separately on the same scale beam as hydraulic cement provided the scale increments are such that the specified weighing accuracy can be maintained. If, however, the supplementary cementitious is weighed together with the hydraulic cement, the hydraulic cement shall be weighed first and the accuracy shall apply to the combined weight. 501.6.4 Scale Accuracy. Scales shall be designed and built so that they are accurate to within 0.4 percent of the net applied load in the hopper will be maintained. The change in load required to change the position of rest of the indicating element or elements of indicating scales an observable amount shall not be greater than 0.15 percent of the nominal scale capacity. For this purpose, the Contractor shall store, on the premises, a set of sensitivity weights, which will be readily available to County personnel. Exposed fulcrums, clevises, and similar working parts of the scale shall be kept clean. When beam-type scales are used, a separate beam shall be provided for each type of material to be used and means shall be provided for adjustment of tare. The interlock control shall be set to the required tolerance. 501.7 Weighing Tolerances. 501.7.1 The weighing and batching equipment shall be designed and maintained in such condition that the materials for each batch can be quickly and accurately weighed and shall be operated within a tolerance of plus or minus 1.0 percent for cementitious materials and plus or minus 2.0 percent for aggregates. If, for any reason, equipment previously approved becomes unsatisfactory, it shall be repaired or replaced before proceeding with the work. 501.7.1.1 Batchers. For batchers, the following tolerances shall apply based on the required scale reading. 501.7.1.1.1 Cement and Other Cementitious Materials. When the quantity of cementitious material exceeds 30 percent of the full capacity of the scale, the measured quantity of hydraulic cement shall be within ±1 percent of the required mass and the cumulative measured quantity of hydraulic cement plus supplementary cementitious materials shall also be within ±1 percent of the required cumulative mass at each intermediate weighing. For concrete batches less than 3 cubic yards, the measured quantity of hydraulic cement and the measured cumulative quantity of hydraulic cement plus supplementary cementitious materials used shall not be less than required amount nor more than 4 percent in excess.
9/1/2023
501-20
Ready-Mixed Concrete
501.7.1.1.2 Aggregates. For aggregates measured in individual or cumulative weight batchers, when the required intermediate or final mass is less than 30 percent of the scale capacity the aggregate mass shall be within ± 3 percent of the required weight of materials being weighed or ±0.3 percent of the scale capacity, whichever is less. When aggregates measured in individual weight batchers, and the required mass of aggregate is equal to or greater than 30 percent of the scale capacity, the quantity of aggregate shall be within ±2 percent of the required mass. When aggregates measured in a cumulative aggregate weight batcher, and the required intermediate and final cumulative mass of aggregate components is equal to or greater than 30 percent of the scale capacity, the quantity of aggregate at each successive weighing shall be within ±1 percent of the required mass. 501.7.1.1.3 Water and Ice. For water and ice additions, ±1 percent of the required (total mixing water) weight of materials being weighed or ±0.3 percent of the scale capacity, whichever is greater. In the case of truck mixers, total water shall be measured or weighed to an accuracy of ±3 percent of the specified total amount. 501.7.1.1.4 Admixtures. 1) Powdered. ±3 percent of the required weight of materials being weighed; or 2) Liquid. ± 0.3 percent of the scale capacity or ± the minimum dosage rate per 100 pounds of hydraulic cement as it applies to each type of admixture, whichever is greater. 3) Fibers. Fibers shall be measured by weight with an accuracy of -3 percent to +5 percent of the amount required per batch. 501.7.1.2 Volumetric Batching Equipment. For volumetric batching equipment the following tolerances shall apply to the required volume of material being batched: 501.7.1.2.1 Water. ±1 percent of the required volume of (total mixing water) material being batched or ±1 gallon, whichever is greater. 501.7.1.2.2 Admixtures. ±3 percent of the required volume of material being batched or ± the minimum dosage rate per 100 pounds of cementitious material as it applies to each type of admixture, whichever is greater. 501.7.1.2.3 Fibers. Fibers shall be measured by volume with an accuracy of -3 percent to +5 percent of the amount required per batch. 501.7.2 Water. Mixing water shall consist of water added to the batch, ice added to the batch, water occurring as surface moisture on the aggregates, and water introduced in the form of admixtures, and is measured by volume or by weight. The admixture manufacturer shall specify the amount of water in their admixture in the product’s technical data sheet.
9/1/2023
501-21
Ready-Mixed Concrete
501.7.2.1 Weight. If measured by weight, scales shall conform to the (accuracy of 1 percent of the total required mixing water ±1 percent of the required weight of material being weighed or ±0.3 percent of scale capacity, whichever is greater) requirements of Section 501.6.2. Added ice shall be measured by weight. Wash water shall be discharged prior to loading the next batch of concrete. Total water shall be measured or weighed to an accuracy of ±3 percent of the specified total amount. 501.7.2.2 Volume. The device for the measurement shall be readily adjustable, and, under all operating conditions, shall measure the required quantity within a tolerance of one quart or one percent, whichever is greater. The device shall be so arranged that the flow of water be automatically stopped when the required quantity has been delivered. Water measuring tanks shall be of adequate capacity to furnish the maximum quantity of mixing water required and shall be equipped with outside taps and valves to provide for checking their calibration under conditions similar to operating conditions. 501.7.3 Admixtures. Powdered or dry admixtures shall be measured by weight and liquid admixtures by weight or volume. 501.8 Hot and Cold Weather Production and Delivery. The capability of the production facility to produce concrete within the temperature limits of the contract documents shall be evaluated and verified. 501.8.1 Cold Weather. 501.8.1.1 Definition. Cold weather is defined as period when the ambient air temperature has fallen to or is expected to fall below 40°F during the protection period. The protection period is defined as the time required to produce the in-place compressive strength specified for form removal, pavement opening or structural safety. 501.8.1.2 Boiler Capacity. To qualify as a cold-weather production plant an estimate of the average daily production (cubic yards) during freezing weather will be needed. For cold weather production using heated mixing water, the plant shall have a minimum heating capacity of 15 boiler output horsepower (502,500 BTU/hr.) per 100 cubic yards of average daily cold weather concrete production. The heating capacity of hot water heater(s) or boiler(s) must be determined if not shown on an information plate on the heating unit. The capacity of any hot water storage used in the heating process shall be available to the Engineer. 501.8.1.3 Concrete Temperature. If Engineer approval has been granted for the Contractor to place the concrete while the ambient temperature is at or lower than 45°F, the producer shall take precautionary measures to prevent damage by freezing, such as heating mixing water, heating aggregates uniformly by either steam or a dry heat system, or applying heat directly to the contents of the mixer. The use of live steam on or through the binned aggregate is prohibited. Aggregates shall not be heated higher than 150°F and the temperature of the aggregates and mixing water combined shall be not higher than 100°F when the cement is added. Except for very early opening strength pavement concrete, the maximum temperature of concrete produced with heated aggregates, heated water, or both, shall at no time during its production or transportation exceed 80°F.
9/1/2023
501-22
Ready-Mixed Concrete
501.8.1.3.1 Mixing and Placement Temperatures. Measurement of the concrete temperature shall be made in accordance with ASTM C 1064 and at the time of discharge for the first load, when slump or air-content is tested, and as often as necessary to ensure specification compliance. Unless otherwise authorized by the Engineer, the temperature of mixes at the time of mixing and placement during cold weather shall be maintained as follows or as indicated otherwise by the contract documents. Concrete that fails to meet the temperature requirements at the time of placement shall be rejected for use.
Least Dimension of Section (LD, inches)
Cold Weather Concrete Mixing and Placement Temperature, (°F) Concrete Temperature at Time of Mixing
Concrete Temperature at the Time of Placement
Minimum
Maximum
Minimum
Maximum
LD < 12
60
80
55
75
12 ≤ LD < 36
55
75
50
70
36 ≤ LD ≤ 72
50
70
45
65
LD > 72
45
65
40
60
Note: Seal concrete temperature at the time of placement shall be at least 60°F.
501.8.1.3.2 Protection Temperature. The minimum temperature of concrete during the specified protection period shall be the minimum specified for the least section dimension. To evaluate thermal curing methods, the Engineer will monitor the temperature at the surface of the concrete. Monitor concrete temperatures at corners and edges to evaluate the effectiveness of the protection provided. The date, time and outside ambient temperature, and temperature of concrete as placed, and weather conditions (such as calm, windy, clear, cloudy) shall be recorded by the Engineer at a frequency of no less than twice per 24-hour period. Measure and record the concrete surface temperature at more than one location in the section cast and use the lowest reading to represent the temperature of that section. Measurement of the concrete temperature readings shall be made in the permanent job records. 501.8.1.3.3 Ambient Air Temperature Limitations. Concrete shall not be placed when the ambient temperature is at or below 40°F, unless authorized by the Engineer. Discontinue mixing and concrete placement when the descending ambient air temperature reaches 35°F. When a forecasted high of at least 40°F is expected, do not begin concrete placement until the ambient air temperature is at least 35°F and rising. 501.8.1.3.4 Seal Concrete. Depending on the volume at the time of placement and anticipated thermal conditions within the placement, seal concrete temperature at the time of placement shall be in the range of 60°F to 90°F. When placed underwater, the Contractor shall place and maintain seal concrete above 40°F.
9/1/2023
501-23
Ready-Mixed Concrete
501.8.1.4 Frozen Materials. Frozen materials or materials containing ice shall not be used. Cement or fine aggregate containing lumps or crusts of hardened material or frost shall not be used. Aggregates shall not be heated with a direct gas or oil flame or on sheet metal over fire. Fine aggregate shall not be heated by direct steam. The addition of salts to prevent freezing is not permitted. 501.8.1.5 Accelerating Admixture. When ambient temperatures are forecasted to be less than or equal to 40°F during the specified protection period, all concrete may contain an approved ASTM C 494 Type C liquid set and strength accelerator. The Contractor shall use the minimum amount of accelerator to achieve the desired set time and specified compressive strength. If, during cold weather conditions, an accelerator is not used, the Contractor shall supply maturity/temperature sensors in accordance with Section 507, to document concrete temperature. When the temperature of the concrete during the specified protection period falls below 32°F the concrete shall be removed and replaced. 1) Reinforced Concrete. Concrete exposed to sulfates, reinforced with weld wire reinforcement, steel fibers, reinforcing steel bars (excluding dowel bars and tie bars), pre-stressed concrete, in concrete placed over prestressed concrete structural frames, post-tensioned slabs on ground, in concrete cast on leave-inplace galvanized steel forms, in concrete with embedded aluminum or concrete containing embedded dissimilar metals shall contain a non-chloride set and strength accelerating (NCA) admixture. At ambient temperatures above 40°F, the Contractor has the option to use an approved non-chloride set and strength accelerating admixture for all other reinforced concrete to accelerate early strength gains, unless the contract documents specify otherwise. 2) Non-Reinforced Concrete. Except for conditions specified above and when using sulfate-resisting concrete, all other concrete shall meet the same placement and ASTM requirements, but a liquid-based calcium chloride accelerator may be used. An accelerator dosage of no less than 0.5 percent or no more than 2 percent of calcium chloride per 100 weight of cementitious materials, in solution form in accordance with Section 1068, is allowed. At ambient temperatures above 40°F, the Contractor has the option to use an approved chloride set and strength accelerating admixture for all other non-reinforced concrete to accelerate early strength gains, unless the contract documents specify otherwise. See table below for maximum dosage rates: Table of Calcium Chloride: Amount Introduced
0.5
Liquid form 32% solution, (ounces per 100 pounds of cementitious materials) 17.4
1.0
31.5
1.5
52.2
2.0
69.6
Calcium Chloride by mass of cementitious materials, (%)
Note: For calcium chloride concentrations in excess of 32%, reduce the dosage so as not to exceed the percentage of calcium chloride by mass of cementitious materials. Source: ACI 212.3R-10 Table 5.1(29% concentration)
9/1/2023
501-24
Ready-Mixed Concrete
501.8.1.6 Non-Air Entrained Concrete. Concrete for slabs or other flatwork exposed to cycles of freezing and thawing in a wet condition during the construction period shall be air entrained as specified for Class B concrete even though the concrete may not be exposed to freezing in service. 501.8.1.7 Supplementary Cementitious Material Use. The Engineer may allow the use of GGBFS during cold weather if the contractor or utility submits an approved plan that ensures the specified concrete minimum temperature and compressive strength will be met. 501.8.1.8 Concrete Workability. Concrete during cold weather shall maintain workability for at least 20 minutes. During cold weather bleed water may remain on the surface for extended periods. The Contractor shall proportion the concrete mixture to minimize bleeding. If bleed water is present, skim off the excess with a rope or hose before finishing. 501.8.2 Hot Weather. 501.8.2.1 Definition. Hot weather is defined as job-site conditions that accelerate the rate of moisture loss or rate of cement hydration of freshly mixed concrete, including when an average ambient temperature of 80°F or higher exists during the time of placement. The average ambient temperature is the average of the highest and lowest temperature during the period from midnight to midnight. 501.8.2.2 Ready-mix concrete production during hot weather conditions shall be delivered to the job site at a concrete temperature as low as practical and within specification limits. Concrete containing cement or fine aggregate lumps or crusts of hardened material shall not be used. To maintain placement temperature limitations, the production plant shall have a system for spraying and cooling aggregates, or a system for delivering chilling mixing water, or a system for weighing and delivering crushed ice to the mixer, provided water equivalent of ice is calculated to total amount of mixing water. The volume of ice shall not exceed 75 percent of the mixing water volume. 501.8.2.3 Admixtures. When concrete temperatures at the time of placement exceed 90°F the following admixture limitations shall be followed: 501.8.2.3.1 Water Reducing-Retarding Admixture. ASTM C 494 Type D, water reducing and retarding admixture shall be used in an amount in accordance with Section 501.16. For structural concrete see Section 703. 501.8.2.4 Maximum Allowable Concrete Temperature. Measurement of the concrete temperature shall be made in accordance with ASTM C 1064 and at the time of discharge for the first load, when slump, self-consolidating concrete properties, and entrained air content is tested, and as often as necessary to ensure specification compliance. Concrete that exceeds the maximum temperature requirements at the time of placement shall be rejected.
9/1/2023
501-25
Ready-Mixed Concrete
501.8.2.4.1 Structural Concrete. For structural and seal concrete, plastic concrete temperatures of up to 90°F at the time of placement will be permitted, unless specified otherwise in the contract documents. 501.8.2.4.2 Other Concrete. For pavement and other non-structural concrete, plastic concrete temperatures up to 95°F as measured at the time of placement, may be permitted by the Engineer provided job site conditions allow placement and finishing without excessive use of water or overworking of the surface, unless the temperature is specified otherwise in the contract documents. The occurrence within 24 hours of unusual surface distress (rapid slump loss, excessive cracking, early setting time, poor finishability) shall be cause to revert to a maximum 90°F plastic concrete temperature at the time of placement. 501.8.3 Initial Curing of Strength Test Specimens. To prevent moisture loss during the initial curing period, cure in accordance with ASTM C31, with the exception of ASTM C1611 and ASTM C1621 for self-consolidated concrete. During initial curing, the ideal specimen temperature range should be maintained at 60°F to 80°F. The Contractor shall assist the Engineer by providing what is needed to maintain the initial curing temperatures. 501.8.3.1 Initial 48-Hour Storage. The Contractor shall provide initial curing and storage of concrete test specimens, cast for acceptance, for the first 48 hours (±24 hours). Specimens shall be stored in conditions that maintain the temperature immediately adjacent to the specimens in a range of 60°F to 80°F and in an environment preventing moisture loss from the specimens. The maximum and minimum temperature during initial curing shall be recorded with a calibrated temperature recording device and reported on the cylinder report by the Engineer. 501.9 Plant Calibration. Personnel, scales, and equipment necessary for calibrating the plant and for verifying the accuracy of proportions, shall be furnished by the Contractor. The equipment shall include standard 50-pound test weights equal to 20 percent of the net load capacity of the scales, to the nearest 50-pound increment. However, not more than twenty 50-pound weights will be required. Plant scales and water metering devices shall be calibrated and certified by an approved commercial scale service. Weights shall be calibrated by the governing state body of weights and measures in accordance to the requirements established by the United States Department of Agriculture (USDA). 501.9.1 Calibration Frequency and Certification. All equipment shall be calibrated and certified annually and whenever the plants are moved or when found to be out of tolerance. A uniformity test shall be performed at the time of calibration in accordance with Section 501.11.3. Plant calibration and verification, in which County forces were not present, shall require a copy of the certification and uniformity test results to be submitted to the Engineer for review and approval. This does not preclude interim checks by County forces. 501.9.1.1 Non-Potable / Well Water Certification. Non-potable / well water shall be sampled and tested by County forces at least annually for compliance with Section 1070. Well water out of compliance will result in suspension of use until the manufacture can demonstrate compliance with Section 1070.
9/1/2023
501-26
Ready-Mixed Concrete
501.10 Plant Mixer and Agitator Equipment. The concrete mixer shall be stationary mixers, truck mixers, or a type approved by the Engineer. Mixers and agitators shall be capable of combining the components of concrete into a thoroughly mixed and uniform mass free from balls or lumps of cementitious material. Agitators may be truck mixers or truck agitators. Stationary mixers shall be equipped with a metal plate or plates on which are plainly marked the mixing speed of the drum or paddles, and the maximum capacity in terms of volume of mixed concrete. Mixing time shall be in accordance with Section 501.10.1.1, unless a reduction of mixing time is requested by the Contractor. When a reduction in mixing time is requested by the Contractor the tests required in Section 501.11.3, shall be performed at the time requested. 501.10.1 The mixer shall produce concrete uniform in color, in appearance, and in distribution of the materials throughout the mass. Variations in the mixed concrete reasonably attributable to worn pickup or throw over blades will be just cause for inspection of such blades. When such inspection reveals the blades to be worn down more than 1 inch below the original height of the manufacturer's design, the blades shall be repaired or replaced. A copy of the manufacturer's design, showing dimensions and arrangement of blades shall be made immediately available to the Engineer upon request. 501.10.1.1 Mixing. When used for the complete mixing of concrete, stationary mixers shall be equipped with an acceptable timing device that will not permit the batch to be discharged until the specified mixing time has elapsed. For mixers having a capacity of 1 cubic yard or less, the batch shall be so charged into the mixer cement, aggregates, and not less than 60 percent of the water shall be mixed a minimum of one minute. For mixers of greater capacity, the one-minute minimum mixing time shall be increased 15 seconds for each cubic yard or fraction thereof of additional capacity. The remaining water shall be added within 15 seconds after all other materials for the batch are in the mixer. If mixers having multiple compartment drums are used, the time required to transfer material between compartments will be considered mixing time. The speed at which the drum shall rotate shall be as designated by the manufacturer of the equipment. If such mixing does not result in concrete having a uniform and smooth texture, a sufficient number of additional revolutions at the same rate shall be given until a thorough mixing of each batch of concrete is secured. The mixing time shall be measured from the time all cement, aggregates, and 60 percent of the water, are in the drum. 501.10.1.2 Batch Capacity Limitations. The volume of concrete mixed in each stationary mixer batch shall not exceed the manufacturer's rated mixing capacity. When the concrete is truck mixed, the volume of mixed concrete shall not exceed 63 percent of the total volume of the drum or container. When the concrete is central mixed, the volume of concrete in the truck mixer or agitator shall not exceed 80 percent of the total volume of the drum or container. For self-consolidating concrete, the volume of concrete batched shall be such that no spillage occurs during transport. 501.10.2 Mixing Time Device. The mixer shall be equipped with an attachment for automatically timing the mixing of each batch of concrete. The timing device shall consist of an automatic arrangement for locking the discharge chute and a device for warning the operator when all materials have been mixed the required length of time. Should the timing or locking device become inoperable, a manual timing device shall be provided to complete the day's operation. 501.10.3 Materials for a batch of concrete shall not be placed in any compartment of the mixing drum until the material for the previous batch has been discharged from that compartment.
9/1/2023
501-27
Ready-Mixed Concrete
501.11 Central and Truck Mixed Concrete. The following additional requirements shall apply to central and truck mixed concrete. 501.11.1 Mixer Inspection. All central mixers, truck mixers, and agitators shall be in accordance with these specifications prior to use. Inspections of the equipment shall be made periodically during the work. Only equipment found acceptable and capable of producing uniform results will be permitted. 501.11.2 Daily Storage Verification. Storage facilities for all materials shall be designed to permit the Engineer to make necessary inspections prior to the batching operations. The facilities shall also permit identification of approved materials at all times and shall be designed to avoid any mixing with, or contaminating by, unapproved materials. 501.11.2.1 When aggregates are trucked to the proportioning plant, the trucks must dump off a ramp or into a walled pit. In either case, they must dump into a floored area. This floor shall consist of a substantial platform or a layer of similar aggregate at least 18 inches thick placed entirely below the elevation of the surrounding ground. 501.11.2.2 Bins. When stationary mixers are used, storage bins with adequate separate compartments shall be provided for bulk cement, when used, for fine aggregate, and for each required size of coarse aggregate. The equipment used for delivery to bins shall not permit intermingling of aggregates. Each compartment shall be designed to discharge efficiently and freely into the weighing hopper. Portable bins shall be fully loaded and permitted to stand for at least 12 hours before operations start. Portable fine aggregate bins shall be equipped with a tilted screening device which shall reject all material coarser than 1 inch and through which all fine aggregate must pass upon entering that compartment. 501.11.2.3 Aggregate Moisture Content Variation. Coarse and fine aggregate shall be so furnished and handled that variations in the moisture content affecting the uniform consistency of the concrete will be avoided. Batch quantities of materials shall be adjusted to compensate for the free moisture in the aggregates. Any aggregate fractions used which vary more than plus or minus one percentage point from the mean moisture content established near the start of the day's operations on the structure section, when delivered to the weighing hopper during any one pour of concrete, will be subject to rejection. The Engineer may permit a change in the mean moisture content, and the moisture content of the aggregate shall then vary not more than plus or minus one percentage point from the newly established mean. These provisions shall in no way alter the slump and mixing water requirements of the specifications for concrete. 501.11.2.3.1 Fine Aggregate Moisture Sensing Device. The fine aggregate bin or weighing hopper shall be equipped with a moisture sensing device which shall consistently indicate the moisture content within one-half of one percent of the dry weight of the aggregate. The indicator shall be in such position that it may be readily observed by the operator during batching operations.
9/1/2023
501-28
Ready-Mixed Concrete
501.11.3 Uniformity Testing. Central mixed concrete shall be mixed in a stationary mixer in accordance with the requirements specified herein. Except as otherwise permitted in Section 501.11.7, concrete transported to the point of delivery in either a truck mixer or agitator truck shall be operated at manufacturer's agitating speed. Concrete transported to the point of delivery in non-agitating equipment shall be in accordance with Section 501.11.11. The mixing time shall be in accordance with Section 501.10.1.1 and as necessary to produce concrete which meets five of the six uniformity criteria (mass per cubic foot, air content, slump (or slump flow when self-consolidating concrete is used), coarse aggregate content, unit weight of air-free mortar based on average for all comparative samples tested, and average 7 day compressive strength for each sample, based on average strength of all comparative test specimens) when tested as prescribed in Annex A1 of ASTM C 94, with the following additions and exceptions: 1) A uniformity test shall be performed during the annual calibration at a central mix drum plant and at the beginning of production for a project at a mobile paving plant; 2) The two samples shall be obtained within an elapsed time of not more than 15 minutes; 3) The air content, slump, (slump flow when self-consolidating concrete is used), and mix proportions of the concrete tested shall meet the requirements of Section 501 for that class of concrete or the uniformity test shall be invalid; 4) The use of a one-quarter cubic foot (one-half cubic foot for aggregate with a nominal maximum size at or above 1½ inches) measure will be permitted in determination of weight per cubic foot; 5) Cylinders may be cured in damp sand after the first 48 hours; 6) The Contractor may designate the mixing time for which uniformity tests are to be performed. The mixing time shall be a minimum of 60 seconds. The maximum mixing time shall not exceed the mixing time established by the uniformity test by more than 60 seconds for air-entrained concrete. The mixed concrete shall meet the uniformity requirements specified above before any concrete may be used for pavement or structures. However, the Engineer may allow the use of the test concrete for appropriate incidental construction. The tests shall be performed by the Contractor in the presence of the Engineer. No direct payment will be made for labor, equipment, materials, or testing. After operational procedures of batching and mixing are thus established, no changes in procedure will be permitted without re-establishing procedures by uniformity tests. 501.11.3.1 Measuring Mixing Time. Measurement of mixing time shall start at the time that all the solid materials are in the drum and shall end at the beginning of the next sequential operation. The batch shall be so charged into the mixer that some water enters in advance of the cement and aggregate and all water is in the drum by the end of the first one-fourth of the specified mixing time. 501.11.3.2 Verification of Mixer. Mixer performance tests shall be repeated whenever the appearance of the concrete or the coarse aggregate content of samples selected, as set out in ASTM C 94 and as modified above indicates that adequate mixing is not being accomplished.
9/1/2023
501-29
Ready-Mixed Concrete
501.11.4 Truck Mixed Concrete. Truck mixed concrete shall be mixed at the proportioning plant and the mixer shall operate at agitating speed while in transit. However, truck mixed concrete may be mixed at the point of delivery provided the cement, or cement and mixing water, are added at that point. Mixing of truck mixed concrete shall commence immediately after the introduction of the mixing water to the cement and aggregates, or the introduction of the cement to the aggregate. 501.11.4.1 Automated Slump Management System. All specifications and testing requirements remain the same unless noted in this section. When the Contractor elects to make admixture additions during transportation to the job, the trucks shall make water additions during transportation in accordance with ASTM C94/C94M. The system shall also be capable of performing the following: 1) Meter and report the water added to the truck to an accuracy of ±3 percent. 2) Meter and report the admixture added to the truck to an accuracy of ±3 percent if admixture additions are to be made on the truck. 3) Cease additions of water when reaching the maximum water content for the mixture design. 4) Total water and admixture added from system must be annotated on delivery ticket before discharge of material. 501.11.5 Truck Mixer Requirements. A truck mixer shall consist of a watertight revolving drum suitably mounted and fitted with adequate blades and equipped with a device for determining the number of mixing revolutions. Truck mixers shall produce a thoroughly mixed and uniform mass of concrete and shall discharge the concrete without segregation. A truck agitator shall consist of a watertight revolving drum, or a watertight container suitably mounted and fitted with adequate revolving blades and a removable cover. Truck agitators shall transport and discharge the concrete without segregation. At suitable intervals, mixers and agitators shall be cleaned of accumulation of hardened concrete or mortar. 501.11.6 Rating Plate. Except as hereinafter permitted, each truck mixer shall have a permanently attached metal rating plate issued by, and in accordance with the capacity requirements of, the Truck Mixer Manufacturers Bureau, as approved by NRMCA, on which is stated the maximum capacity in terms of volume of mixed concrete for the various uses to which the equipment is applicable. The truck shall also have attached a manufacturer's data plate, which shall state the actual capacity as an agitator, the maximum and minimum mixing and agitating speeds. When truck mixers are used for mixing or agitating, the volume of concrete in each batch shall not exceed the maximum capacity shown on the metal rating plate issued by the Truck Mixer Manufacturers Bureau, as approved by NRMCA, except that if a lower capacity for agitating is shown on the manufacturer's data plate, that lower capacity shall govern. The batch volume, when the equipment is used as a mixer and as an agitator, shall not exceed 63 percent and 80 percent of the gross interior volume, respectively. The minimum batch size for truck mixers shall be one cubic yard. The Engineer may reduce the batch size or reject use of any truck mixer that does not produce concrete uniform in color, appearance, and distribution of materials throughout the mass. A quantity of concrete that results in axle and gross loads in excess of statutory limits will not be permitted.
9/1/2023
501-30
Ready-Mixed Concrete
501.11.7 Truck Mix and Agitator Mixing Speed and Revolutions. Truck mixers and agitators shall be operated at the speed of rotation designated by the manufacturer of the equipment. Truck mixers shall be equipped with functioning counters or similar means to enable verification of the number of revolutions applied to the drum.
Truck Mixed Concrete
Revolutions of the Drum (At Mixing Speed) Minimum
Maximum
Truck mixed
70
100
Truck mixed (less than 91 percent of rated capacity)
50
100
After adding Water (all types), each time
30
---
As per manufacturers' recommendation
Admixtures added in the field
501.11.7.1 Truck mixed concrete shall initially be mixed at not less than 70 or more than 100 revolutions of the drum, at mixing speed, after all of the ingredients, including water, are in the mixer. The exceptions are when the batch volume does not exceed 57.5 percent of the gross volume of the drum or 91 percent of the rated maximum capacity; the number of revolutions required for mixing shall be not less than 50 nor more than 100. When a truck mixer or truck agitator is used for transporting concrete that has been completely mixed, agitation of the concrete shall continue during transportation at the speed designated by the manufacturer of the equipment as agitating speed. 501.11.7.2 Truck mixed fiber reinforced concrete shall be mixed from not less than 130 or no more than 200 revolutions of the drum at mixing speed before discharge. 501.11.8 Allowable Job Site Additions. The maximum revolution limit is 300, so field added admixtures will not be allowed if the specified revolutions or more cause the total to exceed 300. 501.11.8.1 Water. Prior to discharge of concrete other than for testing, water may be added to the mixture not more than two (2) times after initial mixing is completed. Water addition shall not exceed the allowed amount on the delivery ticket and shall not exceed the specified slump. All water additions shall be completed within 15 minutes from the start of the first addition of water. Each time water is added, the drum shall be turned an additional 30 revolutions or more, if necessary, at mixing speed, until uniform mixing is accomplished. Water shall not be added to the batch after discharge into the forms, the conveyance device or grade. Water shall be measured within a tolerance of one percent of the total effective water required for the batch. Water addition shall be recorded in gallons on the material delivery ticket. No concrete acceptance testing will be performed before completion of job site water addition. Water used to wash the drum of the mixer shall not be used as mixing water. All water added will be included in determining the effective water in the mixture. Water addition shall not exceed the maximum allowed slump or water to cementitious ratio for the mix.
9/1/2023
501-31
Ready-Mixed Concrete
501.11.8.2 Other Admixtures. Admixture type, manufacturer, brand name and dosage range shall be indicated on the approved mix design. 501.11.8.2.1 Air Entrainment. When a preliminary sample taken within the time limits specified and prior to the discharge for placement shows an air content below specification limits, the contractor can re-dose per section 501.14.5 Re-dosing. 501.11.8.2.2 Admixture Additions on Job Site. Job site admixture additions shall be limited to water reducers, set or strength accelerators, and corrosion inhibitors. Instructions to discharge admixtures shall be furnished as herein before specified. Addition of admixture shall be measured to the nearest ounce and recorded on the material delivery ticket. Material Safety Data Sheet and storage labeling shall be available at job site and conform to current governing regulations. 1) The mixture at the time of placement shall not have a water/cementitious ratio to exceed the specified maximum or have a water/cementitious ratio in excess 0.03 of the mix design value, whichever is lower. 2) All Admixtures Additions. The drum shall be turned additional revolutions in accordance with Section 501.11.7 at mixing speed or 5 minutes of mixing, or until uniform mixing is accomplished. 501.11.8.3 Revolution Limits. Revolutions shall not exceed the limitations specified in Section 501.11.8. Water additions at job site shall be limited to comply with the water-tocementitious ratio requirement and that will produce workable concrete without exceeding the maximum allowable slump specified. 501.11.8.4 Admixture Additions In-Transit. Admixture additions are permitted during transportation to the jobsite and at the jobsite when made in accordance with the following: 1) The truck shall be equipped with automated slump or slump flow monitoring equipment capable of obtaining one or more physical measurements on the truck mixer related to concrete slump or slump flow and providing an indication of slump or slump flow based on pre-established correlations. The slump or slump flow measurement equipment shall report in terms of slump or slump flow. 2) The truck shall be equipped with a device for measurement of admixture added to the truck mixer. This device shall be accurate to ±3 percent of the amount added with said device. 3) Admixture shall be injected into the mixer under such pressure and direction of flow to allow for admixture to contact with concrete within the mixer without substantially contacting the mixer drum walls. 4) If admixture is added, the mixer shall be rotated for an additional 30 drum revolutions, or more if necessary, at mixing speed to ensure a homogeneous mix is attained. Said mixing shall take place after the last admixture addition but before the start of discharge.
9/1/2023
501-32
Ready-Mixed Concrete
5) Record the total amount of admixture added by said equipment on the delivery ticket. 6) The admixture added shall meet the requirements of ASTM C 494 Type A, C, D, F, or G. 501.11.9 Water Measuring Equipment Tolerance. Water measuring equipment at the plant or central mixer shall meet the requirements of Section 501.7.2. If the truck mixer is not equipped with a tank and an automatic water measuring device, a calibrated tank or a meter shall be installed on the truck or at the job site for measuring additional water used to obtain satisfactory workability of dry batches. Each increment of water added at the job site shall be measured within a tolerance of one percent of the total effective water for the batch. 501.11.10 Batch to Discharge Time Limitations. The discharge of concrete shall be completed within the time specified below after the introduction of mixing water to the cement and aggregates or the introduction of the cement to the aggregates. Central or truck mixed concrete shall be delivered to the site of the work and meet the following conditions: Maximum Time from Batch to Discharge (Minutes)
Conditions
Non-Agitating Hauling Equipment When concrete temperature at time of discharge is 90°F or higher
30
For pavement
30
All other applications
45 Truck Mixer or Agitator
For bridge deck surface slabs
60
For High Early and Very Early mixes
75
All other applications
90
501.11.10.1 Maximum Allowable Revolutions. Truck mixed concrete shall not exceed 300 revolutions after the beginning of mixing. If the mixing time or revolution limits have been exceeded and the mixture workability, air entrainment, temperature, slump, or slump flow limitations have not been surpassed, the Engineer may allow placement of the mixture.
9/1/2023
501-33
Ready-Mixed Concrete
501.11.10.2 Other Discharge Time Limitations. 1) Placing Concrete at Night. The Contractor shall not mix or place concrete without sufficient natural light, unless an adequate, artificial lighting system is in place, is in accordance with Section 612.80, and is approved by the Engineer. 2) Hot Weather Reduction. In hot weather or under conditions contributing to quick stiffening of the concrete, the time shall be reduced, as directed by the Engineer. Concrete shall be discharged without delay and the time required between the start and completion of discharge shall not exceed 15 minutes for all pavements, bridge deck slabs, and other structural pours. 3) Small Formed Pours. For small formed pours, defined as curbs, curb and gutters, sidewalk, paved drainage, and paved approach for private entrances, the discharge time may be extended beyond 15 minutes, as necessary, to provide for proper placing and inspection procedures. However, the batch to discharge time shall not exceed that specified. 501.11.11 Non-Agitating Equipment. 501.11.11.1 Discharge Time Limitations. The discharge of concrete, for pavement, transported in non-agitating equipment shall be completed within 30 minutes after introduction of the mixing water to the cement and aggregates. The discharge of concrete for other than pavement, transported in non-agitating equipment, shall be completed within 45 minutes after introduction of the mixing water to the hydraulic cement and aggregates. 501.11.11.2 Body Requirement. Bodies of non-agitating hauling equipment shall be smooth, mortar-tight, metal containers. Containers shall be specifically designed to transport concrete, shaped with rounded corners to minimize segregation, and equipped with gates that will permit positive control of the discharge of the concrete. Containers shall be capable of discharging the concrete at a satisfactory, controlled rate without segregation. If unloading the concrete is accomplished by tilting the body, baffles may be required to retard the discharge. 501.11.11.3 Cover Requirements. As directed by the Engineer, a waterproof cover of canvas for non-agitating hauling equipment shall be provided for protection against contamination and the weather during transportation. Each truck shall have a waterresistant cover of canvas or other suitable material of such size as to cover the top of the load and extend down over the sides of the truck. The cover shall extend down over the sides and ends of the bed for a distance of at least 1 foot and shall be fastened securely all around the truck bed to protect the mixture from the weather (wind, rain, solar radiation), dust and vegetation. 501.11.11.4 Material Hauling Restrictions. Grout, seal concrete, self-consolidating concrete, and other high slump materials shall not be transported in non-agitating hauling equipment.
9/1/2023
501-34
Ready-Mixed Concrete
501.11.12 Testing Facilities. Proper facilities shall be provided for the Engineer to inspect ingredients and processes used in the manufacture and delivery of the concrete. A Type 1 Field Laboratory, meeting the requirements of Section 601.2, shall be provided at the proportioning plant sites for use by the County for the duration of contracts. No direct payment will be made for providing the laboratory. Facilities for obtaining representative samples of each fraction of aggregate, cement, and admixture(s), prior to incorporation into the mix, shall be provided by the producer. Aggregate samples may be taken either by sampling the flowing aggregate stream or by belt sampling. The producer shall furnish the proper equipment and personnel necessary to assist the Engineer in obtaining a representative sample. 501.11.13 Delivery Tickets. Prior to unloading at the site, the manufacturer of each load of truck or central mixed concrete shall furnish a delivery ticket to the Engineer, on which is shown information concerning the concrete as follows: Plant Generated Information: 1)
Name of ready-mix company and batch plant;
2)
Serial number of ticket;
3)
Date;
4)
Truck number;
5)
Name of Contractor;
6)
Specific designation of job: Federal Project number when applicable / County Project Name / Street name / County project number;
7)
St. Louis County plant-specific mix number assigned to the mix being placed;
8)
Specific class or designation of concrete in conformance with contract documents;
9)
Type, brand, and amount of fiber used;
10) Quantity of concrete in cubic yards (batched and totaled); 11) Time when batch was loaded, or of first mixing of cement and aggregates; 12) When truck mixed, reading of revolution counter once all ingredients are loaded into the mixer. Additional Information: 13) When requested by the Engineer, information necessary to calculate the total mixing water, in gallons per cubic yard; 14) Ice or hot water used;
9/1/2023
501-35
Ready-Mixed Concrete
15) When load certification is required: a) Signature or initials of producer’s representative; b) When requested by the Engineer, each load of certified concrete shall be accompanied by a ticket listing mix proportions, time of batching and setting on revolution counter, total mixing revolutions and shall be signed by certified plant personnel in accordance with ASTM C 94 Section 14.2. Jobsite Generated Information: 16) Arrival time on project; 17) Admixture(s) name and quantity added on the job site; 18) Time when truck has finished discharging load; 19) When truck mixed, reading of revolution counter once all ingredients are discharged from the mixer; 20) Water added at jobsite to attain pouring consistency, initialed by the Contractor. 501.11.14 Conveying. Rapidly convey concrete from mixer to final deposition by methods that prevent segregation or loss of constituents and ensure the required concrete quality. Use of aluminum pipes or chutes is prohibited. 501.11.15 Conveying Equipment. Submit data on the conveying equipment and methods for transporting, handling, and depositing the concrete. Prior to the placement of the concrete, the Engineer may require the Contractor to demonstrate the capability of the equipment to convey the concrete mixture. The conveying equipment shall conform to the following requirements: 501.11.15.1 Buckets. The interior hopper slope shall be not less than 58 degrees from the horizontal, the minimum dimension of the clear gate opening shall be at least five times the nominal maximum-size aggregate, and the area of the gate opening shall not be less than 2 square feet. The maximum dimension of the gate opening shall not be greater than twice the minimum dimension. The bucket gates shall be essentially grout tight when closed and may be manually, pneumatically, or hydraulically operated except that buckets larger than 2 cubic yards shall not be manually operated. The design of the bucket shall provide means for positive regulation of the amount and rate of deposit of concrete in each dumping position. If concrete is to be placed through installed horizontal or sloping reinforcing bars, the bucket shall discharge concrete into a pipe or elephant trunk that is long enough to extend through the reinforcing bars. 501.11.15.2 Transfer Hoppers. Concrete may be charged into non-agitating hoppers for transfer to other conveying devices. Transfer hoppers shall be capable of receiving concrete directly from delivery vehicles and have conical-shaped discharge features. The transfer hopper shall be equipped with a hydraulically operated gate and with a means of external vibration to effect complete discharge. Concrete shall not be held in non-agitating transfer hoppers.
9/1/2023
501-36
Ready-Mixed Concrete
501.11.15.3 Belt Conveyors. Use belt conveyors that are horizontal or at a slope that will not cause excessive segregation or loss of constituents. Belt conveyors shall be designed and operated to assure a uniform flow of concrete from mixer to final place of deposit without segregation of ingredients or loss of mortar and shall be provided with positive means for preventing segregation of the concrete at the transfer points and the point of placing. Belt conveyors shall be constructed such that the idler spacing shall not exceed 36 inches. The belt speed shall be a minimum of 300 feet per minute and a maximum of 750 feet per minute. If concrete is to be placed through installed horizontal or sloping reinforcing bars, the conveyor shall discharge concrete into a pipe or elephant trunk that is long enough to extend through the reinforcing bars. Protect concrete to minimize drying and effects of temperature rise. Use an acceptable discharge baffle or hopper at the discharge end to prevent segregation. Do not allow mortar to adhere to the belt return length. 501.11.15.4 Chutes. Use metal or metal-lined chutes having rounded bottoms and sloped between one vertical section to two horizontal sections and one vertical to three horizontal sections of chute. Chutes longer than 20 feet and chutes not meeting slope requirements may be used provided the discharge is into a hopper before distributing into the forms. A discharge deflector shall be used when required by the Engineer. Separate chutes and other similar equipment will not be permitted for conveying concrete. 501.11.15.5 Concrete Pumps. Concrete may be conveyed by positive displacement pump when approved. The pumping equipment shall be piston or squeeze pressure. The pipeline shall be rigid steel pipe or heavy-duty flexible hose. The inside diameter of the pipe shall be at least three times the nominal maximum-size coarse aggregate in the concrete mixture to be pumped but not less than 4 inches. Aluminum pipe shall not be used. Use pumping equipment that has sufficient capacity so that: 1) Initial setting of previously placed concrete does not occur before subsequent placement; 2) Discharge of pumped concrete does not result in segregation; and 3) Modification of accepted concrete mixture is not required, unless permitted otherwise. 501.11.15.6 Underwater (Tremie) Placement. Tremie placement typically utilizes a vertical metal pipe (8 to 12 inches in diameter), constructed with sections having flange couplings fitted with gaskets, with a hopper on top through which concrete is directed to its point of placement underwater. The discharge ends on both the tremie pipe and the tremie bucket shall be fabricated to allow for the full opening of the discharge ends of the pipe or bucket, by slightly raising the pipe or bucket. The initial concrete is separated from the water by a pig (go-devil) inserted in the tremie pipe ahead of the concrete, or by having the pipe closed at the mouth by a valve. After filling the pipe with concrete, the pipe is raised to allow the pig to escape, or the valve is opened. Initially, tremie pipes should not be raised more than 1 to 2 feet to establish flow. Concrete continues to be placed through the pipe, keeping its mouth embedded in the seal created by the previously deposited concrete. The tremie shall not be raised above the top of the concrete being placed.
9/1/2023
501-37
Ready-Mixed Concrete
501.12 Volumetric Batched and Continuous Mixed Concrete. Upon written request by the Contractor, the Engineer may approve the use of concrete proportioned by volume. If concrete is proportioned by volume, the requirements of Section 501, with the following modifications, shall apply. 501.12.1 Proportional Devices. Volume proportioning devices, such as counters, calibrated gate openings, or flow meters, shall be available for controlling and determining the quantities of the ingredients discharged. In operation, the entire measuring and dispensing mechanism shall produce the specified proportions of each ingredient. 501.12.2 Controls. All indicating devices that affect the accuracy of proportioning and mixing of concrete shall be in full view of, and near enough to be read by, the operator while concrete is being produced. The operator shall have convenient access to all controls. 501.12.3 Proportioning Device Calibration. The proportioning devices shall be calibrated by the Contractor in the presence of and subject to the approval of the Engineer. Calibration of the cement and aggregate proportioning devices shall be accomplished by weighing each component. Calibration of the admixture and water proportioning devices shall be accomplished by weight or volume. Tolerances in proportioning the individual components are as follows:
Tolerances in Proportioning the Individual Components Tolerance (Percent) Item Minimum
Maximum
Cement or total cementitious, Weight
0
+4
Aggregate, Weight
-2
+2
Admixtures, Weight or Volume
-3
+3
Water, Weight or Volume *
-1
+1
* Or ±1qt, whichever is greater.
501.12.4 Verification of Yield. Verification of the proportioning devices may be required at any time by the Engineer. Verification shall be accomplished as follows. With the cement meter set on zero and all other controls set for the designated mix, the activated mixer shall discharge mixed material into a one-quarter cubic yard container measuring 36 inches x 36 inches x 9 inches. When the container is level-struck full, making provision for settling the material into all corners, the cement meter must show a discharge equal to the design proportion of cement for one-quarter cubic yard. A tolerance of ±⅛ inch from the top of the container will be permitted. If correct yield is not obtained either the proportioning devices shall be adjusted to obtain the design mix or the proportioning devices shall be recalibrated as directed by the Engineer.
9/1/2023
501-38
Ready-Mixed Concrete
501.12.5 Water Control. The rate of water supplied shall be measured by a calibrated flowmeter coordinated with the cement and aggregate feeding mechanism and with the mixer. The rate shall be adjustable in order to control slump at the desired level. 501.12.6 Liquid Admixtures. Liquid admixtures shall be dispensed through a controlled flow meter. A positive means to observe the continuous flow of material shall be provided. If an admixture requires diluting, the admixture shall be diluted and thoroughly mixed prior to introducing the admixture into the dispenser. When admixtures are diluted, the ratio of dilution and the mixing shall be approved by and performed in the presence of the Engineer. 501.12.7 Mixing Mechanism. The concrete mixer shall be approved by the Engineer and shall be an auger-type continuous mixer used in conjunction with volumetric proportioning. The mixer shall produce concrete, uniform in color and appearance, with homogeneous distribution of the material throughout the mixture. Mixing time necessary to produce uniform concrete shall be established by the Contractor and shall comply with other requirements of these specifications. Only equipment found acceptable in every respect and capable of producing uniform results will be permitted. 501.12.7.1 Material Storage Capacity. The continuous mixer shall be capable of carrying sufficient unmixed dry bulk cement, fine aggregate, coarse aggregate, admixtures, and water, in separate compartments, to produce no less than 6 cubic yards of concrete at the job site. Each batching or mixing unit, or both, shall carry, in a prominent place, a metal plate or plates. The plate(s) shall be plainly marked with the gross volume of the unit in terms of mixed concrete, discharge speed, and the weight-calibrated constant of the machine in terms of a revolution counter or other output indicator. 501.12.7.2 Measurement of Cement and Cementitious Materials. The continuous mixer shall be capable of positive measurement of cement and cementitious materials being introduced into the mix. A recording meter visible to the operator and equipped with a ticket printout shall indicate this quantity. 501.12.7.3 Measurement of Water and Admixtures. The continuous mixer shall provide positive control of the flow of water and admixtures into the mixing chamber. Water flow shall be indicated by a flow meter and be readily adjustable to provide for minor variations in aggregate moisture. The mixer shall be capable of continuously circulating or mechanically agitating the admixtures. 501.12.7.4 Fine Aggregate Scalping Screen. The continuous mixer shall have a 1-inch maximum size scalping screen over the fine aggregate bin to screen out mud balls, conglomerate lumps, or any other contaminant material that could interrupt the flow of fine aggregate during proportioning. 501.12.7.5 Batching Operations. The continuous mixer shall be capable of being calibrated to automatically proportion and blend all components on a continuous or intermittent basis, as required, and shall discharge mixed material through a conventional chute.
9/1/2023
501-39
Ready-Mixed Concrete
501.12.8 Handling of Materials. Storage facilities for all material shall be designed to permit the Engineer to make necessary inspections prior to the batching operations. The facilities shall also permit identification of approved material at all times and shall be designed to avoid mixing with or contamination by, unapproved material. Coarse and fine aggregates shall be furnished and handled so variations in the moisture content affecting the uniform consistency of the concrete will be avoided. 501.12.8.1 Disposition of Unapproved Material Incorporation. Concrete with unapproved materials incorporated shall be removed and replaced. If the use of unapproved material is determined by the Engineer to be a result of the material supplier or concrete plant, that supplier or producer will be given two weeks to investigate the root cause of the problem. The response shall be submitted in writing to the Engineer as to what corrective action(s) will be taken to resolve the problem, including any supporting documentation. During the investigation and response period the use of that material supplier or concrete plant may be suspended for all County work until the issue is resolved. 501.13 High Early or Very Early Strength Concrete. High early or very early strength concrete shall only be used with the written approval of the Engineer or be specified in the contract documents. If Type III, high early strength cement is used, the concrete shall be proportioned in accordance with the requirements of Section 501.3 for the various classes of concrete. If Type I/II or IL Portland cement is used to obtain high or very early strength concrete, the proportions will be reviewed and approved in advance by the Engineer. Control of slump, time of set, and workability at the time of placement shall be controlled by use of admixtures only. 501.14 Air-Entrained Concrete. Air content for all classifications of normal-weight plastic concrete shall be determined in accordance with AASHTO T 152. For lightweight concrete air content shall be determined in accordance with AASHTO T 196. Lightweight concrete is concrete made with either all lightweight coarse aggregate, all lightweight fine aggregate, or both. Lightweight aggregates are as defined in Section 1005. For self-consolidating concrete, determine the air content in accordance with AASHTO T 152, except that the concrete shall be filled in one lift and not consolidated. Light tamping of the sides of the air-meter is permitted for selfconsolidated concrete. Air-entrained concrete shall be used for concrete extending at or above the frost line (30 inches). 501.14.1 Other Concrete. At the Contractor's option, all other concrete (except seal concrete and concrete not exposed to freeze thaw during construction and intended use) may be airentrained, but only in accordance with the requirements of these specifications.
9/1/2023
501-40
Ready-Mixed Concrete
501.14.2 Required Entrained Air Content. Air entrainment is based on the maximum nominal aggregate size. When air-entrained concrete with a nominal maximum size aggregate greater than ½ inch is used, the quantity of air by volume shall be as follows:
Required Entrained Air Content Air Content by Volume (Percent) Class of Concrete A-1, B, B-1, B-2, MB-2, Seal and Pavement MSD-A
Target
Operating Tolerance
6½
± 1½
In accordance with MSD "Standard Construction Specification for Sewers and Drainage Facilities"
501.14.2.1 There shall be no intentional deviation from the designated air content. An occasional deviation in air content exceeding the upper operating tolerance may be permitted if, in the judgment of the Engineer, the deviation is such that it will not seriously affect the serviceability of the concrete. 501.14.2.2 For concrete with design compressive strength f’c ≥ 5000 psi, a reduction of air content by 1.0 percent will be permitted. 501.14.2.3 For concrete with a maximum nominal aggregate size of ½ inch or less, the entrained air shall be 7.5 ±1.5 percent. 501.14.3 Consistency. To avoid wide fluctuations in air content, the ready-mix producer shall maintain close control over uniformity of cement, aggregates, consistency of the concrete, operation of proportioning and mixing equipment, and mixing time. Air entrainment shall be obtained by use of an approved air-entraining admixture added in the quantity required to obtain the designated air content. It shall be the ready-mix producer's responsibility to determine and use the quantity of admixture necessary to obtain the specified air content within the permitted operating tolerance. 501.14.4 Incorporation Procedures. Air-entraining admixtures shall be added to the concrete during the mixing process. The admixture shall be of such volume and strength that the admixture can be accurately measured and dispensed in accordance with the manufacturer’s recommendations. The device shall be so arranged that the flow of air-entraining admixture will be automatically stopped when the required quantity has been delivered. 501.14.4.1 Dispenser Calibration Requirements. The dispenser shall be so constructed that it can be accurately calibrated at various settings and shall be provided with means by which the discharge can be readily diverted from the stream of mixing water to a container for measurement. The dispenser calibration shall be performed at the same frequency as the aggregate scales and shall consistently deliver the required quantity of admixture within a tolerance of ±3 percent.
9/1/2023
501-41
Ready-Mixed Concrete
501.14.5 Re-dosing. When the job site measured air content is below the minimum specified value, the Contractor will be allowed to re-dose the concrete in the field one time. The Contractor shall submit a Re-dosing Plan to the Engineer for approval. The Re-dosing Plan shall be approved prior to use. The Re-dosing Plan shall address the following: 1) Field measurement of the air entrainment admixture; 2) Brand of air entrainment admixture being used; 3) Incorporation and mixing of the air entrainment admixture; 4) The use of additional water. 501.14.5.1 Other Requirements. All other requirements of this specification shall apply. 501.15 Concrete Admixtures for Retarding Set. If specified in the contract, an approved ASTM C 494 Type D water-reducing and retarding admixture shall be provided and incorporated into the concrete. If not specified in the contract, the use of an approved water reducing and retarding admixture will be permitted upon written notification by the Contractor. The use of any retarding admixture will be by approval of the Engineer and contingent upon satisfactory performance on the work. Permission for its use may be withdrawn at any time satisfactory results are not obtained. The use of a retarder for extending the delivery or discharge time of the concrete, or for modifying temperature requirements for placement, will not be approved. Retarding admixtures shall be added in accordance with Section 501.12.6 by means of a dispenser conforming to the requirements of that section. No direct payment will be made for furnishing the retarding admixture or incorporating the admixture into the mixture. 501.16 Water-Reducing Admixtures. 1) High Range Water Reducers. When a high-range water reducer is used, it shall be an ASTM C 494 Type F high-range water-reducing (HRWR). The dosage rate of Type F HRWR shall be within the ranges recommended by the manufacturer to achieve at least a 13 percent water/cementitious ratio reduction, added at the manufacturing plant, and approved by the Engineer. Any cementitious material substitution allowed by specifications shall be based on the reduced cement content. 2) Mid-Range Water Reducers. For all but cold weather conditions, an ASTM C 494 Type D Water Reducing and Retarding Admixture (MRWRR) may also be used in concrete mixes in place of a HRWR. For all other weather conditions, an ASTM C 494 Type A Water Reducing Admixture (MRWR) may also be used in concrete mixtures in place of a HRWR. The dosage rate of MRWRR or MRWR shall be within the ranges recommended by the manufacturer, added at the manufacturing plant, and approved by the Engineer. 3) Water Reducer Dispenser. Water reducing admixture shall be added in accordance with Section 501.12.6 by means of a dispenser conforming to the requirements of that section. The amount of water contained in the water-reducer admixture shall be included as per Section 501.5 in the overall water content of the concrete.
9/1/2023
501-42
Ready-Mixed Concrete
4) Water Reducer in Seal Concrete. For massive placement of seal concrete, the use of a HRWR is prohibited, unless slump loss testing has been performed and demonstrates no detrimental results. 5) Self-Consolidating Concrete. When a HRWR is used to produce flowing concrete, the admixture shall also meet the requirements of ASTM C 1017 Type 1, Plasticizing, or Type 2, Plasticizing and Retarding Admixtures. 6) Payment for Use of Water Reducer. No direct payment will be made for furnishing the water-reducing admixture or incorporating the admixture into the mixture. 501.16.1 B-2 or Modified B-2 Utilized. B-2 or Modified B-2 concrete shall use a waterreducing admixture type appropriate with the weather conditions at the time of placement. 501.16.2 Silica Fume Utilized. Concrete using silica fume shall use an ASTM C 494 Type F high-range water-reducing admixture. An ASTM C 494 Type B retarding admixture will also be required. 501.16.3 Fiber Utilized. Concrete using fibers shall use an ASTM C 494 Type A or F waterreducing admixture type appropriate with the weather conditions at the time of placement. 501.16.4 Consistency Requirement. When water-reducer admixture is used, the maximum allowed slump at the time of placement may be increased from 4 inches to a maximum of 6 inches. The increased slump shall not result in aggregate segregation. Truck mixed concrete load size shall not be less than 50 percent nor more than 67 percent of the maximum rated mixing capacity to ensure uniform concrete properties when using water reducing admixture. The concrete shall be homogeneous with no aggregate segregation. 501.17 Accelerating Admixtures. ASTM C 494 Type C non-chloride accelerating (NCA) admixtures shall be used to accelerate set time and strength gain in reinforced concrete. Calciumchloride based ASTM C 494 Type C admixtures shall be used to accelerate set time and strength gain in non-reinforced concrete. The use of calcium chloride in concrete mixtures shall not be used in reinforced, prestressed, structural, in concrete floors placed over prestressed concrete structural frames, in concrete used in concrete cast on leave-in-place galvanized steel forms or in concrete containing embedded dissimilar metals or sulfate-resisting concrete. When two different metals, such as aluminum and steel, are in contact within concrete, corrosion can occur because each metal has a unique electrochemical potential. 1) A reduction of batch water by 7 pounds per gallon of calcium chloride accelerator used shall be made; 2) No allowance of calcium chloride shall be made when welded wire reinforcement or steel fibers are used; 3) No direct payment will be made for furnishing the calcium chloride or non-chloride accelerating admixtures into the concrete mixture. 501.17.1 Allowance of Calcium Chloride in VES or HE Pavement. When specified in the contract documents or approved by the Engineer, the use of liquid calcium chloride in place of a non-chloride strength accelerator will be allowed in VES (Very Early Strength 4 to 6 hour opening time) or HE (High Early 24 to 48 hour opening time) Non-Reinforced (or Macro Fiber Reinforced) Portland Cement Concrete Pavement.
9/1/2023
501-43
Ready-Mixed Concrete
501.18 Shrinkage-Reducing Admixtures. To reduce the effects of drying shrinkage cracking, the Contractor may use an ASTM C 494, Type S shrinkage-reducing admixture in concrete mixtures. The mix water content should be reduced to account for the quantity of shrinkage- reducing admixture used. The Contractor shall follow the admixture manufacturer's recommendations regarding a higher dosage, contract chloride restrictions, mixing water reduction, air entraining tolerance limits, set time, and suitability for use in very severe freeze-thawing environments. No allowance for reduction in compressive strength will be permitted. The increase in cementitious material or admixture used to achieve the minimum required compressive strength shall be at no additional cost to the County. 501.19 Other Admixtures. The Contractor may propose the use of corrosion inhibiting admixtures, viscosity modifying admixtures, ASR-controlling admixtures, anti-washout admixtures, and other admixtures that are ASTM C 494 approved. The admixture must also be compatible with other admixtures and concrete mix components, have a dosage recommended by the manufacturer for the weather conditions at the time of placement, and are approved in advance by the Engineer. 501.20 Admixture Identification, Delivery and Storage. Approved admixtures added by the Contractor on the job site shall be delivered in the original containers, with the original manufacturer's label in place. The Contractor shall follow manufacturer's guidelines for storage, mixing, and application, and shall protect the admixture from freezing and contamination. Non- standard containers used to transport admixtures may be used when approved by the Engineer and properly labeled. 501.21 Supplementary Cementitious Materials in Concrete. The Contractor may use fly ash, Ground Granulated Blast Furnace Slag (GGBFS), or silica fume in the production of concrete in accordance with these specifications. Ternary mixes will be allowed for all concrete classes. Ternary mixes are mixes that contain a combination of Portland cement and two supplementary cementitious materials. Supplementary cementitious materials may be used to replace no more than 40 percent of the Portland cement. Replacement of cement with supplementary cementitious materials shall be in accordance with Section 501.3.5.4. 501.21.1 Fly Ash in Concrete. Approved Class C or F fly ash may be used to replace Type I, I/II or IL cement, on a pound for pound basis in accordance with Section 501.3.5.4 in all concrete. 501.21.1.1 Changes in class or source of fly ash used in concrete structures will be permitted only with the written approval of the Engineer. Only fly ash resulting in concrete of the same color shall be used in any individual unit of the structure. 501.21.2 Ground Granulated Blast Furnace Slag (GGBFS) in Concrete. Approved GGBFS may be used to replace Type I, I/II or IL cement on a pound for pound basis in accordance with Section 501.3.5.4 in all concrete. 501.21.2.1 Changes in class or source of GGBFS used in concrete structures will be permitted only with the written approval of the Engineer. Only GGBFS resulting in concrete of the same color shall be used in any individual unit of the structure. 501.21.3 Silica Fume. Approved silica fume may be used to replace a percent of the Portland cement on a pound for pound basis in accordance with Section 501.3.5.4 in all concrete. A water-reducing admixture shall be used when silica fume is used.
9/1/2023
501-44
Ready-Mixed Concrete
501.21.3.1 Changes in class or source of silica fume used in concrete structures will be permitted only with the written approval of the Engineer. Only silica fume resulting in concrete of the same color shall be used in any individual unit of the structure. 501.21.4 Source Changes. Changes in class or source of fly ash, grade and source of GGBFS, brand and source of silica fume used in concrete structures will be permitted only with written approval from the Engineer. Only fly ash, GGBFS, or silica fume resulting in concrete of the same color shall be used in any individual unit of the structure. 501.21.5 Mix Proportions. When fly ash, GGBFS, or silica fume is used, an adjustment in design mix proportions will be required to correct the volume yield of mixture. Approval shall be obtained from the Engineer prior to any change in mix design or proportions. 501.21.6 Mixing Water. Maximum mixing water shall be based on total cementitious material. The quantity of mixing water in the concrete shall be considered the net quantity after proper allowance has been made for absorption by the aggregate. 501.21.7 Measuring Cementitious Materials. Fly ash, GGBFS, and silica fume will be considered as cement when measuring mixing time. 501.21.7.1 Fly Ash and Ground Granulated Blast Furnace Slag. Fly ash or GGBFS shall be measured in the same manner and with the same accuracy as cement. Fly ash or GGBFS may be weighed separately on the same scale as cement, provided the scale increments are such that the specified weighing accuracy can be maintained. If the fly ash or GGBFS is weighed together with the cement, the cement shall be weighed first and the accuracy shall apply to the combined weight. 501.21.7.2 Silica Fume. Silica fume shall be measured by weight or volume within a tolerance of plus or minus 2 percent. 501.21.8 Silica Fume Batching Sequence. Silica fume shall be added at the plant at the same point in the batch sequence as recommended by the manufacturer of the material. The silica fume may be added by hand methods. 501.21.9 Calculating Silica Fume Solids. For silica fume solutions, the quantity of liquid silica fume admixture needed to furnish the required silica fume solids shall be calculated based on the weight per gallon and percent solids of the silica fume admixture being used. 501.22 Commercial Mixture. If specified in the contract that an approved commercial mixture of concrete may be used, the Contractor shall notify the Engineer in writing, setting out for approval the source and proportions of the mixture proposed to be furnished. The statement shall include the following: 1) The types and sources of aggregate. 2) Type and source of cement and other cementitious material. 3) Scale weights of each aggregate proposed as pounds per cubic yard of concrete.
9/1/2023
501-45
Ready-Mixed Concrete
4) Quantity of water proposed, as pounds or gallons per cubic yard of concrete. 5) Quantity of cement proposed as pounds per cubic yard of concrete. 6) Type, source, and weight or volume of liquid or solid admixture. 501.22.1 Minimum Cement Content. The concrete shall contain no less than 517 pounds of cementitious material per cubic yard. The use of fly ash, GGBFS, and silica fume shall be in accordance with Section 501.3.5.3. The plant shall comply with other requirements of these specifications or be as approved by the Engineer. The concrete will be subject to acceptance or rejection by visual inspection at the job site. 501.22.2 Minimum Compressive Strength and Air Entrainment. Commercial concrete shall have a minimum f’ c (28-day design compressive strength) requirement of 3,000 pounds per square inch (psi) as determined in accordance with ASTM C 39. Commercial concrete placed above the frost line shall be air entrained and have air content from 5.0 percent to 8.0 percent per AASHTO T 152. 501.22.3 Certification. The supplier shall furnish certification with the first truck load of each day's production of concrete that the material and mix proportions used are in accordance with the approved mixture. Upon completion of the work, plant certification shall be furnished by the supplier for the total quantity delivered.
9/1/2023
501-46
Ready-Mixed Concrete
Section 502
Portland Cement Concrete Pavement
502.1 Description. This work shall consist of placement, consolidating, finishing, and curing of a full-depth Portland cement concrete shoulders or pavement, with or without reinforcement as specified, as shown on the plans or as directed by the Engineer. Nighttime shoulder or pavement placement, finishing and curing lighting requirements shall be in accordance with Section 612.80. 502.2 Materials. All material, proportioning, air-entrainment, mixing, slump and transporting for Portland cement concrete shall be in accordance with Section 501, Portland Cement Concrete. Coarse aggregates for pavement concrete shall consist of Class B or D crushed limestone in accordance with Section 1005. All materials shall conform to Division 1000, Material Details, and specifically as follows: Item
Section
Emulsified Asphalt (SS-1, SS-1H, CSS-1 or CSS-1H)
1015
Reinforcing Steel for Concrete
1036
Epoxy Resin Material
1039
Concrete Curing Material
1055
Material for Joints
1057
502.2.1 Allowance for Testing. The Contractor shall make allowance for sampling of concrete for quality control testing purposes. 502.2.2 Concrete Mix Designs. The Contractor's concrete pavement mix design properties shall meet the requirements of Section 501. 502.2.3 Material Rendered Unfit. The Engineer may at any time reject and require the Contractor to dispose of any batch of concrete mixture which is rendered unfit for use due to contamination, segregation, improper slump, improper temperature or improper entrained air content. Such rejection may be based on only visual inspection. In the event of such rejection, the Contractor may take a representative sample of the rejected material in the presence of the engineer, and if demonstrated in the laboratory in the presence of the Engineer that such material was erroneously rejected, payment will be made for the material at the contract unit price. 502.3 Equipment. Provide the Engineer with an equipment list and their specifications a minimum of 14 days prior to the planned start of pavement placement. Equipment and tools necessary for handling material and performing all parts of work shall be approved by the Engineer as to design, capacity, and mechanical condition. The equipment shall be at the job site a minimum of one full work day ahead of the start of construction operations to be examined thoroughly by the Engineer for approval and shall be in accordance with the following:
3/15/2022
502-1
Portland Cement Concrete Pavement
502.3.1 Batching Plant, Mixer and Hauling Equipment. The batching plant, mixer, water measuring equipment, weighing and hauling equipment shall conform to the requirements of Section 501 and Section 502. Manufacturing plants out of calibration shall not be used. 502.3.1.1 Central or truck mixed concrete shall be produced and delivered from not more than three (3) plants per day for any individual project or subdivision. Prior approval will be required to use multiple plants on the same day. This restriction will not apply to material suppliers who qualify as "Disadvantaged Business Enterprises", when D.B.E. participation is stipulated in the construction contract. 502.3.1.1.1 Mixes shall use the same cementitious type and brand, water, aggregate gradation and source, and admixture material brand and type and proportions. 502.3.1.1.2 Mixing. Mixing water may be added in accordance with Section 501, water shall not be added to a partial load. 502.3.1.2 Delivery Route Weight Restrictions. Loaded hauling equipment weight shall not exceed statute weight limitations, posted weight limits or limits required by the municipal jurisdiction, whichever is less, along the hauling route to the job site. No additional compensation will be granted for compliance with this requirement. 502.3.2 Slip Form Paving. Concrete shoulders or mainline pavement shall be constructed by the use of sliding form methods. Paving gaps, small pours, and irregular shaped areas may be paved by other methods as approved by the Engineer. Slip form construction shall be in accordance with these specifications. 502.3.2.1 Slip Form Grade Trimmer. Use a standard manufacture grade trimmer that is automatically controlled (from a reference system) either from a preset grade control stringline in regard to both line and grade or be equipped with GPS Machine Guidance. 502.3.2.1.1 Water Supply Equipment. The water supply equipment shall be of such capacity and design as to ensure an ample supply and adequate pressure simultaneously for all the requirements of machinery, mixing, curing, wetting subgrade, wetting aggregate base, and all other features of the work. 502.3.2.2 Concrete Conveying Equipment. Concrete conveying equipment shall be in accordance with Section 501.11.15, shall not cause damage to the base, and shall be approved in advance by the Engineer. Concrete shall be conveyed evenly across the width to be paved and shall not be placed above the mid-point of the auger of the paver. 502.3.2.3 Concrete Spreader. Use a standard manufacture self-propelled concrete spreader equipped with a power-driven device mounted on crawler tracks for transversely spreading the concrete uniformly across the base. Use a concrete spreader that is capable of spreading and striking-off the concrete. The Engineer may waive the use of a self-propelled concrete spreader in areas of narrow or irregular dimensions.
3/15/2022
502-2
Portland Cement Concrete Pavement
502.3.2.4 Equipment for Slip Form Paving. Slip form machines shall be furnished that are capable of spreading, consolidating, screeding, and float-finishing the freshly placed concrete in one complete pass of the machine, providing a dense and homogeneous pavement with minimal hand finishing. No apparent slumping of the concrete shall occur 6-inches or more measured from the pavement edge. The paving machine shall be equipped with the following: 1) Electronic controls to control line and grade from either or both sides of the machine, or from averaging-skis that reference the grade or using GPS machine guidance operating within the same tolerance. 2) Vibrators to vibrate the concrete for the full width and depth of the strip of pavement being placed; 3) A positive interlock system to stop all vibration and tamping elements when the forward motion of the machine is interrupted. Operate the paving machine with a continuous forward movement and coordinate mixing, delivering, and spreading concrete to provide uniform progress without stopping and starting the paving machine. Apply no tractive force to the machine, except that which is controlled from the machine. The paver shall be a heavy-duty, self-propelled machine designed specifically for paving and finishing high quality pavement. The slipform paverfinisher shall be automatically controlled and crawler mounted with padded tracks so as to be completely stable under all operating conditions. The paver minimum weight and horsepower (hp) shall be as follows: Slip form Paver Equipment Paving Width, feet < 30
Power, HP Per Foot of Paving Width
Weight, Pounds Per Foot of Paving Width
Minimum
Maximum
Minimum
Maximum
6
-
2,000
-
The paver shall spread, consolidate, and shape the plastic concrete to the desired cross section in one pass. The mechanisms for forming the pavement shall be easily adjustable in width and thickness and for required crown. In addition to other spreaders required by paragraph above, the paver shall be equipped with a full width knock-down auger or paddle mechanism, capable of operating in both directions, which will evenly spread the fresh concrete in front of the screed or extrusion plate. The paver shall finish the surface and edges so that no edge slump beyond allowable tolerance occurs. Suitable moving side forms shall be provided that are adjustable and will produce smooth, even edges, perpendicular to the top surface and meeting specification requirements for alignment and freedom from edge slump. Slip form paver forward operation shall be no less than 4 feet per minute and no more than 6 feet per minute.
3/15/2022
502-3
Portland Cement Concrete Pavement
502.3.2.4.1 Edge Slump Tolerance. Paving equipment shall be operated so edge slump is minimized. Edge slump, as measured to within 6 to 12 inches away from the slab edge, of ¼ inch or more, will trigger immediate corrective action. If such a problem develops, paving shall be stopped, and measures taken to correct excessive edge slump before paving resumes. If the edge slump is not detected in time, the Engineer may require patching, removal and replacement of the effected slab, and/or diamond grinding to correct the irregularity. 502.3.2.4.2 Maximum Slip Form Paving Depth. The slip form paver shall provide the consolidation energy for pavements as thick as 15 inches. 502.3.2.5 Stringline Guidance. Before the grade is prepared for paving operations, install the stringline. The stringline may be wire, cable, woven nylon, polyethylene rope, or similar material. 1) Paving hubs, or construction stakes, are installed at certain intervals outside the pad line, along with pie stakes (flats) showing the difference in elevation between the top of the slab and the hub. A stringline support stake is securely placed just outside each hub so that the stringline will be directly over the hub. Stringline support stakes will be set not to exceed the following frequencies: a) Tangent sections at no more than 25 feet intervals; b) At the Point of Curvature and Point Tangent on horizontal curves; c) At the point of vertical curvature (PVC) and point of vertical tangency (PVT); d) For vertical curve(s) with a rate of change (the sum of the percent grade ahead plus percent grade behind divided by 100) ≥ 0.6; ramp, superelevations; and 100 feet < horizontal curve radii < 1,000 feet, no more than 12.5 feet intervals; e) For horizontal curve radii ≤ 100 feet, no more than 5 feet intervals; and f) At the beginning of superelevations, at breakpoints, and the end of superelevation transitions. 2) The appropriate stringline height is calculated relative to the hub elevations, the offset distance (either level or projected) between hub and pavement reference point, and the desired grade; 3) Finally, the line is installed between stakes, adjusted to the desired height, and made taut; 4) Hand winches are generally installed at about 1,000-foot intervals. The winches allow the line to be tightened to prevent sagging between stakes. (Apply stringline tension carefully; a line break may cause injuries); and 5) For maximum control, stringlines shall be set on both sides of the proposed pavement.
3/15/2022
502-4
Portland Cement Concrete Pavement
502.3.2.6 Automated Machine Guidance (AMG). The Contractor may use equipment with AMG that results in meeting the same horizontal and vertical accuracy requirements as conventional construction as detailed in the Standard Specifications. 502.3.2.6.2 Additional Engineer Responsibilities. For new construction, Engineer will set initial horizontal and vertical control points in the field for the project as indicated in the contract documents. For reconstruction or PCC overlays, the Engineer will furnish information on existing horizontal and vertical control points. Engineer will provide project specific localized coordinate system if required. The control information utilized in establishing the localized coordinate system, specifically rotation, scaling, and translation may be requested from the Engineer. For paving, Engineer will review and approve proposed surface model within two weeks following receipt of the model. 502.3.2.6.3 Additional Contractor Responsibilities. Provide a GPS rover, readily available for the Engineer to use during normal working hours for the duration of contract. This GPS rover will be stored and maintained by the Contractor. Provide the Engineer and inspection staff a minimum of 8 hours of formal training on the use of the Contractor's AMG systems, prior to the beginning of the use of any GPS machine guidance. Contractor bears all costs, including but not limited to cost of actual reconstruction of work that may be incurred due to errors in application of AMG techniques. Grade elevation errors, rework resulting from errors or failures of AMG system, and associated quantity adjustments resulting from Contractor's activities are at no cost to Contracting Authority. Delays or errors due to late submittals, operation of the GPS machine control system, or satellite reception of signals to operate AMG system will not result in adjustment to contract unit prices or justification for granting contract extensions. Check and recalibrate, if necessary, AMG system at beginning of each work day. On Special Use Permit (SUP) projects, in addition to the GPS machine control, the Contractor shall provide centerline stakes, slope stakes, and grade stakes from the beginning thru the end of the project, at 500 foot intervals on tangent, and at 250 foot intervals on horizontal curves, transitions, intersections, interchanges and break points. GPS controlled machine grading does not eliminate the need for finish staking. At least one week prior to preconstruction conference, submit to Engineer for review a written AMG Work Plan which includes the following: 1) Equipment type; 2) Control software manufacturer and version;
3/15/2022
502-5
Portland Cement Concrete Pavement
3) Proposed location of local GPS base station for broadcasting differential correction data to rover units; and 4) Proposed locations where AMG will be used. Provide minimum of 30 calendar days' notice when there are changes to proposed AMG locations that will require additional construction staking by the Engineer. Contractor may perform this additional staking at no additional cost to Contracting Authority. 502.3.2.7 Reinforcement. Welded wire reinforcement wire size, materials, storage, handling, setting depth, spacing and support type based on pavement thickness shall be in accordance with Section 505.2.1 when specified in the contract documents. Reinforcing steel bars shall be in accordance with Section 505.2.2 when specified in the contract documents. Macro-synthetic fiber reinforcement shall meet the material, storage, delivery, handling and mixing requirements of Section 505.2.3 when specified in the contract documents. 502.3.2.8 Joint Reinforcement Requirements. Joint type, epoxy coating, grade, bar size, bar type, storage, handling and spacing depending upon pavement thickness shall be in accordance with Section 505.2.4. 502.3.2.9 Keyway. Where adjacent lanes of pavement are constructed separately, use slip form paving machines or steel side forms to form a keyway along the construction joint. Keyway shall be placed to the proper height as shown in the plans and supported by attached legs resting on the aggregate base. The keyway must be held firmly against the form to prevent infiltration of mortar or misalignment. Keyway sections will be butted tightly except at expansion or contraction joints where they will be gapped. Infiltration mortar shall be removed to produce a clean, fillable joint. 502.3.3 Fixed Form Paving. 502.3.3.1 Water Supply Equipment. Shall be in accordance with Section 502.3.2.1. 502.3.3.2 Concrete Spreader. Use a standard manufacture self-propelled concrete spreader equipped with a power-driven device for transversely spreading the concrete uniformly across the base. Use a concrete spreader that rides on the fixed forms and is capable of spreading and striking-off the concrete. The Engineer may waive the use of a self-propelled concrete spreader in areas of narrow or irregular dimensions. 502.3.3.3 Side Form Paver. Furnish mechanical, self-propelled spreading and finishing machines capable of compacting and finishing the concrete with minimal hand finishing. Equip the machine with one 18-inch minimum width screed with compensating springs to minimize the effect of the screed's momentum on the side forms, or 2 independently operated screeds.
3/15/2022
502-6
Portland Cement Concrete Pavement
502.3.3.3.1 Maximum Side Form Paving Depth. The side form paver shall provide the consolidation energy for pavements as thick as 10-inches. Coordinate the number of driving wheels, power of the motor, and the machine's mass to prevent slippage. Any machine that displaces the side forms will not be permitted. Concrete shall be thoroughly vibrated along the forms or sides and along expansion and key type longitudinal joints. Attachments on finishing machines that vibrate the concrete adjacent to forms and longitudinal joints will be permitted provided satisfactory results are attained. Care shall be taken that the vibrator does not penetrate the subgrade or dislodge or move the joints. The vibrating shall be sufficient to produce a smooth pavement edge. Honeycombed edges may be cause for rejection of the pavement. 502.3.3.4 Rail Paver. Rail paver equipment carriage power and weight requirements shall be in accordance with the table below and meet the approval of the Engineer. The finishing machine shall be equipped with a mechanical strike off device and either a rotating cylinder(s) or a longitudinal oscillating screed which transversely finished the surface of the concrete to the proper pavement elevation and cross section within the specified tolerance. The Contractor may attach other equipment to the finishing machine to enhance the final finish when approved by the Engineer. Rail Paver Equipment Paving Width (Feet) 12 to 30
Carriage Power (HP)
Weight, Pounds Per Foot of Paving Width
Minimum
Maximum
Minimum
Maximum
25
-
1,000
-
Rail pavers may be equipped with one or two vibrators that move transversely in front of the screed. Fixed vibrators may be used near the form edges. Provide manual vibration with the consolidation energy required for the pavement thickness. 502.3.3.4.1 Maximum Rail Paver Paving Depth. Rail pavers shall not be used for pavement thicknesses greater than 10 inches. 502.3.3.5 Finishing Machine. The fixed form finishing machine shall be power driven, designed for concrete paving, and meet the approval of the Engineer. The finishing machine shall be operated on rails or other supports that will not deflect under the applied loads. The supports shall be adjustable for elevation and shall be completely in place for the full length of the area to be finished. The supports shall be approved by the Engineer before placing of concrete is started. The screed shall be of one of the two types:
3/15/2022
502-7
Portland Cement Concrete Pavement
1) Oscillating Screed. The finishing machine shall be equipped with at least two transversely oscillating screeds or a pan-type screed and extrusion plate capable of placing, spreading, consolidating, screeding and finishing the concrete to the proper pavement elevation and cross section within the specified tolerance with significant amount of hand finishing, except when the use of cutting straightedges, is required. The screed or extrusion plate shall be constructed to provide adjustment for crown in the pavement. The entire machine shall provide adjustment for variation in lane width or thickness and to prevent more than 8 inches of the screed or extrusion plate extending over previously placed concrete on either end when paving fill-in lanes. Machines that cause displacement of properly installed forms or cause ruts or indentations in the prepared underlying materials and machines that cause frequent delays due to mechanical failures shall be replaced as directed by the Engineer. 2) Pan-Type Screed. The pan-type paver shall be equipped with augers, strike off and tamper bars ahead of the pan screed with at least one trailing oscillating screed or belt finisher. The pan shall be sufficiently braced and stiffened to ensure no deflection. Internal vibrators with pressure compensating controls meeting the requirements of this section shall be attached to the paver. If the paver is powered by cable and motor, a steering sensor shall be required, and the motor shall be hydraulically operated. One switch or control, which stops or starts all paver functions simultaneously, shall be provided. 502.3.3.6 Mechanical Longitudinal Float. The machine shall be so constructed that the travel of the floating mechanism can be adjusted to conform to the pavement cross section, elevation, and surface smoothness shown on the plans. The float shall be a minimum of 10-feet in length and 1-foot in width. It shall be equipped with a power-driven floating screed and shall oscillate longitudinally with respect to the pavement during its transverse travel across the pavement. It may be either attached to the finishing machine or formless paver, self-propelled on rollers operating on forms or self-propelled operating on tracks. If attached to a finishing machine or formless paver, it shall be rigidly supported by a frame at the rear in a manner approved by the Engineer. If self-propelled, the tracks or rollers from which the float operates shall be in good working condition. The tracks or rollers from which the float operates shall be accurately adjusted and coordinated with the adjustments of the finishing machine or formless paver so that a small amount of mortar is carried ahead of the float at all times. 502.3.3.7 Vibratory Screeds (Hand-Operated and Self-Propelled). Vibratory screeds shall be constructed of a steel truss, of eccentric shaft design. The screed shall also be equipped with a crown / invert section when required by pavement cross-section. The screed shall be designed for concrete with 3 inch or greater slump. Screed truss blades shall be at least 12 inches apart and be constructed of at least 10-guage galvanized steel. The vibratory screed shall be at least 2 feet longer than the maximum width of the slab to be struck off. The range of operating frequencies for surface vibratory screed and the minimum engine horsepower and vibration frequency shall be in accordance with the table below. The vibratory screed shall be equipped with a manual or self-propelled winch.
3/15/2022
502-8
Portland Cement Concrete Pavement
Vibratory Screed Equipment Paving Width (Feet)
Carriage Power (HP)
Vibration Frequency (VPM)
Minimum
Maximum
Minimum
Maximum
7
-
3,000
6,000
8 to 30
502.3.3.8 Tube Finishers (Single and Revolving Triple Tube). No means of applying water to the surface shall be incorporated in the pipe float. All rolling tubes shall be free from deformation and shall be straight and free from bends and warps. Tubes shall not be used to span a crowned transverse section. A single, seamless pipe float if used, shall be a rotating pipe 6 to 10 inches in diameter and sufficiently long to span the full paving width. The pipe float shall be mounted on either a self-propelled frame that spans the paving lane or may be hand pulled. The tube finisher shall be at least 2 feet longer than the maximum width of the slab to be struck off. Revolving triple tube finishers shall be equipped with three, 6-to-10-inch diameter minimum tubes sufficiently long to span the full paving width with a minimum tube weight of 19 pounds per foot of length. The pipe float shall be mounted on a self-propelled frame equipped with a minimum engine horsepower and a minimum operating weight as indicated in the table below. Triple-Tube Screed Equipment Engine Power (HP)
Operating Weight (Pounds*)
Paving Width (W), (Feet)
Minimum
Maximum
Minimum
Maximum
10 < W ≤ 20
26
-
2,700
-
20 < W ≤ 30**
40
-
3,800
-
* Based on 22-foot-long tube length. ** Additional paving width with the approval of the Engineer.
502.3.3.9 Membrane Curing Equipment. Equipment for applying membrane-forming curing compound shall be mounted on a self-propelled frame and either crawler mounted or rubber tires that spans the paving lane. The reservoir for curing compound shall be constantly mechanically (not air) agitated during operation and shall contain means for completely draining the reservoir. The spraying system shall consist of a mechanically powered pump which will maintain constant pressure during operation, an operable pressure gauge, and either a series of spray nozzles evenly spaced across the lane to give uniformly overlapping coverage or a single spray nozzle which is mounted on a carriage which automatically traverses the lane width at a speed correlated with the forward movement of the overall frame. All spray nozzles shall be protected with wind screens. Flush nozzles daily before use. At the beginning of the project, calibrate the spraying system in the presence of the Engineer. Sprayer calibration shall be in accordance with ASTM D 2995, Method A for a minimum rate of application of not less than 1 gallon per no more than 150 square yards of paving surface.
3/15/2022
502-9
Portland Cement Concrete Pavement
502.3.3.9.1 Hand Spraying. Any hand-operated sprayers allowed by the Engineer shall be compressed air supplied by a mechanical air compressor. At the beginning of the project, calibrate the spraying system in the presence of the Engineer. Sprayer calibration shall be in accordance with ASTM D 2995, Method A, for a minimum rate of application of at least 1 gallon per no more than 75 square yards of paving surface. If the curing equipment fails to apply an even coating of compound at the specified rate, it shall immediately be replaced. Hand spraying equipment may be used on all vertical edges, hand finished sections, and all other pavement surfaces. 502.3.4 Forms. Straight side forms, except as otherwise permitted, shall be of metal and approved section, with a base width sufficient to support the finishing equipment to be used as specified herein. Forms shall be 10 feet in length, made of steel not thinner than ¼ inch, and have a 2-inch top turn-down flange. For forms of trapezoidal cross section, the minimum thickness of 3⁄16 inch will be allowed. They shall have flange braces extending outward on the base not less than ⅔ the height of the form and spaced not more than 5 feet apart. The height shall be equal to the edge thickness of the pavement. Each form section shall be straight and free from bends and warps. No section shall show a variation greater than ⅛ inch/10 feet from the true plane surface on the top, and ¼ inch/10 feet along the face of the form. The method of connecting form sections shall be locking type that will insure a tight, neat joint. Each 10 foot form will be securely held in position by a ⅞ inch minimum diameter steel form pin at each end and at least one intermediate pin of the minimum length specified in the table below to hold the forms in place to maintain the alignment and elevation of the form line during the paving operations. Form pins shall be driven slightly below grade so as not to interfere with the strikeoff and finishing of the concrete pavement. Extend forms beyond construction bulkheads to provide a working platform at the end of placement. Forms shall be cleaned and coated with a form release agent before concrete placement and prior to placement of keyways and bent bars. 5-foot and 10-foot Form Requirements Requirements
Property
Minimum
Maximum
¼
-
5 As determined by pavement thickness specified Equal to the depth of pavement thickness specified 2
10
Horizontal Top Face Variation, inch per 10 feet
-
⅛
Vertical Face Variation, inch per 10 feet
-
¼
⅔ form depth
-
Material (Steel) Thickness, inch Section Length, feet Depth, inches Base Width, inches Horizontal Top Face width, inches
Flange Bracing-extending outward on the base
3/15/2022
502-10
-
Portland Cement Concrete Pavement
Form Staking Pin Minimum Requirements Form Size (Inches) Height
Base
Number of Stakes per Form
Minimum Stake Length (Inches)
6
6
3
18
7
7
3
18
8
8
3
18
9
9
3
21
10
10
3
24
12
12
3
30
14
14
3
36
Forms for Use with Vibratory Screed. Metal forms that will be used to support a vibrating screed shall be made of no less than 10 gauge steel with a minimum 4 inch wide base and have a minimum of two flange braces with provisions for pin locking in each 10 foot section. Header (Transverse Construction Joint). The header shall be shaped to conform to the cross section required by the plans. It shall be wood or metal and of sufficient thickness and rigidity to provide a vertical construction joint. At no less than12 hours after paving is completed, the Contractor may elect to make a transverse full-depth saw cut 5 feet from the hardened slab, gang drill and install dowel bars. 502.3.4.1 Keyways. Forms shall be used where necessary to produce a concrete pavement of plan section and the forms shall incorporate a keyway where required. Longitudinal tongue and groove joints of the specified type and size shall be constructed at locations shown on the plans or approved by the engineer. The groove side of the joint shall be slip-formed or formed with approved metal forms that will produce a keyway conforming to plan location and dimensions. The form shall remain in place for sufficient time to prevent slump. Metal forms may be left in place if approved by the engineer. The tongue side of the joint may be constructed without forms provided the plan section of the concrete and joint is maintained. 502.3.4.2 Radial Forming. Light-Duty (no mechanical paving or finishing equipment) flexible or curved forms for curved form lines shall comply with the grade and alignment requirements of Section 502.3.4, except that straight steel form sections 5 to10 feet in length may be used for form lines having horizontal radii greater than 200 feet. Special forms of wood or steel will be permitted for curved form lines having horizontal radii of 200 feet or less, and may be permitted if approved by the Engineer in other special cases where it is not practicable to use standard pavement forms. Straight steel form sections, 5 feet in length, will be acceptable for curved form lines having a radius of not less than 100 feet. Forms shall be of sufficient rigidity to prevent distortion in edge alignment due to pressure
3/15/2022
502-11
Portland Cement Concrete Pavement
of the concrete. For pavement thickness less than 8 inches, wood forms may be used with a minimum nominal thickness of 1 inch. Radii of 32 feet or less will be formed with segmented steel (or wood forms with a minimum nominal thickness of 1 inch, shall be the full depth of the concrete slab, be straight and free from warp and will be held securely to line and grade given with approved form pins, as required by the Engineer. Form pins shall be driven slightly below grade so as not to interfere with the strike-off and finishing of the concrete pavement. Curved or flexible forms shall not be used as a track for operating paving and finishing equipment. The uses of built-up forms are not approved for use for side forms. All forms will be set on the base without support devices. Forms shall be cleaned and coated with a form release agent before placement of keyways and tie bars. Light-Duty 5-foot and 10-foot Form Requirements Requirements
Property
Minimum
Maximum
Material (Steel) Thickness, inch
⅛
-
Material (Wood) Thickness, inch
1
-
Section Length, feet
5
10
As determined by pavement thickness specified
-
Steel Form Base Width, inches
⅛
2
Horizontal Top Face Variation, inch per 10 feet
-
⅛
Vertical Face Variation, inch per 10 feet
-
¼
Form pins per form, each*
3
-
Form Pin length, inches
Sufficient length to hold forms in place without movement during paving operations
-
Depth, inches
* May be more frequent based on pavement thickness or radii 502.3.5 Strike-Off. An approved strike-off template to level the concrete prior to placing welded wire reinforcement or tie bars shall be provided when a mechanical concrete spreader is not used.
3/15/2022
502-12
Portland Cement Concrete Pavement
502.3.6 Vibrators. Vibrators shall be on-site and checked for operation before concrete placement begins. Use either internal type (spud or tube) vibrators or surface type (pan or screed) vibrators with non-metallic heads, coated by the manufacturer. Use vibrators mounted on the concrete spreader, the finishing machine or a separate carriage. Use vibrators capable of vibrating the full depth of the rigid pavement without coming in contact with the joint, load transfer device, subgrade or forms. Vibrators should operate only when the machine the vibrators are attached to is moving. Additional requirements for vibrators for rigid pavement: Frequency of Vibration (Vibrations Per Minute) Type
Surface
Internal
Application
Operating Range* Minimum
Maximum
Pan or screed vibrators
3,500
6,000
Vibratory Roller Screeds
100
400
Hand Vibrator
4,500
8,000
L-shaped spud vibrators (both hand operated and gang mounted); hand-held immersion vibrator
5,000
9,000
* As determined in air
502.3.6.1 Slip Form Paving. Vibrators used for full width vibration of the concrete shall be the internal type. Vibrating equipment shall be capable of angular adjustment that can be maintained during vibration. Vibrator frequency from vibrator to vibrator shall be uniform and be adjustable based on paving speed and concrete mix. Vibrators shall be operated in accordance with the manufacturer's recommendation at a frequency to provide satisfactory results. 502.3.6.2 All Paving Types. The Contractor shall have a satisfactory tachometer, equipped with a range from at least 3,000 to 12,000 VPM to check vibrator operation before use, at least twice daily, and at a random time during placement as determined by the Engineer. The tachometer shall be available at all times for checking the vibration frequency. (Note: Rubber coated vibrators shall be provided when epoxy coated transverse or longitudinal reinforcement is used.) Do not allow the vibrator head closer than 2 inches from joints, existing pavement, utility appurtenances, block-outs, load transfer devices, reinforcement, grade, or side forms. Provide a sufficient number of vibrators to consolidate each batch as it is placed. Provide at least one spare vibrator at the site in case of breakdown. If the vibrator fails and cannot be replaced, suspend operations and remove unconsolidated concrete. 502.3.7 Texturing Equipment. Texturing equipment shall be as specified below. Before use, the texturing equipment shall be demonstrated, in the presence of the Engineer, on a test section. The equipment shall be modified as necessary to produce the texture directed.
3/15/2022
502-13
Portland Cement Concrete Pavement
502.3.7.1 Burlap Drag. For residential subdivision paving a burlap drag finish is required. A burlap drag shall consist of a piece of material as long as the lane width securely attached to a separate wheel mounted frame spanning the paving lane or to one of the other similar pieces of equipment. Width of the material shall provide 24 to 36 inches dragging flat on the pavement surface. Length shall be at least equal to the width of the slab. The material shall be clean, reasonably new burlap, completely saturated with water before attachment to the frame, always re-saturated burlap before start of use and kept clean and saturated during use. Burlap shall conform to AASHTO M 182, Class 3 or 4 weighing 10 to 12 ounces per yard based on a 40-inch width. 502.3.7.2 Artificial Turf. The artificial turf drag shall be full-width and the leading transverse edge shall be securely fastened to a lightweight pole on a traveling bridge with at least 2 feet of the artificial turf in contact with the concrete. A variety of different types of artificial turf are available and approval of any one type will be done only after it has been demonstrated by the Contractor to provide a satisfactory texture. One type that has provided satisfactory texture consists of 7,200 approximately 0.85 inches long polyethylene turf blades per square foot. 502.3.7.3 Wire Comb. A wire comb shall be not less than 10-feet long with a single line of wires exposed to a length of approximately 4-inches. The wire shall be blue tempered and polished spring steel with nominal dimensions of 0.028 inch thick and 0.100 to 0.125 inch wide. The wires shall be spaced to provide ½ inch clear space between wires and securely mounted in a rigid head with the width of each wire parallel to the longitudinal centerline of the head. The wire comb shall be mechanically operated with the length of the comb parallel to the pavement centerline and capable of traversing the full width of pavement in a single pass at a uniform speed and at a uniform depth. No overlapping will be allowed. Final approval of the wire comb will be based on satisfactory performance during actual use. Texturing equipment, other than a wire comb, may be approved provided it produces a texture equivalent to that produced by a wire comb and upon satisfactory performance during actual use. Hand use of a wire comb of standard dimension, approximately 2-feet wide, will be permitted with prior approval of the Engineer. Provide a finished surface free of tinning defects. Complete before tinning tears or unduly roughens the concrete. An unsatisfactorily combed area will be refloated and retextured. If satisfactory results are not achieved before final set, a texturing machine may be required. 502.3.7.4 Broom. Brooms shall be of push broom type, at least 18 inches in width. They shall contain a maximum of three rows of good quality bass or bassine fiber 4½ inches or less in length. The handle shall be at least 1 foot longer than ½ the width of the slab and shall be readily adjustable. Two or more brooms shall be provided. 502.3.7.5 Diamond Grinding. Diamond grinding, when specified in the contract documents, shall be performed using equipment specified in Section 627. 502.3.8 Finishing, Grooving and Edging Tools. The Contractor shall provide all finishing tools necessary for proper finishing of the concrete pavement. Use aluminum, magnesium, or wooden hand finishing tools. The grooving tool shall have a ⅜ inch radius and have grooving depth of 1½ inches. The edging tools shall have a radius of ¼ inch and shall be approved by the Engineer. Two or more edging tools shall be provided. When allowed, the grooving tool shall be equipped with a handle 1 foot longer than ½ the width of the slab and shall be readily adjustable. Two or more grooving tools shall be provided.
3/15/2022
502-14
Portland Cement Concrete Pavement
502.3.9 Other Small Tools. The Contractor shall provide generators, shovels, sledge hammers, axes, pry bars, rakes, picks, tape measures, hand saws, hammers, string line, or levels. 502.3.9.1 Floats and Straightedges. Two or more 10-foot straightedges of an approved type and two or more long-handled floats, each having a minimum blade length of 36 inches in length and 6 inches in width, are to be available at all times. The handle shall be at least 3 feet longer than ½ the width of the slab. The blades will be composed of aluminum or magnesium, reinforced on the upper edge and rigidly jointed to the handle. The blades shall be capable of producing the proper section and slope. Blades shall be replaced when edges become wavy or warped. Straightedges shall not be used for moving or finishing concrete. 502.3.9.2 Metal Dies. Metal dies with beveled face numerals not less than 3 inches or more than 5 inches high shall be available at all times. The metal dies shall be thick enough to make an indentation of ¼ inch. A satisfactory die shall be used for marking the point designated by the even station number and all equations. This equipment is required for arterial road pavement only. 502.3.9.3 Footbridges. Two footbridges, so designed that they can be readily transported from place to place, and which have no part in contact with the concrete pavement, shall be available at all times. Contractors performing paving in new residential subdivisions will be permitted to proceed without footbridges if they choose. 502.3.10 Rain Protection. Sufficient burlap, waterproof paper, or white or opaque polyethylene sheeting, in accordance with Section 1055, shall be on site and available for use for the protection of the pavement in case of rain or breakdown of the curing equipment. It is the Contractor's responsibility to protect the pavement from damage due to rain. Failure to properly protect unhardened concrete may constitute cause for the removal and replacement of defective pavement at the Contractor's expense. 502.3.11 Concrete Saw. Provide sawing equipment adequate in number of units and power to complete sawing to the required dimensions. When sawed joints are required, equipment complete with an abrasive wheel or a diamond-edge, water-cooled blade capable of providing a groove of the specified dimensions in the hardened concrete shall be provided. Equipment may be a wet-cut saw, referred to as a "conventional concrete saw" or a lighter weight dry-cut saw, referred to as an "early-entry concrete saw", used to establish joints sooner than the conventional saw. Provide at least one standby saw in good working order and a supply of saw blades at the site of the work at all times during sawing operations. 502.3.12 Drills. Use gang drills with a minimum of 2 independently powered and driven drills for horizontal drilling. Use tungsten carbide drill bits. Rest and reference the drill rig frame on and to the pavement surface such that the drilled holes are cylindrical, perpendicular to the surface being drilled, and repeatable in terms of position and alignment. Hand-held drills, or gang drills resting on the base or sub-base, are permitted for drilling holes in longitudinal joints if there is not enough room to use gang drills resting on the pavement surface. This typically occurs when traffic is being maintained on a previous placement. Drill used to drill dowel bar holes should be sized to ensure that there is no excessive chipping or spalling of concrete around dowel bars.
3/15/2022
502-15
Portland Cement Concrete Pavement
502.3.13 Equipment for Sealing Joints. Equipment for sealing joints shall be in accordance with Section 502.9.3. 502.4 Construction Requirements. On projects requiring less than 2,500 sq. yd. of Portland cement concrete pavement or requiring individual placement areas of less than 500 sq. yd., or irregular areas at locations inaccessible to slip-form paving equipment, Portland cement concrete pavement may be placed with approved placement and finishing equipment using stationary side forms. Hand screeding and float finishing may only be used on small irregular areas as allowed by the Engineer. 502.4.1 Mixing and Placement Limitations. No concrete shall be mixed, placed or finished when the natural light is insufficient, unless an adequate and approved artificial lighting system is operated. Concreting operations shall not begin or continue: 1) During rain; 2) On any surface with standing water; 3) On any unstable subgrade or aggregate base; 4) When weather conditions prevent the proper handling or finishing of the mixture. 502.4.1.1 Cold Weather. The Contractor shall provide concrete so that at the time of placement the concrete shall be within the temperature requirements in accordance with Section 501. The Contractor shall provide a method, meeting the approval from the Engineer, of monitoring the concrete that demonstrates that the concrete has been protected from freezing. Regardless of precautions taken, the Contractor shall assume all risks, and all frozen concrete shall be replaced at the Contractor's expense. Cold weather is defined in accordance with Section 501.8.1. Concreting operations shall not continue: 1) During Cold Weather. Pouring operations will not begin until the ambient air temperature has reached 35°F and rising, with a predicted (National Weather Service) high temperature of 40°F or above and will be discontinued when the ambient air temperature in the shade falls below 35°F; 2) On or against any frozen surface; 3) On or against any pavement, reinforcement, forms or base material (to a depth of the thickness of the base material specified) that is at or below 35°F; 4) Unless authorized by the Engineer during critical temperature periods (below 35°F); or 5) When the concrete temperature at the time of placement is less than that specified for the plan thickness as defined in Section 501.8.1.3.1.
3/15/2022
502-16
Portland Cement Concrete Pavement
If approval has been granted for the Contractor to place the concrete while the ambient temperature is below 40°F, the Contractor shall take precautionary measures in accordance with Sections 501.8.1.3, 501.8.1.4, and 501.8.1.5. In order to prevent exposure of new pavement to deicing chemicals concrete shall not be placed when the national weather service forecast predicts winter weather of snow or ice within the next 7 days, unless approved in advance by the Engineer. 502.4.1.1.1 Strength Acceleration. When the mean daily ambient temperature is expected to remain below 45 °F during the first 72 hour curing period, the Engineer may allow the use of an additional 94 pounds of cement per cubic yard or an ASTM C 494 Type C admixture to accelerate the rate of strength gain. An accelerating admixture will be required when the projected mean daily ambient temperature within 72 hours after paving is predicted by the National Weather Service to be at or below 35°F. If the dosage rate is not determined by the manufacturer, use the table below for the accelerator dosage for the lowest ambient temperature expected during the curing period. The use of an approved, non-corrosive strength accelerator will be required for reinforced concrete, unless specified otherwise in the contract documents. The Contractor shall receive no additional compensation for strength acceleration. Strength Accelerator Dosage Requirements1 Lowest Mean Ambient Air Temperature Expected During Curing Period (T)
1
Dosage Rate (Percent per 100 pounds of Cementitious Materials) Maximum With Additional Cement
Maximum Without Additional Cement
T < 35°F
1
1.5
35°F ≤ T < 40°F
0.5
1
T ≥ 40°F
0.0
0.5
A reduced dosage of up to 50 percent is allowed for slip-form construction.
502.4.1.1.2 Opening to Service. If repeated cycles of freezing and thawing are anticipated, the concrete shall be kept warm long enough to allow it to develop a compressive strength, as determined by maturity or field cured cylinders. 502.4.1.1.3 Thermal Protection Plan. Thermal protection is a function of the mix cement content, accelerating admixture, pavement thickness, and temperature of the concrete at the time of placement, the surface area size and ambient temperature, and ambient temperature during the curing period. Very early opening strength concrete shall be effectively protected from freezing for a period of at least 4 hours after it has been placed or until the minimum specified compressive strength has been attained by maturity testing. High early opening strength concrete shall be effectively protected from freezing for a period of at least three (3) equivalent curing days after it has been placed or until the minimum specified compressive strength has been attained by field cured concrete test specimens or by maturity testing. All other concrete pavement shall be effectively protected from freezing for a period of at least five (5) equivalent curing days after it has been placed or until a minimum compressive strength of 3,500 psi has been
3/15/2022
502-17
Portland Cement Concrete Pavement
attained by field cured concrete test specimens or by maturity testing. For concrete pavement less than or equal to 12 inches in thickness, that is cast on grade with a temperature of less than 35°F, curing protection will be extended up to ten equivalent curing days and the curing blankets will be supplemented with heat systems or enclosures until 3,500 psi compressive strength has been attained by field cured concrete test specimens or by maturity testing. Protection will be required for not more than ten (10) equivalent curing days. The minimum temperature of concrete at the time of placement shall be no less than the minimum specified for the pavement design thickness, LD, in Section 501.8.1.3. The Contractor shall provide a Thermal Protection Plan that conforms to the requirements established in ACI 306, "Guide to Cold Weather Concreting" for concrete exposed to repeated freeze-thaw cycles, and these specifications for review by the Engineer at least one month prior to use during cold weather placement of concrete. At a minimum, the plan shall demonstrate that the concrete has been protected from freezing and address: 1) Plan introduction, include: a) This Cold Weather Concreting Plan is submitted as required by the Project Specifications and conforms to the requirements established in ACI 306.1, b) County definition of cold weather in Section 501. 2) Production: a) Describe the means to be used for meeting requirements for the minimum and maximum concrete placement temperatures. b) Action to be taken if the placement temperature falls below the specified minimum for each pavement thickness, for at least 3 ambient temperature ranges, and shall include material description and thickness. c) Transportation and placement steps to ensure that the placement temperature doesn't drop below the allowable minimum. 3) Protection: a) Describe the proposed protection methods for different temperature ranges using one or more of the following. R-values for insulating blankets shall be selected "without airspace". When exposed to direct heat all protection materials shall be rated as flame retardant : i) ASTM C 494 Type C or E accelerating admixture; ii) Increasing the cementitious materials; iii) Decreasing the water / cementitious material ratio; iv) Replacing the Type I/II cement with Type III cement. b) Insulation material with designated R-value such as : i) Polystyrene foam sheets; ii) Poly Burlap Curing Blankets;
3/15/2022
502-18
Portland Cement Concrete Pavement
iii) Moisture impervious Insulation blankets(closed-cell polypropylene foam). c) Polyethylene sheeting (include mil thickness and R-value). The number of insulating blankets needed to supply a required R-value; d) Heat systems; e) Enclosures. 4) Moist Curing: a) Method(s) to be used to prevent concrete from drying during the required curing period i) Moisture Impervious Insulating Blankets (See Section 502.4.1.6). ii) Curing Compound. 5) Temperature Monitoring: a) Indicate how you will allow the concrete to cool so the maximum cooling rate isn't exceeded. b) Abrupt changes in weather or equipment failures. c) Indicate in your plan the weather services you will monitor to predict local weather changes (Section 502.4.1.6). d) Briefly describe any backup placing and finishing machines, heaters, or other equipment that you'll have on hand in case of breakdowns. e) Procedure for installing emergency construction joints: i) Anticipated tensile strains in the fresh concrete as related to heating and cooling of the concrete material; ii) Anticipated weather conditions such as ambient temperatures, wind velocity, and relative humidity; iii) Anticipated timing of initial sawing of joints. Regardless of precautions taken, the Contractor shall assume all protection risks, and all frozen concrete shall be removed and replaced at no cost to the County.
3/15/2022
502-19
Portland Cement Concrete Pavement
502.4.1.1.4 Cover Material Requirements. At any time of the year, if the National Weather Service forecast for the construction area predicts temperatures below 35°F within 72 hours after placement, or when temperatures below 35°F actually occur, provide the minimum level of thermal protection specified below for concrete that has yet to conform to the opening criteria specified. Black polyethylene sheeting (Section 1058.2), burlap and curing blankets shall be used to provide thermal curing. If the blankets do not provide the level of moist curing required, polyethylene sheet material in accordance with Section 1055 will be placed over the concrete pavement prior to placement of the burlap or thermal curing blanket(s). Each curing blanket (Section 1055.4.1.4) shall have a minimum R-value of 3. Curing blankets, burlap and polyethylene sheet material shall extend a minimum of 18 inches beyond the limits of the paving surface. Cover materials shall be so placed and weighted that they remain in contact with the pavement surfaces and edges, providing an airtight enclosure. Thermal and moist curing materials may be removed for a period not to exceed 30 minutes, to allow for form removal or saw cutting of pavement and then be immediately replaced. The following range of temperatures (T) will dictate the minimum cover method required: Lowest Temperature Forecasted Minimum Type of Protection1 During Curing Period (T, °F) 32 ≥ T > 27
1 Layer of burlap2
27 ≥ T > 24
2 Layers of burlap2
T ≤ 24
6-12 inches of straw (or 4 layers of burlap)
1
The protection shall remain until one of the following conditions is met: a. The pavement is 5 calendar days old. b. Opening strength is attained. c. Forecasted low temperatures exceed 35ºF for the next 48 hours. d. Forecasted high temperatures exceed 55ºF for the next 24 hours and subgrade temperatures are above 40ºF.
2
Covered with 6 mil black poly. Thermal Curing Blankets in accordance with Section 502.6.6 may be used in place of straw or burlap.
Check the effectiveness of your insulation by taking the temperature of the concrete. Placing a thermometer between the insulation and the concrete will allow you to determine the effectiveness of the insulating layer. If the temperature begins to drop, use additional material or material with a higher "R" value. 502.4.1.1.5 Concrete Temperature Measurement. When the ambient temperature at the time of placement is 40°F or less, the plastic concrete temperature shall be taken and recorded at a minimum rate of one test per hour. During the curing period, the Contractor will make provisions so that the Engineer may record the high and low temperature of the concrete at least twice per 24-hour curing period.
3/15/2022
502-20
Portland Cement Concrete Pavement
502.4.1.2 Hot Weather. Hot weather is any time during the concrete placement that the average ambient air temperature as determined in accordance with Section 501.8.2.1, is above 80°F. The Contractor shall provide a Temperature Management Plan, developed in accordance with ACI 305, "Guide to Hot Weather Concreting", for review by the Engineer at least 7 days prior to use during hot weather concrete placement of concrete. 502.4.2 Setting Forms. Forms shall be set sufficiently in advance of the concrete placement to insure continuous paving operation. Forms shall be set so that they rest firmly throughout their length upon the thoroughly compacted aggregate base. Any aggregate base which is more than ¼ inch below the established grade at the form line shall be brought to grade for a sufficient width, at least 12 inches outside the area required by the pavement, to support the forms adequately, and shall be compacted to specified density. The Contractor shall make any temporary measures to insure proper drainage so that erosion will not take place beneath the pavement to be placed. 502.4.2.1 Forms shall be staked into place with not less than three pins for each 10-foot section. A pin shall be placed at each side of every joint. Form sections shall be tightly locked, free from play or movement in any direction. If the aggregate base or subgrade becomes soft and yielding after the forms have been set and before the concrete is placed, the forms shall be reset on a stable foundation. 502.4.2.2 Both straight and curved forms shall be supported in such position that the face of the form shall be vertical on tangents and perpendicular to the superelevated section on curves. The vertical alignment of the top of the form, at any joint, shall not vary more than ⅛ inch from the true grade line during placing, compacting, and finishing operations. The form horizontal alignment shall not vary more than ¼ inch from the true alignment. The alignment and grade elevations of the forms shall be checked, and corrections made by the Contractor immediately before placing the concrete. 502.4.2.3 Unless otherwise permitted, sufficient forms shall be provided so that at least 500 feet of forms on each side of the roadbed are accurately set at all times in their required final position in advance of the point where concrete is being placed. Each time forms are used they shall be cleaned thoroughly and coated with a form release agent before reuse. 502.4.3 Slip Form Construction. The aggregate base for sliding formed Portland cement concrete pavements shall be compacted and brought to the proper cross-section and density in accordance with Section 304, "Aggregate Base", and widened 36 inches beyond the inside sliding form face. No additional compensation will be made for the additional two feet of aggregate base and plating across inlet or utility appurtenances required for slip form paving crawler tracks. 502.4.3.1 Low areas of treated bases shall be filled only with concrete integral with the pavement. No direct payment will be made for the concrete used to fill these low areas. 502.4.3.2 If the density of the underlying surface is disturbed by the trimming operations, correct it by additional compaction and retest it at the option of the Engineer before the concrete is placed. 502.4.4 Proportioning and Mixing Concrete. Concrete shall be proportioned and mixed in accordance with Section 501, by one of the following methods:
3/15/2022
502-21
Portland Cement Concrete Pavement
502.4.4.1 Paving Mixers. Semi-automatic control will be required for cement and aggregate batching for concrete mixed in paving mixers at the point of deposition. This shall consist of controlling the flow of material by means of gates or valves which may be separately and manually opened to allow material to be weighed but which are closed automatically when the pre-determined weight of each material is reached. The batching equipment shall be interlocked so that: 1) The charging mechanism of any weigh hopper cannot be opened until the scale has returned to zero and the discharge mechanism of the weigh hopper has closed; 2) The discharge mechanism of the weigh hopper cannot be opened if the charging mechanism is open; 3) The discharge mechanism cannot be opened until all ingredients have been batched to their designated weights, within the specified tolerances; 4) If separate aggregate components are weighed cumulatively in a single hopper, the aggregates will be weighed in the selected sequence and the cement weighed in a separate hopper. The cement shall be kept separate from the aggregates until the batch ingredients are released for discharge. 502.4.4.2 Truck or Central Mixers. In addition to the above requirements, automatic, fully interlocked, batching control will be required for concrete mixed in truck or central mixers and hauled to the point of deposition as a mixed product. This shall consist of batching all aggregate, cement, and water by means of automatic or metering, with all additives dispensed automatically and interlocked with the automatic weighing or metering controls. For central mixed concrete, the mixing cycle shall be timed and interlocked with the weight batch cycle. The weight setting controls shall be suitably enclosed in a compartment equipped so that it may be locked when directed by the Engineer. The automatic batching equipment shall be capable of conversion to manual operation, if necessary. In the event of an automatic equipment breakdown, manual operation of the plant will be permitted until the end of the workday. 502.4.5 Placing Concrete. The concrete shall be uniformly deposited full depth over the entire width of the prepared aggregate base in such a manner as to prevent segregation and to minimize handling. Mixers, including truck mixers and trucks used for transporting concrete, will be permitted to discharge concrete by chute or by dumping directly on the prepared base provided the underlying material is not damaged or distorted. The Contractor shall apply labor to guide equipment through areas with overhead wires or appurtenances that may be damaged as the equipment conveys or places concrete. At any point in conveyance, the free vertical drop of the concrete shall not exceed 3 feet. Vibrators, backhoes, front end loaders, skid steer loaders and other grading equipment shall not be used to distribute the concrete in front of the paver. All joint reinforcement shall be reset and restaked, with any damaged bars or baskets to be removed and replaced before concrete is placed on them. Concrete shall be uniformly vibrated before strike-off. Hauling equipment or other mechanical equipment can be permitted on adjoining previously constructed concrete pavement when the concrete compressive strength reaches 3,500 psi as determined by field cured cylinders, cores, or maturity method. Subgrade and subbase planers, concrete pavers, and concrete finishing equipment may be permitted to ride upon the edges of previously constructed concrete pavements when the concrete compressive strength reaches 3,000 psi as determined by field cured cylinders, cores, or maturity method. Honeycomb in the concrete pavement edge may 3/15/2022
502-22
Portland Cement Concrete Pavement
be cause for rejection of the concrete. Necessary hand spreading shall be done with shovels, not rakes. Workers shall not be allowed to walk in the freshly mixed concrete with boots or shoes coated with earth or foreign substances. 1) Lateral Deviation. Lateral deviation from established alignment of the pavement edge shall not exceed plus or minus 1¼ inch in any lane. 2) Vertical Deviation. Vertical deviation from established grade shall not exceed plus or minus ½ inch at any point. 3) Utility Appurtenance Box Outs. Box outs and exposed utility appurtenances shall initially be set below grade so as not to be disturbed by the paver and shall be reset to grade at the time the pavement is being finished. Avoid concrete inflow into any utility appurtenance, immediately removing concrete that flows into the utility appurtenance. If aggregate is used to fill box out to reduce concrete waste, aggregate shall be filled no less than 3 inches from the top of the inside of the box out. A ¾ inch thick plywood cover over the box out area may be used in place of the aggregate fill. Comply with contract documents for the size and shape of the box out. 502.4.5.1 Slip Form Construction. For new construction, slip form machines shall be furnished for projects that do not meet the requirements for hand-finish (Section 502.4.7.2). Slip form machines shall be capable of spreading, consolidating, screeding, and float-finishing the freshly placed concrete in one complete pass of the machine, providing a dense and homogeneous pavement with minimal hand finishing. Pave no more than 24-feet wide mainline pavement in a single operation except as follows: 1) The Contractor may pave a maximum of 2 lanes plus a 6-foot shoulder (30 feet maximum) in a single operation; 2) Approval will be based on satisfactory performance of the Contractor's operation. 502.4.5.2 Side Form Construction. Furnish mechanical, self-propelled spreading and finishing machines capable of compacting and finishing the concrete with minimal hand finishing. Equip the machine with one 18-inch minimum width screed with compensating springs to minimize the effect of the screed's momentum on the side forms, or two independently operated screeds. The side forms shall be of dimensions, shape, and strength to support the concrete laterally for a sufficient length of time so that no edge slumping exceeds the requirements of Section 502.4.7.7.1. 502.4.5.2.1 Coordinate the number of driving wheels, power of the motor, and the machine's mass to prevent slippage. Any machine that displaces the side forms will not be permitted.
3/15/2022
502-23
Portland Cement Concrete Pavement
502.4.5.2.2 When side form construction is to be constructed on the edge of a new concrete pavement, the concrete compressive strength of the riding surface shall be 3,000 psi or greater, determined by field cured specimens, cores, or maturity method. The Contractor will provide sufficient forms so that there will be no delay in placing concrete due to the lack of forms. 502.4.5.2.3 Concrete shall be deposited as near to expansion and contraction joints as possible without disturbing them but shall not be dumped from the discharge bucket or hopper onto a joint assembly unless the hopper is centered above the joint assembly. Concrete shall be thoroughly consolidated along the faces of all forms and previously placed concrete and along expansion and key type longitudinal joints by means of vibrators inserted in the concrete. Attachments on finishing machines that vibrate the concrete adjacent to forms and longitudinal joints will be permitted provided satisfactory results are attained. Insertion of the vibrator shall be perpendicular to concrete profile for no less than 5 seconds and no longer than 15 seconds and shall be withdrawn slowly so as to prevent entrapping air voids. Vibrators shall not be used to move concrete. Care shall be taken that the vibrator does not penetrate the aggregate base, come in contact with the side form, reinforcing steel, or adjoining concrete or dislodge or move the joints. The vibrating shall be sufficient to produce a smooth pavement edge. Honeycombed edges may be cause for rejection of the pavement. 502.4.5.3 Subdivision Paving. The concrete shall be deposited full depth over the entire width of the base between forms in such manner as to require as little rehandling as practicable. Where concrete is being placed for non-arterial, mainline slip form paving, the concrete may be directly deposited from trucks onto the base providing the paving equipment is capable of properly spreading the concrete. 502.4.5.4 Construction of Irregular Areas. In irregular areas or areas inaccessible to paving equipment, construct the pavement using side forms. Strike-off, consolidate, float, and surface finish the concrete as follows: 1) Thoroughly and uniformly vibrate and compact the concrete during placement without segregating the material; 2) Using templates or screeds, strike-off the concrete to shape it to the required cross-section between the forms. Carry a slight excess of concrete in front of the leading edge of the template or screed; 3) Float the surface to the required grade and cross-section; 4) Finish the surface according to Section 502.4.7.7. 502.4.6 Tie Bar Placement. Tie bar placement shall be in accordance with Section 505. Tie bars may be bent at right angles against the form of the first lane constructed and straightened into final position before placing concrete in the adjacent lane. Grade 60 tie bars shall not be bent or re-straightened during construction. Do not bend or straighten tie bars into correct position by more than 90 degrees. Repair or replace broken or badly damaged tie bars. With slip form paving, tie bars may be hydraulically inserted through metal keyways. Tie bars shall be supported in the proper position by chairs driven through the aggregate base and into the subgrade or may be placed by approved mechanical methods prior to the consolidation of the concrete after the concrete has been struck-off. Tie bars shall be free from dirt, oil, paint and 3/15/2022
502-24
Portland Cement Concrete Pavement
grease. Where tie bars are required at longitudinal construction joints, a tongue and groove type joint shall be constructed, and the tie bars shall be installed in the groove side of the joint. The bars shall be positioned before concrete pavement consolidation. 502.4.7 Final Strike-Off, Consolidation, and Finishing. 502.4.7.1 Machine Finishing. Machine finishing by extrusion methods or vibrating and screeding processes will be required for all concrete, except as permitted by Section 502.4.7.2. The concrete shall be spread as soon as it is placed, and it shall be struck off and screeded by a finishing machine. The machine shall go over each area as many times and at such intervals as necessary to give proper consolidation and leave a surface of uniform texture. Excessive operation over a given area shall be avoided. When side forms are used, the tops of the forms shall be kept clean by an effective device attached to the machine, and the travel of the machine on the forms shall be maintained true without lift, wobbling, or other variation tending to affect the precision finish. During the first pass of the finishing machine, a uniform ridge of concrete shall be maintained ahead of the front screed for its entire length. When in operation, the screed shall be moved forward with a combined longitudinal and transverse shearing motion, always moving in the direction in which the work is progressing, and so manipulated that neither end is raised from the side forms during the striking-off process. If necessary, this shall be repeated until the surface is of uniform texture, true to grade and cross section, and free from porous areas. 502.4.7.2 Hand Finishing. Hand finishing methods will not be permitted, except under the following conditions: in the event of breakdown of the mechanical equipment, hand methods may be used to finish the concrete already deposited on the grade; in areas of narrow widths or of irregular dimensions where operation of the mechanical equipment is impractical. Concrete, as soon as placed, shall be consolidated, struck off and screeded. An approved vibratory or tube finisher portable screed shall be used. A second screed shall be provided for striking off the bottom layer of concrete when reinforcement is used. The screed for the surface shall be a least 2 feet longer than the maximum width of the slab to be struck off. It shall be of approved design, sufficiently rigid to retain its shape, and shall be constructed either of metal or of other suitable material covered with metal. Consolidation shall be attained by the use of suitable vibrators. Compacting and finishing pavement by hand methods will be permitted for the following conditions: 1) For all curves having a form line radius of less than 200 feet or where wood forms are used; 2) For all tapered and irregular shaped areas; 3) For isolated pavement lane(s) when approved by the Engineer; 4) For pavement lanes of less than 10 feet in width and 300 feet in length; 5) For bridge approaches and pavement to first expansion joint; 6) When obstructions (i.e., utility pole) or construction phasing prohibit the use of slip form paving;
3/15/2022
502-25
Portland Cement Concrete Pavement
7) When a breakdown of the slip form paver, mechanical compacting and finishing equipment occurs or in the event of some other emergency. After a breakdown, only material that has already been proportioned and is within time limits (as determined by time stamped on material ticket) may be finished by hand. 502.4.7.2.1 Hand finishing shall consist of all operations required under Section 502.4.7.2, except mechanical finishing equipment will not be required. If a mechanical float is not used, a manually operated longitudinal float worked from each side of the pavement shall be used. The final surface texture may be applied manually with a wire comb meeting the requirements of Section 502.3.8.3. 502.4.7.2.2 Subdivision Paving. In irregular shaped areas of subdivision paving such as "cul-de-sacs", "eyebrows" and the handwork portion of "Tee" intersections, the Contractor will be allowed to use a 10-foot-long float to strike off and finish the concrete surface. The Contractor will be required to use a vibratory screed in subdivision pavement widening and taper lanes adjacent to mainline pavement. The screed shall also be used on any mainline pavement not poured with a slip form paver other than in the irregular shaped areas mentioned above. 502.4.7.3 Consolidation. Concrete shall be consolidated by vibrating the mass promptly following placement. Vibrating tubes shall extend into the concrete the distance necessary to provide adequate consolidation. Approved pan-type vibrators operated on the surface of the concrete may be used in lieu of tube type internal vibrators. Vibrators shall be operated only when the machine to which the vibrators are attached is moving. Care shall be taken that the vibrator does not penetrate the aggregate base or dislodge or move the joints, dowel bars, tie bars, or reinforcing steel. Vibrators shall not come in contact with the reinforcement, load transfer devices, base, adjacent pavement or side forms. 502.4.7.4 Addition of Finishing Water. Moisture in any form shall not be applied to the surface of the concrete except for emergency conditions. When emergency conditions exist and it becomes necessary to apply additional moisture to the surface of the concrete in order to complete the final finishing operation, water may only be applied in the form of a fine pressure spray. Under such conditions, placement of additional concrete on the base shall be discontinued until the emergency conditions cease to exist. 502.4.7.5 Strike-Off of Concrete and Placement of Welded Wire Reinforcement. Following the placing of the concrete, it shall be struck off so that when the concrete is properly consolidated and finished, the surface of the pavement will be at the proper elevation and cross section. When reinforced concrete pavement is placed in two layers, the entire width of the bottom layer shall be struck off to such length and depth that the sheet of welded wire reinforcement may be laid full length on the concrete in its final position without further manipulation. The reinforcement shall be placed directly upon the concrete, then place the top layer of concrete, strike it off and screed it. Any portion of the bottom layer of concrete that has been in place more than 30 minutes without being covered with the top layer shall be removed and replaced with freshly mixed concrete at the Contractor's expense. When reinforced concrete is placed in one layer, the reinforcement may be positioned in advance of the concrete placement or it may be placed in the plastic concrete after initial spreading by mechanical or vibration into correct position by means of a reinforcement installer. When manual placement requires that the Contractor work on top 3/15/2022
502-26
Portland Cement Concrete Pavement
of the freshly inserted reinforcement, the reinforcement shall be placed on approved bar supports provided by the Contractor, at the Contractor's expense, and spaced in accordance with Section 505. If a "wire pattern" appears on the surface of the fresh pavement, immediately modify placement procedures to eliminate the problem. 502.4.7.6 Floating. After the concrete has been struck off and consolidated, it shall be further smoothed and trued by means of a longitudinal float using one of the following methods: 1) Hand Method. Float handles shall not be less than 12 feet in length and have blades no less than 6 inches in width, stiffened to prevent flexibility and warping. The float shall be operated from foot bridges spanning but not touching the concrete or from the edge of the pavement. Floating shall pass gradually from one side of the pavement to the other. Forward movement along the centerline of the pavement shall be in successive advances of not more than one-half the length of the float. Any excess water or laitance in excess of ⅛ inch thick shall be removed and wasted. 2) Mechanical Method. The Contractor may use a machine composed of a cutting and smoothing float(s), suspended from and guided by a rigid frame and constantly in contact with, the side forms or underlying surface. If necessary, long-handled floats having blades not less than 5 feet in length and 6 inches in width may be used to smooth and fill in open-textured areas in the pavement. When the crown of the pavement will not permit the use of the mechanical float, the surface shall be floated transversely by means of a long-handled float. Care shall be taken not to work the crown out of the pavement during the operation. After floating, any excess water and laitance in excess of ⅛ inch thick shall be removed and wasted. Successive drags shall be lapped one-half the length of the blade. 502.4.7.7 Straightedge Testing and Surface Correction. After the pavement has been struck off and while the concrete is still plastic, it shall be tested for trueness with a Contractor furnished 10-foot straightedge swung from handles 3 feet longer than one-half the width of the slab. The straightedge shall be held in contact with the surface in successive positions parallel to the centerline and the whole area gone over from one side of the slab to the other, as necessary. Advancing shall be in successive stages of not more than one-half the length of the straightedge. Any water and laitance in excess of ⅛ inch thick shall be removed from the surface of the pavement and wasted. Any depressions shall be immediately filled with freshly mixed concrete, struck off, consolidated, and refinished. High areas shall be cut down and refinished. Special attention shall be given to assure that the surface across joints meets the smoothness requirements of Sections 502.7.1 or 502.7.2. Straightedge testing and surface corrections shall continue until the entire surface is found to be free from observable departures from the straightedge and until the slab conforms to the required grade and cross section. The use of long-handled wood floats shall be confined to a minimum; they may be used only in emergencies and in areas not accessible to finishing equipment.
3/15/2022
502-27
Portland Cement Concrete Pavement
502.4.7.7.1 Edge Slump. When slip-form paving is used, not more than 15 percent of the total free edge of each 500 feet of pavement, or fraction thereof, shall have an edge slump exceeding ¼ inch, and none of the free edge of the pavement shall have an edge slump exceeding ⅜ inch. Areas exceeding this limit shall be corrected while the concrete is in a plastic state. Areas not corrected and exceeding this limit shall require removal and replacement of the entire effected slab. 502.4.7.8 Surface Texture. The surface of the pavement shall be finished with a wire comb, wet burlap drag, artificial turf or broom finish for all newly constructed concrete pavements. It is important that the texturing equipment not tear or unduly roughen the pavement surface during the operation. Any imperfections resulting from the texturing operation shall be corrected. 502.4.7.8.1 Texturing with Wire Comb. After surface irregularities have been removed, the Arterial Road concrete pavement shall be given a uniformly roughened surface finish by use of a wire comb or other approved texturing device that produces a texture similar to that produced by a wire comb. The texturing operation shall be executed so that the transverse corrugations will be uniform in appearance. Successive passes of the comb, or other approved device, shall be overlapped the minimum necessary to obtain a continuously textured surface. The surface texture produced shall have the characteristics of a texture produced using a wire comb as specified in Section 502.3.8.3, and which has an average texture depth of approximately ⅛ inch. Texturing shall be completed while the concrete is in such condition that it will not be torn or unduly roughened, and before it has attained its initial set. The texturing device shall be cleaned or replaced as often as necessary to obtain the required surface texture. Upon completion of texturing, the pavement surface shall be uniform in appearance and free from surplus water, rough or porous spots, irregularities, depressions, and other objectionable features. Small or irregular areas, or areas not suitable for machine texturing when adjacent surrounding concrete is ready for texturing, shall be textured with a hand operated device producing a textured surface equivalent to that required for machine combing. 502.4.7.8.2 Wet Burlap Drag. New subdivision pavement shall be surface textured with a wet burlap drag unless otherwise directed by the Engineer. If a burlap drag is used to texture the pavement surface, it shall be at least 15 ounces per square yard. To obtain a textured surface, the transverse threads of the burlap shall be removed approximately 1 foot from the trailing edge. A heavy buildup of grout on the burlap threads produces the desired wide sweeping longitudinal striations on the pavement surface. The corrugations shall be uniform in appearance and approximately 1⁄16 of an inch in depth. 504.4.7.8.3 Artificial Turf. With approval of the Engineer, New Subdivision concrete pavement may be surface textured with artificial turf meeting the qualifications specified herein. If artificial turf is used to texture the surface, it shall be applied by dragging the surface of the pavement in the direction of concrete placement with an approved fullwidth drag made with artificial turf. The leading transverse edge of the artificial turf drag will be securely fastened to a lightweight pole on a traveling bridge. At least 2 feet of the artificial turf shall be in contact with the concrete surface during dragging operations. The corrugations shall be uniform in appearance and approximately 1⁄16 inch in depth.
3/15/2022
502-28
Portland Cement Concrete Pavement
502.4.7.8.4 Wet Burlap or Broom. If the contract requires concrete to be tinted and after surface irregularities have been removed, the concrete pavement shall be given a uniformly roughened surface finish by the use of a fabric drag or a broom. The damp fabric drag shall be dragged in a longitudinal direction. Brooms shall be drawn across the surface from the centerline toward each edge with the broom held perpendicular to the surface, each stroke slightly overlapping the preceding stroke. The brooming operation shall be executed so that the corrugations will be uniform in appearance and not more than 1⁄16 inch deep. A machine capable of producing a finished surface similar to that required for hand brooming may be used. Brooming or dragging shall be completed before the concrete is in a condition that it will be torn or unduly roughened and before the concrete has attained its initial set. The brooms or the fabric shall be cleaned or replaced as often as necessary to attain the required surface texture. Upon completion of brooming or dragging, the surface of the pavement shall be uniform in appearance and shall be free from surplus water, rough or porous spots, irregularities, depressions, and other objectionable features. 502.4.7.9 Edging at Forms and Joints. After the final finish, but before the concrete's initial set, the edges of the concrete along each form line, and of each side of transverse expansion joints, formed joints, emergency construction joints, and transverse construction joints shall be worked with an edging tool having a radius of approximately ⅜ inch. A welldefined and continuous radius having a smooth, dense mortar finish shall be produced. Do not use mortar buildup to round edges. The surface of the concrete shall not be unduly disturbed by tilting of the tool during use. Tool marks on the slab shall be eliminated by brooming or dragging the surface. In doing this, the rounding of the corner of the slab shall not be disturbed. Do not tool edges if the joint is to be widened to provide a reservoir for joint sealant. All concrete on top of the joint filler shall be completely removed. All joints shall be tested with a straightedge before the concrete has set, and corrections made if one side of the joint is higher than the other. 502.4.7.10 Station Numbers. The Contractor shall indent station numbers into all arterial roadway pavement immediately following the final finishing operations and before the concrete‘s final set. The numbers shall be placed at alternating full stations as ascertained by measurements determined by the Engineer. Equations in stationing shall also be marked in the pavement. 1) On Undivided Pavement. The station numbers shall be on the left side of the pavement with respect to the ascending stationing and shall be on the pavement edge unless an integral curb is involved, in which case the numbers shall be placed on the face of the curb. 2) On Divided Pavement. Station numbers shall be placed on the median side of each pavement. The numbers shall be placed facing the centerline of the pavement, or the centerline of each pavement in the case of divided pavements. The numbers shall be placed on a troweled area of the finished surface. No direct payment will be made for marking station numbers.
3/15/2022
502-29
Portland Cement Concrete Pavement
502.5 Joints. Joints shall be of designated type and dimensions and constructed at the locations shown on the plans or as approved by the Engineer. All joints shall be constructed with their faces perpendicular to the surface of the pavement and finished or edged as shown in the plans. Joints shall not vary more than ½ inch from their designated position and shall be true to line with no more than ¼ inch variation in 10 feet. The surface across the joints shall be tested with a 10-foot straightedge as the joints are finished and any irregularities in excess of ¼ inch shall be corrected before the concrete has hardened. When curbs or medians are constructed integral with the pavement, construct the transverse joints continuous through the curb or median. Where joints are preformed, the form or joint shall be set and securely fastened to insure that the joint is in the required position when the concrete is finished. The final position of epoxy-coated smooth steel dowels and deformed steel tie bars shall be parallel to the subgrade and perpendicular to the line of the joint. Dowel supporting assemblies shall conform to one of the types shown on the plans. Do not place bent dowel baskets or tie bars. Do not leave non-parallel tie bars or dowel baskets in place. The concrete shall be placed to avoid displacement or disarrangement of the joint installations. Joints shall be so prepared, finished, or cut to provide a groove of uniform width and depth as shown on the plans. 502.5.1 Subdivision Paving. Transverse grooving for subdivision streets shall be allowed provided that the groove is a minimum of 1¼ inches deep and that all concrete deposited above the level of the finished pavement surface, due to the grooving procedure, is refinished. The Engineer shall have the option of requiring saw cut joints in subdivision paving wherever deemed necessary. 502.5.2 Expansion Joints. Expansion joints shall extend for the full cross section and full depth of the concrete pavement. The filler shall be pre-molded, furnished in lengths equal to the pavement width or equal to the width of one lane, and staked or fastened into position perpendicular to the proposed finished surface. Damaged or repaired joint filler shall not be used unless authorized by the Engineer. Filler placed prior to the placement of the concrete and acting as a guide for edging the joint and protection for the filler during the placing and finishing of the concrete, shall be installed with a removable cap or edging bar to serve leaving a void no more than: 1) 1 inch ± ⅛ inch for Type AA; 2) 2 inches ± ⅛ inch for A2 Joints; 3) ½ inch ± ⅛ inch for ½ inch wide joints; and 4) 1 inch ± ⅛ inch for 1-inch-wide joints. Joints constructed after the placement of concrete shall be sawed full depth. The filler shall rest snugly on the base from form to form and shall be securely staked in a perpendicular position to the base. The joints shall be finished and tooled while the concrete is still plastic. The joints shall be sealed as required in Section 502.9. Upon removal of the forms, any struts or fins of concrete extending across the joint shall be removed to the full width of the joint and the full thickness of the concrete pavement.
3/15/2022
502-30
Portland Cement Concrete Pavement
502.5.3 Construction Joints. Construction joints shall be made at the close of each day's work or when the work is stopped or interrupted for more than 30 minutes. Transverse construction joints shall be located 15 feet from the last contraction joint. No transverse construction joint shall be constructed within 10 feet of an expansion or contraction joint. For transverse contraction joint spacing of less than 15 feet, the transverse construction joint shall be located within the normal sequence of contraction joint spacing as shown on the plans. Construction joints shall be constructed perpendicular to the top surface and the centerline of the concrete pavement. Construction headers at the end of the day will always be placed at a contraction joint containing a load transfer device. The joint shall be so formed as to consist of a two piece header of 2 inch nominal wood or a standard paving form which will produce a smooth face on a vertical joint and shall be firmly held in place with approved staking pins placed on an interval which will rigidly hold the form in place. The required header shall conform to the cross section of the pavement. Before paving operations are resumed, the header shall be removed carefully, and all surplus concrete and other refuse shall be removed from the aggregate base. Construction joints at all other locations will be so formed as to produce a vertical smooth joint and shall be composed of a nominal 2 inch thick wooden or standard paving form predrilled for the specified diameter of deformed reinforcing steel dowels (meeting the requirements of Section 505 and Section 1057.3) at the length and embedded at one-half the bar length at a center-to-center 12 inch spacing into the proposed slab. An alternate construction joint may be obtained by placing epoxy-coated, deformed reinforcing steel bent bars in position against a vertical form of required dimension. Both methods will incorporate a keyway in combination with the dowels. 502.5.4 Longitudinal Construction Joints (Tie Bars). Epoxy-coated, deformed steel tie bars (meeting the requirements of Section 505 and Section 1057.4) of specified length, size, spacing, and materials shall be placed perpendicular to the longitudinal joint and parallel to the approved grade to tie lanes of pavement together that are to be constructed separately. The tie bars shall be installed and approved before the concrete is placed in the adjacent lane. The Contractor may: 1) Form the tie bar in place. Bending of a Grade 60 bar more than one time will not be allowed, or 2) Install the tie bars in place in predrilled holes, blown clean and dry, immediately followed by the application of an approved bonding agent in accordance with Section 1039.30. 502.5.5 Transverse Contraction Joints. Transverse contraction joints shall consist of planes of weakness created by cutting grooves in the surface of the pavement and shall include load transfer devices. Transverse contraction joints of the dimensions, spacing, and type as shown in the contract documents, shall be sawed with an approved concrete saw to produce a slot at least ⅛ inch wide. An approved marking system shall be used to assure that joints are over the mid-lengths of the load transfer devices. 502.5.5.1 Load Transfer Devices. Epoxy-coated dowel bars shall meet the requirements of Section 1057.1.1. The dowels shall be placed at the mid-depth of the slab, 18 inches in length and spaced 12 inches apart, starting 6 inches from the edge of pavement or longitudinal joint. Dowel bar diameter is 1 inch for 7 to 8½ inch thick pavement, 1¼ inches for 9 to 10½ inch thick pavement and 1½ inches for 11 inch or thicker pavement. Dowel bar assemblies, when used, shall be held in position parallel to the surface and centerline of the slab by 0-gauge metal staking pins. Staking pins shall be at least 18 inches in length. No 3/15/2022
502-31
Portland Cement Concrete Pavement
less than 6 pins per assembly unit shall be installed with suitable hooks that penetrate the base at least 10 inches and meet the approval of the Engineer. The free end of the dowel bar, for a length of 11 inches, shall be uniformly coated with approved graphite grease or pre-coated in accordance with Section 1057. Excessive coating shall be avoided. The dowel bar assembly shall be completely assembled before being placed in position. The assembly shall be installed so that the dowel bars are parallel to the proposed surface and to each other and at right angles to the pavement centerline. Any deviation from the correct alignment greater than ⅛ inch in 12 inches shall be corrected before any concrete is placed. 502.5.6 Keyways. Keyways (only female keys permitted) shall be formed in the plastic concrete by means of side forms or the use of keyway liners that are inserted during the slipform operations. The keyway shall be formed to a tolerance of ¼ inch in any dimension and shall be of sufficient stiffness to support the upper keyway flange without distortion or slumping of the top of the flange. The dimensions of the keyway forms shall not vary more than plus or minus ¼ inch from the mid-depth of the pavement. Liners that remain in place permanently and become part of the keyed joint shall be made of galvanized, copper clad, or of similar rust-resistant material compatible with plastic and hardened concrete and shall not interfere with joint reservoir sawing and sealing. 502.5.7 Sawing of Joints. Unless otherwise provided, all transverse contraction and all longitudinal joints in the pavement and curbs shall be sawed in a single cutting operation with the joint groove cut to the dimensions shown on the plans except as herein specified. Joints in Portland cement concrete shall have a minimum width of ⅛ inch. When a standard (water cooled diamond bladed) concrete saw is used the pavement will be at a minimum 950 PSI compressive strength. 1) For pavement <7 inches thick the minimum sawed joint depth will be a minimum depth of (T/4) the specified pavement thickness. 2) For pavement >7 inches thick the minimum sawed joint depth will be a minimum depth of (T/3) the specified pavement thickness. When using early entry (drycut, lightweight) saws the concrete will be at a minimum 150psi compressive strength. 1) Saw joints 2¼ to 2½ inches deep. When the groove for poured type transverse joints is cut prior to removal of the forms, the groove shall be cut as close as is practical to the concrete pavement edge, and the resulting crescent shaped plug in the groove, immediately adjacent to the form, will be acceptable. For intersections and irregular pavement, joints shall be sawed at locations as directed by the Engineer. Sawing of the joints shall commence as soon as the concrete has hardened sufficiently to permit sawing without excessive raveling. If an early-entry concrete saw is used, all joint grooves shall be established within 12 hours of finishing. Sawing shall continue regardless of the weather conditions and the effort coordinated to meet all local and county noise ordinances. All slurry and debris produced in the sawing of joints shall be removed by vacuuming and washing. All joints shall be sawed before uncontrolled shrinkage cracking takes place. The sawing of any joint shall be omitted if a crack occurs at or near the joint location prior to the time of sawing. Sawing shall be discontinued when a crack develops ahead of the saw. If a crack develops in the concrete pavement, remove and replace a full slab properly attached
3/15/2022
502-32
Portland Cement Concrete Pavement
to adjacent slabs. In general, all transverse joints should be sawed first, followed by longitudinal joints in sequence unless otherwise directed. The County reserves the right to have the Contractor install pre-molded type joints on multiple width construction when the use of sawed joints fails to prevent random cracking. Construction joints may be formed by full depth sawing. Any non-reinforced concrete pavement with random cracking not controlled by dowels or tie bars shall be removed and replaced using dowels or tie bars as appropriate to the nearest controlled. 502.5.8 Adding New Pavement. New pavement constructed parallel to existing pavement shall be tied to the existing pavement with the existing longitudinal tie bars. The epoxy coated tie bars shall be straightened and incorporated into the new abutting slabs. Where tie bars do not exist, the Contractor will gang drill bar holes to the diameter and depth in accordance with the manufacturer's recommendation for a tie bar of the size and length in accordance with the pavement thickness specified in Section 505. New epoxy-coated bars of the size and length for the pavement thickness specified in Section 505 will be anchored into place at least 1 hour in advance of paving operations. The epoxy bonding agent will meet specifications of Section 1039.30. Existing pavement joints shall be duplicated in the abutting slabs. No direct payment will be made for the work. The Contractor shall submit in advance, for approval, the information on the epoxy bonding material proposed for use. 502.5.9 Joint Filler at Railroad Crossings. Bituminous filler for use between railroad crossing approach slabs and the crossing shall be an approved bituminous mixture in accordance with Section 405. The mixture shall be tamped into a firm and compacted state. 502.5.10 Box-Outs for Utility Access. Fixtures falling entirely within a slab shall be adjusted to the design elevation prior to placing concrete. Care must be taken during the paving process to not disturb the utility frame, valves box or other appurtenances. Fixtures falling outside the slab but interfere with the track line of the paver shall be adequately braced and supported to support the paving equipment. Box out areas that use any paving method except slipform shall be set to the appropriate grade. Slipforming over box-outs will require the box-out to initially be set below grade for paving clearance purposes. The Contractor may place plywood sheets over the block-out to minimize concrete loss. After the slipform form paver has paved over the blockout and before finishing of the pavement begins, the block-out shall be re-set to the design elevation and edged in accordance with the standard details. Required transverse or longitudinal reinforcement may be set in-place at the time of paving or be drilled and anchored in accordance with Section 502.5. 502.6 Curing. Concrete shall be cured once the surface resists marring and within 30 minutes following texturing. The entire surface of the newly placed concrete shall be covered and cured for a period not less than 7 days when using Type I / II or IL cement, three days when using Type III cement with accelerator, or until at least 70 percent of the specified 28 day compressive strength is reached, whichever is least, in accordance with one of the following methods. Failure to provide sufficient cover material of whatever kind the Contractor may elect to use, or lack of water to adequately take care of both curing and other requirements, shall be cause for the Engineer to immediately suspend concreting operations.
3/15/2022
502-33
Portland Cement Concrete Pavement
502.6.1 Joint Sawcut Treatment. When a two sawcut method is used to construct the contraction joint, the curing compound shall be applied to the sawcut immediately after the initial cut has been made. The sealant reservoir shall not be sawed until after the curing period has been completed. When the one cut method is used to construct the contraction joint, the joint shall be cured with wet rope, wet rags, or wet blankets. The rags, ropes, or blankets shall be kept moist for the duration of the curing period. 502.6.2 Impervious Membrane Method. White pigmented membrane material shall meet the requirements of Section 1055. Within thirty minutes after the concrete has been finished and the sheen (free water) has disappeared from the pavement surface, the entire surface and edges of the concrete shall be sealed by pressurized mechanical spraying. The machine shall have the capability of uniform application from uniform pressure. When form paving, the edges shall be sealed with curing compound immediately after the forms are removed. The Contractor shall provide satisfactory equipment to insure uniform coverage of curing material, without loss, on the pavement at the rate of not less than 1 gallon to not more than 150 square feet. Do not apply when raining. If rain falls on the newly coated pavement before the film has dried sufficiently to resist damage, or if the film is damaged in any other way, the Contractor will be required to apply additional curing material to the affected portions. Hand spraying will be permitted by the Engineer for odd widths or shapes or concrete exposed by form removal. Hand spraying will be applied at a rate of not less than 1 gallon to not more than 75 square feet. No additional compensation will be allowed the Contractor for materials or labor to perform this work. The Contractor shall have available, at the site of work and prior to paving, a supply of the approved curing material to cover the day's production. All areas cut by finishing tools subsequent to the application of the curing material shall immediately be given new applications at the hand spray rate specified above. If hair-line cracking develops before the membrane can be applied, the concrete shall be initially cured with wet burlap, as specified in Section 502.6.4, before the membrane is placed. Red-pigmented membrane shall not be used on arterial roadways unless approved by the Engineer. 502.6.2.1 Concrete to be Overlaid with Hot Mix Asphalt. Membrane curing shall not be used on Portland cement concrete to be overlaid with hot mix asphalt. Emulsified asphalt may be used to cure the concrete pavement if the surface course is to be a bituminous type. The Engineer may approve a self-dissipating curing compound, in accordance with Section 1055.4.2.3.3, to permit opening to traffic. 502.6.2.2 High Performance Curing Compound. High performance curing compounds, in accordance with Section 1055.4.2.3.4, are required for concrete pavement opened to traffic in three days or less and that will not be overlaid with hot mix asphalt.
3/15/2022
502-34
Portland Cement Concrete Pavement
502.6.3 White Waterproofed Paper, Polyethylene Sheeting and White PolyethyleneBurlap Sheeting. White waterproofed paper, white polyethylene sheeting, and white polyethylene-burlap sheeting shall meet the requirements of Section 1055 and used when the daily high temperature is greater than 85°F. Black polyethylene sheeting shall be used when daily high temperature is less than 50°F. Any color or transparent polyethylene sheeting may be used when the daily high temperature is greater than or equal to 50°F or less than or equal to 85°F. As soon as the concrete has set sufficiently to prevent marring, the top surface of the pavement shall be covered with units of waterproofed paper, white polyethylene sheeting, or white polyethylene-burlap sheeting, which shall be lapped not less than 18 inches. The sheeting shall have dimensions that will extend at least twice the thickness of the pavement beyond the edges of the pavement. If white polyethylene-burlap sheeting is used, the burlap shall be thoroughly dampened prior to placing and shall be placed next to the concrete. All coverings shall be so placed and weighted that they remain in contact with the pavement surface and edges, providing an airtight cover, for not less than 7 days, unless specified otherwise, after the concrete has been placed. Any torn places or holes shall be repaired immediately in a manner approved by the Engineer. If hair-line cracking develops before the covering can be applied, the concrete shall be initially cured with wet burlap as specified in Section 502.6.4 before the covering is placed. 502.6.4 Mats of Jute or Cotton. Mats of jute or cotton shall meet the requirements of Section 1055. New mats of jute or cotton, and any such mats that have been used for purposes other than curing of concrete, shall be thoroughly washed before being used. The use of mats contaminated with earth or other deleterious substances will not be permitted. The top surface of the pavement shall be completely covered with mats as soon as the concrete has set sufficiently to prevent marring of the surface. Prior to being placed, the mats shall be damp throughout and shall be placed with the wettest side down. The mats shall be handled in such manner that contact with earth or other deleterious substances is avoided, and they shall be so placed that they remain in contact with the pavement surface and edges. The covering shall be kept wet and maintained in position for not less than 7 days after the concrete has been placed. If hair-line cracking develops before the mats can be applied, the concrete shall be initially cured with wet burlap as specified in Section 502.6.4, before the mat covering is placed. 502.6.5 Burlap. Dry burlap shall be in accordance with Section 1055.3.2.2. Dry burlap shall not be placed on the concrete surface. The top surface of the concrete shall be temporarily covered with thoroughly damp burlap after the concrete has set sufficiently to prevent marring of the surface. Burlap shall be handled in such a manner that contact with earth or other deleterious substances is avoided. All burlap, except burlap previously used for curing concrete, shall be thoroughly washed. The burlap shall be kept thoroughly wet until removed for application of the final curing material. Water shall not be allowed to pond on aggregate base. Neither the top nor the edge of the concrete shall be left unprotected for more than thirty (30) minutes. When the burlap is removed, curing shall be continued by one of the approved methods.
3/15/2022
502-35
Portland Cement Concrete Pavement
502.6.6 Thermal Curing Blankets. In cool temperature conditions (not hot weather or cold weather conditions), apply insulating blankets, in accordance with Section 1055.4.1.4, ClosedCell Curing Blankets (Multi-Use), to enhance heat containment for areas requiring early opening (less than 3 day cure) to traffic. Blankets shall extend at least 12 inches beyond the limit of the slab(s) to be cured and are to be weighted in a manner that will result in an air-tight enclosure. If sawing is required, remove and replace curing blankets in no more than 30 minutes. If the blankets do not conform to the moisture retention requirements specified, use polyethylene or curing compounds, specified above, prior to thermal blanket placement. Use shall conform to the following requirements: Minimum Air Temperature (T) During Insulating Period
8
16
24
36
48 - 72
T ≤ 50°F
Insulate
Insulate
Insulate
Insulate
Compound Only
50°F < T ≤ 65°F
Insulate
Insulate
Insulate
Compound Only
Compound Only
65°F < T ≤ 80°F
Insulate
Compound Only
Compound Only
Compound Only
Compound Only
T > 80°F
Compound Only
Compound Only
Compound Only
Compound Only
Compound Only
Required Opening Time (Hours)
502.7 Removing Forms. Forms shall be removed no sooner than 12 hours after placing fresh concrete or until the in-place concrete has attained a compressive strength of 500 psi as determined in accordance with Section 507. 502.7.1 Placement of Maturity Loggers. When concrete strength for form removal is monitored using maturity loggers, the Contractor shall provide loggers that record the temperature of the pavement at 15 minute or shorter intervals. A logger shall be placed within 6 inches from the pavement edge and approximately 2 inches below the surface in the last 50 feet of placement. These loggers will be monitored by the Engineer to determine when the maturity equivalent of 500 psi compressive strength is achieved. Forms may be removed after the pavement reaches the maturity equivalent of 500 psi compressive strength. 502.7.2 Handling, Curing and Backfilling. Form removal shall be handled carefully so as to avoid chipping, spalling, or tearing damage to the concrete pavement. Curing compound shall be applied to the concrete immediately after the forms have been removed. Removed forms will not be placed on pavement during the 72-hour curing period. Honeycombed areas not rejected shall be immediately repaired. If the forms are removed prior to 72 hours after placing concrete, the sides of the concrete shall be cured by one of the methods specified above. Any trench excavated for the forms shall be entirely backfilled, no sooner than 72 hours, so that water will not stand or flow next to the concrete pavement. No payment will be made for the concrete until backfilling is completed to the satisfaction of the Engineer.
3/15/2022
502-36
Portland Cement Concrete Pavement
502.8 Surface Tolerance. As soon as practicable, the pavement surface shall be thoroughly straight edged by the Engineer. On arterial roadways and collector streets, all variations exceeding ⅜ inch/10 feet will be plainly marked. At transverse joints, all surface variations exceeding ¼ inch/10 feet will be plainly marked. 502.8.1 Bump Grinding. A bump is defined as a deviation in the profile greater than that specified in Section 502.8. If corrective work is required, the contractor shall submit a written corrective work proposal to the Engineer, which shall include the description of the equipment, methods and procedures that will be used. The Contractor will not commence corrective work until the equipment, methods and procedures have been approved in writing by the Engineer. Corrective bump grinding shall occur no sooner than 14 days of final placement, after Engineer-approved pavement restoration, and before joint sealing. 502.8.1.1 Equipment. Grinding shall be performed using diamond blades mounted on a self-propelled machine designed for grinding and texturing pavement. The equipment shall weigh a minimum 35,000 pounds, including the grinding head with diamond blades mounted in series, and be of a size that will grind a strip at least 3 feet wide in a single pass. The effective wheel base of the machine shall be no less than 12 feet. The equipment shall have a positive means of vacuuming the grinding residue from the pavement surface, leaving the surface in a clean, near-dry condition. Grinding equipment that causes raveling, aggregate fractures or disturbance to the transverse or longitudinal joints shall not be permitted. Diamond blades shall be of the proper type based on the coarse aggregate to be ground. The equipment shall be maintained to ensure it is in proper working order, with attention paid to the "roundness" of the match and depth control wheels. Any wheel found to be out of round shall be replaced immediately. 502.8.1.1.1 Optional Carbide Bump Grinding. Use grinders of the walk-behind type that have cutting heads of carbide tipped shackles, stars, or blades and have a locking depth control to produce a uniform pavement surface texture. Provide a pavement surface texture consisting of parallel grooves between 3⁄32 inch and ¼ inch wide width a "land area" between grooves 1⁄16 inch and 3⁄16 inch. Operate the grinder by making multiple passes if necessary, with a maximum depth of any single pass of ⅛ inch. Grind longitudinally or transversely across the pavement surface. 502.8.1.2 PCC pavement surface correction (bump grinding) shall be accomplished by grinding the pavement using a grinder (diamond or carbide), by PCC resurfacing, or by replacement. Grinding and texturing equipment shall meet the requirements of Section 502.8.1.1 except the cutting head shall have a minimum width of 8 inches and the weight restriction is waived. Surface correction shall be performed parallel to lane lines or edge lines as directed by the Engineer and each pass shall be parallel to the previous passes. The ground surface shall be of uniform texture.
3/15/2022
502-37
Portland Cement Concrete Pavement
502.8.1.3 Adjacent passes shall not overlap more than 1 inch and they shall not have a vertical difference of more than ⅛ inch as measured from bottom of groove to bottom of groove. Smoothness correction shall begin and end at lines normal to the pavement lane lines or edge lines within any one corrected area. The grinding shall proceed from the center line or lane line toward the pavement edge to maintain the specified pavement cross slope within ±0.5 percent. The remaining requirements of this specification shall be followed. 502.8.1.4 Use grinders of the walk-behind type in accordance with Section 502.8.1.1 for correcting areas 15 feet in length or less. Grind longitudinally or transversely across the pavement surface. If the Engineer directs removal, remove an area at least 6 feet long and extending across the full lane width. Also remove adjacent pavement less than 6 feet from a transverse joint. The use of a bush hammer or other impact device will not be permitted. Such grinding shall be tapered in all directions to provide smooth transitions to areas not requiring grinding. In areas where conditions necessitate that surface grinding be performed to a depth that leaves the final pavement more than 0.6 inch deficient from plan thickness, the effected slab(s) will be removed and replaced in their entirety. 502.8.2 Subdivision Pavements. On subdivision streets (up to 26 feet in width), testing in accordance with Section 502.8 will be performed, except that surface variations exceeding ½ inch in 10 feet will be plainly marked and ground. In areas where conditions necessitate that surface grinding be performed to a depth that leaves the final pavement more than 0.6 inch deficient from plan thickness, the effected slab(s) will be removed and replaced in their entirety. On subdivision streets exceeding 26 feet in width, the surface variation provisions of Section 502.8 shall apply. 502.9 Sealing Joints. All sawed transverse and longitudinal joints and sawed or formed expansion joints shall be sealed with joint sealing material before the pavement is opened to traffic, including construction traffic, and as soon after completion of a minimum curing period of 24 hours providing vehicles are not placed on the pavement when performing the sealing operation. In locations where silicone sealants are required, the concrete shall cure for a minimum of 7 days before sealing. Immediately prior to sealing, the joints shall be thoroughly cleaned and dried. Joint faces shall not be exposed to curing compound before sealing otherwise additional cleaning will be required 1) This item shall consist of the thorough cleaning with suitable tools designed for neatly cleaning and sealing existing cracks and joints and new sawed joints in concrete pavements, curbs and driveways. This work shall include the proper cleaning of joints and cracks per Section 406. 2) This work shall also include removal of all waste material produced in the joint sealing process. A polymer based hot poured crumb rubber elastic-type liquid sealer in accordance with these specifications shall be furnished and installed by the Contractor. Silicone and polyurethane sealants shall be applied in the areas specified.
3/15/2022
502-38
Portland Cement Concrete Pavement
3) For concrete replacement operations, streets scheduled for joint and crack sealing shall consist of all those being repaired under the slab removal and replacement items of the contract, regardless of the amount of slab replacement work performed. All pavement joints, both new and existing, are to be cleaned, dried and sealed within the limits indicated in the contract documents. 4) Concrete pavements are included when crack and joint sealing are measured and
paid by centerline roadway surface to the nearest 0.01 mile. Specifications for concrete pavement joint and crack sealing per section 406.
5) Seasonal Sealant Limitations. When joint and crack cleaning and sealing operations are being performed in conjunction with concrete repairs, those operations will not be permitted on any site until after all work has been completed on that site. Unless otherwise approved by the Engineer, the Contractor shall be responsible for arranging his manpower and equipment efforts to finish all work including crack sealing on each site before continuing to the next site. In addition, it is required that any streets where concrete repairs are complete, be crack sealed on or before November 15th unless specific authorization is granted by the Engineer to work beyond that date. 502.9.1 Materials. 502.9.1.1 Materials used for joint construction, sealing or stabilization shall be consistent with the requirements Section 406 and Section 1057. 502.10 Protection of Pavement. The Contractor shall protect the pavement and its appurtenances against both public traffic and traffic caused by the Contractor's own employees and agents. This shall include flaggers to direct traffic and the erection and maintenance of standard warning signs, lights, pavement bridges or crossovers. Any damaged pavement occurring prior to final acceptance shall be repaired or replaced in a manner acceptable to the Engineer by the Contractor at the Contractor's expense. 502.10.1 Protection of Pavement Against Rain. In order that the concrete may be properly protected against the effects of rain before the concrete is sufficiently hardened, the Contractor will be required to have available, at all times, materials for the protection of the edges and surface of the unhardened concrete. When rain appears imminent, all paving operations shall stop, and all available personnel shall begin covering the surface of the unhardened concrete with the protective covering. Protective material may consist of sheets of burlap, paper, or rolled polyethylene sheeting at least 4 mils thick of sufficient length and width to cover the plastic concrete slab and any edges. The sheeting shall be mounted on either the paver or a separate movable bridge from which it can be unrolled without dragging over the plastic concrete surface. Planks or other material with suitable stakes that can be used as temporary forms shall also be on hand. It will be the Contractor's responsibility to protect the pavement from damage due to rain. Failure to properly protect unhardened concrete may constitute cause for the removal and replacement of defective pavement at the Contractor's expense.
3/15/2022
502-39
Portland Cement Concrete Pavement
502.10.2 Utilities Protection. The Contractor will not start work until all utilities are located. 502.10.2.1 Repairs. When the Contractor disrupts or breaks known utilities of the Jurisdiction or privately owned utilities, such utilities shall be repaired at the Contractor's expense. Unnecessary delays in making repairs shall cause the Engineer to have such repairs deducted from the monies due the Contractor. 502.10.2.2 Drains, Pipe, Tiles. Existing subsurface drains, pipe, and tiles, which are disrupted or broken by construction activities, shall be connected to an adequate outlet. Should no outlet be readily available, the Engineer shall determine a suitable solution. Additional work to relocate drains, pipes and tiles will be considered extra work, and will be paid for as provided in Section 104.3. 502.10.2.3 Gas or Water Stop Boxes and Services. Relocation and adjustments to grade of stop boxes and services shall be by the responsible utility. The Contractor shall not disturb the adjusted stop boxes and services. Adjustment of stems and castings and/or repair of those broken or damaged by the Contractor shall be at the Contractor's expense. 502.11 Opening to Traffic. Traffic is not to be allowed on new concrete pavement earlier than 14 days after concrete placement, unless field cast and cured cylinder concrete compression tests, cores or maturity testing indicate that one of the following conditions is obtained: Pavement Thickness (T) (inches)
a
Minimum Compressive Strength for Opening to Traffic, psi Light Traffic a
All Traffic Types
T≤8
3,000
3,500
8<T≤9
2,400
2,700
9 < T ≤ 10
2,200
2,300
T > 10
2,000
2,000
Light Traffic - The passenger car design vehicle as defined by AASHTO. Also includes minivans, pick-up trucks, sport utility vehicles (SUVs), and standard size vans.
502.11.1 Compressive and maturity strengths will be determined by the Engineer with tests made in accordance with Department methods. 502.11.2 Pavement shall be cleaned by the Contractor to remove all aggregate, dirt, concrete, oil or sealant spills, and other foreign material to the satisfaction of the Engineer. Pavement joints shall be sealed prior to opening to traffic.
3/15/2022
502-40
Portland Cement Concrete Pavement
502.12 Material Acceptance. Pavement shall be constructed strictly in accordance with the thickness, slump, entrained air and compressive strength shown in Section 501. Concrete that is not within the specified slump and air entrainment limits specified shall be rejected prior to use. The thickness and compressive strength of the pavement will be measured and determined, respectively. Where any pavement is found deficient in thickness and /or compressive strength, it may be compensated for at an adjusted unit price per square yard or shall be removed and replaced with satisfactory pavement in accordance with Section 502.15. 502.12.1 Field Determined Thickness. Metal plates will be placed on the subgrade at points selected by the Engineer in areas where the planer has cut or leveled the subgrade or at any points where conditions are conducive to deficient pavement thickness. When the surface of the pavement has been finished to final grade, the Engineer will, for informational purposes, check the thickness of the completed pavement by measuring with a calibrated rod the distance from the surface of the pavement to the metal plates. The Engineer reserves the option to place and stick plates if he deems necessary. The placing of plates does not obligate the Engineer to stick any or all plates. The surface of the pavement shall be satisfactorily restored by the Contractor after thickness measurements have been made. The Contractor shall, if necessary, furnish a bridge to facilitate the taking of the measurements. The Engineer reserves the right to core drill the finished pavement to determine the thickness of the pavement. Cores may be drilled at the same locations as rod measurements or at any other locations. The Contractor may require check cores to verify thicknesses determined by the Engineer, and all costs of check core drilling shall be borne by the Contractor. If the check cores requested by the Contractor indicate that the Engineer's measurement would have erroneously resulted in deductions for, or removal of, thin pavement, the cost of drilling the check cores will not be charged to the Contractor. 502.12.2 Core Determined Thickness. Make the required correction for pavement smoothness before making the pavement thickness determinations. For the purpose of determining the constructed thickness of the pavement, four (4) cores per 1,000 feet of lane poured, or fraction thereof, will be taken at random intervals for each pavement pour. When sections require taking cores with a pavement length less than 250 feet, include that area with the next day’s full section. Sections with areas greater than 250 feet in length will stand as individual sections. In addition, cores will be taken at all locations where thickness measurements taken during construction indicate a thickness deficiency. The thickness deficiency will be sufficient to justify a deduction from the escrow or the contract unit bid price. Additional cores for deficiency determination may be made at any other location as determined by the Engineer. The Engineer will determine the thickness of the cores by the average of 9 measurements in accordance with AASHTO T 148. When the measurement of any core is deficient in excess of 0.2 inch from the plan thickness, additional cores will be taken at adjacent slab(s) parallel to centerline ahead and back of the affected location until the extent of the deficiency has been determined. Core(s) shall be taken no closer than 2 feet from previously drilled core holes, pavement edges, joints, or utility appurtenances. Cores will not be taken in gore areas, intersection curb returns, entrances, shoulders, median, widening less than 5 feet in uniform width, and irregular areas less than 500 square yards. Cores will not be taken for projects with less than 2,500 square yards of concrete pavement.
3/15/2022
502-41
Portland Cement Concrete Pavement
502.12.3 Coring. Cores shall be taken and tested by the Engineer in accordance with AASHTO T 24. Cores shall not be taken until a light traffic minimum compressive strength as specified in Section 502.11 has been attained or no sooner than 14 days after placement. Cores shall be neatly cut with a core drill. The Engineer shall furnish all tools, labor and material for cutting samples and filling the cored hole. The Engineer shall fill the core holes with an approved commercial fast setting pre-packaged concrete at the time of drilling or within one day after sampling for pavements not yet opened to traffic. 502.12.3.1 Sampling Cores. Each core is assumed to be representative of the pavement thickness for a distance extending one-half the distance to the next core, measured along centerline, or in the case of a beginning or ending core, the distance will extend to the end of the pavement section. Cores shall be units capable of being used to test the in-place thickness and compressive strength of the pavement. A sample shall be taken from the finished concrete consisting as follows: Plan Pavement Thickness, T (inches)
Minimum Nominal Core Diameter (inches)
T < 12
4
T ≥ 12
6
502.12.3.2 Testing Cores. The core thickness shall be determined by the average of 9 measurements in accordance with AASHTO T 148. After the thickness is determined, the cores shall be sawed to an L/D ratio of 2.0 and tested in accordance with AASHTO T 24. Test the specimens after 5 day waiting period (in accordance with AASHTO T 24 and within 7 days after coring, unless specified otherwise. The Engineer shall determine the compressive strength by approved methods. Cores shall be tested for compressive strength 28 days after placement. Cores may be tested for opening to traffic compressive strength after placement in accordance with the Engineer’s approval. 502.13 Repairing Defects. 502.13.1 Removal and Replacement of Full Slabs. Where it is necessary to remove full slabs, unless there are keys or dowels present, all edges of the slab shall be cut full depth with a concrete saw. All saw cuts shall be perpendicular to the slab surface. If keys, dowels, or tie bars are present along any edges, these edges shall be sawed full depth 24 inches from the edge if only keys are present, or just beyond the end of the dowels or tie bars if they are present. These joints shall then be carefully sawed on the joint line to within 1 inch of the depth of the dowel or key. 502.13.1.1 The main slab shall be further divided by sawing full depth, at appropriate locations, and each piece lifted out and removed. Suitable equipment shall be used to provide a truly vertical lift and approved safe lifting devices used for attachment to the slabs. The narrow strips along keyed or doweled edges shall be carefully broken up and removed using light, hand-held jackhammers, 15 to 30 lbs., or other approved similar equipment.
3/15/2022
502-42
Portland Cement Concrete Pavement
502.13.1.2 Care shall be taken to prevent damage to the dowels, tie bars, or keys or to concrete to remain in place. The joint face below keys or dowels shall be suitably trimmed so that there is not abrupt offset in any direction greater than ½ inch and no gradual offset greater than 1 inch when tested in a horizontal direction with a 10-foot straightedge. 502.13.1.3 If an underbreak between 1½ and 4 inches deep occurs at any point along any edge, the area shall be repaired as directed by the Engineer before replacing the removed slab. Procedures directed will be similar to those specified for surface spalls, modified as necessary. 502.13.1.4 If underbreak over 4 inches deep occurs, the entire slab containing the underbreak shall be removed and replaced. Where there are no dowels, tie bars, or keys on an edge, or where they have been damaged, dowels of the size and spacing as specified for other joints in similar pavement shall be installed by epoxy grouting them into holes drilled into the existing concrete using procedures as specified. Original damaged dowels or tie bars shall be cut off flush with the joint face. Protruding portions of dowels shall be painted and lightly oiled. All 4 edges of the new slab shall thus contain dowels or original keys or original tie bars. 502.13.1.5 Placement of concrete shall be as specified for original construction. Prior to placement of new concrete, the underlying material (unless it is stabilized) shall be recompacted and shaped as specified in the appropriate Section of these specifications. The surfaces of all four joint faces shall be cleaned of all loose material and contaminants and coated with a double application of membrane forming curing compound as bond breaker. Care shall be taken to prevent any curing compound from contacting dowels or tie bars. The resulting joints around the new slab shall be prepared and sealed as specified for original construction. 502.13.2 Repairing Spalls Along Joints. Where directed, spalls along joints of new slabs, and along parallel cracks used as replacement joints, shall be repaired by first making a vertical saw cut at least 1 inch outside the spalled area and to a depth of at least 2 inches. Saw cuts shall be straight lines forming rectangular areas. The concrete between the saw cut and the joint, or crack, shall be chipped out, using chipping hammers no greater than 15 pounds, to remove all unsound concrete and at least ½ inch of visually sound concrete. The cavity thus formed shall be thoroughly cleaned with high-pressure water jets supplemented with compressed air to remove all loose material. Immediately before filling the cavity, a prime coat of epoxy resin, ASTM C 881 Type V, Grade 2 (Class A-C used shall be dependent on the estimated usage temperature), shall be applied to the dry cleaned surface of all sides and bottom of the cavity, except any joint face. The prime coat shall be applied in a thin coating and scrubbed into the surface with a stiff-bristle brush. Pooling of epoxy resin shall be avoided. The cavity shall be filled with low slump Portland cement concrete or mortar or with epoxy resin concrete or mortar. Concrete shall be used for larger spalls, generally those more than 0.50 cubic foot in size and mortar shall be used for the smaller ones. Any spall less than 0.1 cubic foot shall be repaired only with epoxy resin mortar or ASTM C 881 Type V Grade 3 epoxy resin with the appropriate class (A-C) based on application ambient temperature. Portland cement concrete and mortar mixtures shall be proportioned as directed by the Engineer and shall be mixed, placed, consolidated, and cured as directed by the Engineer. For bonding skid-resistant materials to hardened concrete, Epoxy resin mortars shall be made with ASTM C 881 Type III, Grade I (the appropriate class A-C based on application ambient temperature), epoxy resin, using proportions and mixing and placing procedures as recommended by the manufacturer and approved by the Engineer. The epoxy resin materials 3/15/2022
502-43
Portland Cement Concrete Pavement
shall be placed in the cavity in layers not over 2 inches thick. The time interval between placements of additional layers shall be such that the temperature of the epoxy resin material does not exceed 140°F at any time during hardening. Mechanical vibrators and hand tampers shall be used to consolidate the concrete or mortar. Any repair material on the surrounding surfaces of the existing concrete shall be removed before it hardens. Where the spalled area abuts a joint, an insert or other bond-breaking medium shall be used to prevent bond at the joint face. A reservoir for the joint sealant shall be sawed to the dimensions required for other joints, or as required to be routed for cracks. The reservoir shall be thoroughly cleaned and sealed with the sealer specified for the joints. If any spall penetrates half the depth of the slab or more, the entire slab shall be removed and replaced as previously specified. 502.14 Method of Measurement. Pavement areas will be computed to the nearest 0.1 square yard. Final measurement of the completed pavement will not be made except for authorized changes during construction or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. 502.15 Basis of Payment. 502.15.1 Thickness. If any core thickness measurement is deficient from the design thickness, the County will have the option of either having the Contractor remove and replace the pavement at his expense or allow the Contractor to leave the pavement in place and receive the following deductions in payment. For All Pavement Constructed: Deficiency in Thickness
Deductions, Percent of Bid Price
0.0 inch to 0.2 inch
None
Over 0.2 inch to 0.3 inch
20
Over 0.3 inch to 0.4 inch
35
Over 0.4 inch to 0.5 inch
50
Over 0.5 inch to 0.6 inch
65
Over 0.6 inch
100 or remove and replace
The above deductions will be applied to a section of pavement and extending from the edge of the pavement to a longitudinal joint or between longitudinal joints in that section of pavement in which the deficient measurement was found. Deductions for deficient thickness or damaged pavement may be entered on any estimate after the information becomes available.
3/15/2022
502-44
Portland Cement Concrete Pavement
502.15.2 Compressive Strength. The compressive strength of concrete pavement will be determined through testing of cylinders and / or cores at frequencies determined by the Engineer. The core or set of cylinders will represent the compressive strength for a distance extending one-half the distance to the next core (or set of cylinders), measured along centerline, or in the case of a beginning or ending core (or set of cylinders), the distance will extend to the end of the pavement section. If any compressive strength measurement is deficient from the design compressive strength, the County will have the option of having the Contractor remove and replace the pavement at his expense or allow the Contractor to leave the pavement in place and receive the following deductions in payment. Compressive Strength @ 28 Days (psi)
Deduction of Bid Price or Escrow Amount (Percent)
Less than 4000 to 3800
10
Less than 3800 to 3680
20
Less than 3680 to 3400
40
Less than 3400
100 or remove and replace
Any pavement, for which the sum of deductions for thickness and compressive strength exceeds 80% of the bid price or escrow amount, shall be removed and replaced. 502.15.3 Pavement removal shall be from the edge to a longitudinal joint, or between longitudinal joints, and on each side of the deficient pavement until no portion of the exposed cross sections is more than 0.3 inch deficient, except that there shall not be less than 10 feet of pavement removed. If there remains less than 10 feet of acceptable pavement between the section that has been removed and a transverse contraction, expansion, or construction joint, the Contractor shall remove the pavement to the joint. 502.15.4 Edge Repair. The edge of existing concrete pavement against which new pavement abuts shall be protected from damage at all times. Areas that are damaged during construction shall be repaired at no cost to the County; repair of previously existing damage areas will be considered an incidental part of concrete pavement construction. 502.15.4.1 Spall Repair. Slabs with joint spall deficiency shall be repaired in accordance with the department's guidelines for concrete pavement repair. Spalls shall be repaired where indicated and where directed. Repair materials and procedures shall be as previously specified in Section 502.13.3. 502.15.4.2 Underbreak Repair. All underbreaks shall be repaired. First, all delaminated and loose material shall be carefully re-sawed and removed to the limits specified by the Engineer. Next, the underlying material shall be recompacted, without addition of any new material. Finally, the void shall be completely filled with paving concrete, thoroughly consolidated. Care shall be taken to produce an even joint face from top to bottom. Prior to placing concrete, the underlying material shall be thoroughly moistened. After placement, the exposed surface shall be heavily coated with curing compound.
3/15/2022
502-45
Portland Cement Concrete Pavement
502.15.4.3 Underlying Material. The underlying material adjacent to the edge of an under the existing pavement which is to remain in place shall be protected from damage or disturbance during removal operations and until placement of new concrete, and shall be shaped as shown on the drawings or as directed. Sufficient material shall be kept in place outside the joint line to prevent disturbance (or sloughing) of material under the pavement that is to remain in place. Any material under the portion of the concrete pavement to remain in place, which is disturbed or loses its compaction, shall be carefully removed and replaced with concrete as specified in Section 502.15.4.2. The underlying material outside the joint line shall be thoroughly compacted and moist when new concrete is placed. 502.15.4.4 Edge Slump. The area affected by the downward movement of the concrete along the pavement edge shall be limited to not more than 18 inches from the edge. When excessive edge slump, as defined in Section 502.4.7.7.1, cannot be corrected, the entire slab with excessive edge slump shall be removed and replaced at the expense of the Contractor when so directed by the Engineer. 502.15.5 The contract unit bid price for Portland cement concrete pavement will be considered as full compensation for all materials and other items including reinforcement, dowels, dowel supports, tie bars and supports, keyways, block-outs, watering, curing, joint filler, joint sealing, and any other items entering into the construction of the pavement, and no additional compensation will be allowed for any excess thickness or compressive strength in excess of that specified in Section 501. 502.15.6 The accepted quantities of Portland cement concrete pavement will be paid for at the contract unit bid price per square yard, with proper allowance made for any deductions for deficiency in thickness, low spots, or compressive strength. Pavement not backfilled or that becomes undermined will not be paid for until backfill is completed or undermined area(s) are restored and approved by the Engineer.
3/15/2022
502-46
Portland Cement Concrete Pavement
Section 503
Bridge Approach Slab
503.1 Description. This work shall consist of a reinforced concrete bridge approach slab constructed on a prepared subgrade in accordance with these specifications and in conformity with the lines, grades, thicknesses, and typical cross sections shown on the plans or established by the Engineer. 503.2 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Aggregate for Base
1007.5
Reinforcing Steel for Concrete Structures
1036.1
Concrete Curing Material
1055
Materials for Joints
1057.1
Polyethylene Sheeting
1058
All materials, proportioning, air-entrainment, mixing, slump, and transporting for Portland cement concrete shall be in accordance with Section 501, Portland cement concrete. Approach slabs may be constructed of Class B-1 or pavement concrete. Coarse aggregates for Class B-1 concrete used for approach slabs shall consist of crushed limestone. When mudjacking approach slabs, the Contractor will provide a mix design for approval 14 days prior to intended date of use. 503.3 Construction Requirements. Concrete bridge approach slabs shall be constructed in accordance with Sections 304, 502, 703 and 706 and shall attain a compressive strength of 4,000 psi prior to opening to traffic. Concrete bridge approach slabs shall be textured in accordance with Section 703. Curing shall be in accordance with Section 502, except that a liquid membrane-curing compound shall be in accordance with Section 1055.4.2.3.3 for dissipating curing compounds. Bridge slabs shall require a penetrating protective sealer material applied in accordance with Section 736.The reinforcement shall be supported and held securely in place by approved metal bar supports. The approach slab and the contiguous pavement to the first expansion joint, as shown on the plans, shall be placed as a continuous or monolithic unit of the same concrete mixture. 503.3.1 Voids Under Completed Approach Slabs. Prior to acceptance of the work, all mudjacking (access) holes shall be opened by the Contractor to permit investigation by the Engineer. Any voids or cavities found shall be filled by the Contractor with a sand cement slurry pumped, under pressure, to fill voids and cavities. Care shall be taken during pumping to produce a uniform pressure that will correct any settlement. At completion of the investigation or mud pumping, the holes shall be filled with sand to within 1 inch of the top and the remainder filled with joint sealing material.
2/1/2017
503-1
Bridge Approach Slab
503.4 Method of Measurement. Approach slab areas will be computed to the nearest 0.1 yard2. This area will be measured transversely from out to out and longitudinally from bridge fill face to centerline of sleeper slab. Final measurement of the completed bridge approach slab will not be made except for authorized changes during construction, or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. 503.5 Basis of Payment. The accepted quantity of bridge approach slabs will be paid for at the contract unit bid price per square yard and shall include full compensation for all material, labor, equipment, tools, and incidentals necessary to complete the bridge approach slab. 503.5.1 No direct payment will be made for the reinforcing steel for bridge approach slabs. Also, no direct payment will be made for investigating void conditions under the completed slab, for filling any voids found, nor for correcting settlement.
2/1/2017
503-2
Bridge Approach Slab
Section 504
Concrete Approach Pavement
504.1 Description. This work shall consist of placement and preparation of base material and construction of reinforced concrete approach pavement in accordance with these specifications and in conformity with the lines, grades, thicknesses, and typical cross sections shown on the plans or established by the Engineer. 504.2 Material. All material shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Aggregate for Base
1007.5
Reinforcing Steel for Concrete Structures
1036.2
Concrete Curing Material
1055
Material for Joints
1057.1
All material, proportioning, air-entraining, mixing, slump and transporting of Portland cement concrete shall be in accordance with Section 501. Approach pavement shall be constructed of pavement concrete. 504.3 Construction Requirements. Base placement shall be in accordance with applicable requirements of Section 304. Concrete approach pavement and tied shoulders shall be constructed in accordance with the applicable requirements of Sections 502, 703, and 706. Reinforcement shall be supported and held securely in place by approved metal or plastic bar supports. 504.4 Method of Measurement. Concrete approach pavement areas including tied shoulders will be computed to the nearest 0.1 yard2. Final measurement of the completed concrete approach pavement will not be made except for authorized changes during construction, or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. 504.5 Basis of Payment. The accepted quantity of concrete approach pavement will be paid for at the contract unit price and will be considered full compensation for all labor, equipment, and material to complete the described work.
1/1/2016
504-1
Concrete Approach Pavement
(This Page Intentionally Left Blank)
1/1/2016
504-2
Concrete Approach Pavement
Section 505
Reinforced Concrete Pavement
505.1 Description. This work shall consist of construction of reinforced concrete pavement constructed on a prepared aggregate base over a prepared subgrade in accordance with these specifications and in conformity with the lines, grades, thicknesses, and typical cross sections shown in the contract documents or established by the Engineer. 505.2 Material. All materials, proportioning, mixing, air entraining, and slump of Portland cement concrete shall be in accordance with Section 501, "Portland Cement Concrete". Reinforced concrete pavement shall be constructed of Portland Cement Concrete Pavement (PCCP). Coarse aggregates for PCCP Concrete used for reinforced concrete pavement shall consist of crushed limestone. All material shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Aggregate for Base
1007.5
Reinforcing Steel for Concrete Structures
1036.2
Concrete Curing Material
1055
Material for Joints
1057.1
505.2.1 Welded Steel Wire. Welded steel wire reinforcement for concrete pavement shall be in accordance with Section 1036.4.1. The welded wire reinforcement shall be supplied in either flat sheets or hinged sheets of the size and design shown below. Longitudinally hinged wire reinforcement for sheets of a required width of 8 feet or greater may be used. All steel welded wire reinforcement shall be free from dirt, paint, oil, grease, thick rust and other foreign substances. Thin powdery rust will be acceptable. 505.2.1.1 Supports spacing for all wire reinforced concrete pavements shall be 30 inches (±6 inches) apart. Plastic or wire bar supports, such as chairs and bolsters, shall conform to industry practice as described in the WRI "WWR-500, Manual of Standard Practice" or "TF 702 - Supporting WWR". Where welded wire reinforcement will be required the reinforcement shall be placed (T/3 plus 1 inch [±½ inch]) below the surface of the repair, supported by approved bar supports, and in accordance with the table below. Vertical placement tolerance is Tm (±½ inch).
1/1/2016
Pavement Depth (inches), T 8<T≤9
Welded Wire Reinforcement Depth Below Surface of the Repair (inches), Tm 3¾
9 < T ≤ 10
4¼
10 < T ≤ 11
4½
11 < T ≤ 12
4¾
T > 12
5
505-1
Reinforced Concrete Pavement
The sheet welded wire reinforcement is to be placed between the forms, or between the pavement edges, leaving 2 inches between the ends of the wires and the side forms, pavement edge, utility casting or pavement centerline. 505.2.1.2 Wire spacing and size for concrete pavement shall be ordered by the following criteria: Plain and Deformed Welded Wire Reinforcement Minimum Requirements Pavement Thickness (T) (inches)
Plain Wire
Deformed Wire
T ≤ 10
6 x 12 - W6.5 x W4
6 x 12 - D7 x D4
T > 10
6 x 12 - W8 x W4
6 x 12 - D8 x D4
505.2.1.3 Substitutions of different sheet patterns, but equivalent sized sheets will be permitted when approved in advance by the Engineer. The substituted sheets shall have equivalent or larger reinforcement areas than needed for design or as shown in the contract documents. 505.2.2 Reinforcing Steel Bars. When specified in the contract documents, the epoxycoated Grade 60 Nos. 4, 5, 6, 7 and 8 reinforcement bars shall be supplied in accordance with Section 1056. 505.2.3 Macro-Synthetic Fiber. The contractor is allowed a no-cost substitute of Macrosynthetic fiber blend in place of welded wire reinforcement. Fibers shall meet the following minimum requirements: 1) Ensure that macro-synthetic fibers are manufactured from virgin polyolefins (polypropylene and polyethylene) and comply with ASTM C 1116.4.1.3. Fibers manufactured from materials other than polyolefins must show documentary evidence confirming their long-term resistance to deterioration when in contact with the moisture and alkalis present in cement paste and / or the substances present in air-entraining and chemical admixtures. 2) The minimum fiber length required is 1.50 inches. 3) Ensure that macro-synthetic fibers have an aspect ratio (length divided by the equivalent diameter of the fiber) between 45 and 150. 4) Ensure that macro-synthetic fibers have a minimum tensile strength of 40 ksi when tested in accordance with ASTM D 3822. 5) Minimum dosage rate in pounds of fibers per cubic yard is established by determining a minimum average residual strength of no less than 150 psi when tested in accordance with ASTM C 1399. In all cases, ensure a minimum fiber dosage rate of 5 lbs./yd3 and a maximum fiber dosage rate of 10 lbs./yd3. 6) Ensure that macro-synthetic fibers have a minimum modulus of elasticity of 400 ksi when tested in accordance with ASTM D 3822.
1/1/2016
505-2
Reinforced Concrete Pavement
7) The fiber manufacturer is required to obtain and submit independently performed test results. 505.2.3.1 Fiber material shall be delivered, stored, handled, and mixed in accordance with manufacturer's guidelines. The fiber shall be added at the concrete plant at a minimum addition rate of 5 pounds of fiber per cubic yard of concrete. If the fiber manufacture does not specify a mixing time, the mixing time required to ensure adequate dispersion shall be a minimum of five (5) minutes or 70 revolutions at mixing speed. Additional water shall not be added in the field to increase workability based on appearance of the mixture. A mid-range or high-range water-reducing admixture may be added, at no additional cost to the County, to increase workability of the mixture in the field when authorized by the Engineer. 505.2.4 Joint Requirements for Concrete Pavement. Epoxy-coated transverse dowels shall be in accordance with Section 1036.4.3 Dowel Bars and dowel holes shall be as shown on the construction details. The deformed longitudinal tie bars shall be in accordance with Section 1057.4. Bar size and length for the pavement thickness and joint types are as follows. JOINT REQUIREMENTS FOR CONCRETE PAVEMENT Pavement Thickness (T) (inches) T<7 7≤T<9 9 ≤ T < 11 T ≥ 11 Notes:
Joint Type A A AA, D, G, J A AA, D, G, J AA, D, G, J
Transverse Dowel Bars Dowel Dowel Diameter x Spacing, CTRLength CTR (inches) (inches) None None None None 1 x 18
12”
None
None
1¼ x 18
12
1½ x 18
12
Longitudinal Tie Bars Joint Type
Tie Bar No. Size x Length (inches)
Tie Bar Spacing, CTRCTR (inches)
B, F
No. 5 x 30
30
B, E, F, H
No. 5 x 30
30
B, E, F, H
No. 5 x 30
30
B, E, F, H
No. 6 x 40
30
Dowel Bars Dowels for transverse joints shall be in accordance with the requirements AASHTO M 254, Type B (ASTM A 615) Grade 40 or 60. Dowels spaced 6” (typical) from longitudinal joint or pavement edge. Tie Bars Tie bars for longitudinal joints and construction joints shall be round, deformed and shall be in accordance with AASHTO M 31 (ASTM A 615) Grade 60 except that tie bars which are to be bent and straightened shall be in accordance with AASHTO M 31, Grade 40. Tie bars spaced 15” (typical) from transverse joint or pavement edge. Epoxy Coating The dowels and tie bars shall be epoxy coated in accordance with Section 1036, except the non-abraded coating thickness shall be 7 ± 2 mils, the flexibility of coating requirement will not apply and the cut ends will not be required to be coated.
1/1/2016
505-3
Reinforced Concrete Pavement
505.3 Construction Requirements. Base placement shall be in accordance with Section 304. Reinforced concrete pavement shall be transported, formed, placed, finished, sawed, jointed and sealed, stenciled, protected and constructed in accordance with the applicable requirements of Sections 502, 703 and 706, and shall attain a compressive strength of 3,500 psi prior to opening to traffic. The epoxy-coated Grade reinforcement bars, when specified, shall be supported and held securely in place by approved metal bar supports in accordance with Section 1036.3.5, "Reinforcing Steel Bar Supports". Epoxy-coated Mechanical bar splices are permitted in accordance with Section 1036.5, "Mechanical Connectors for Reinforcing Bars Splice". Reinforced concrete pavement shall be textured in accordance with Section 502. Curing shall be in accordance with Section 502, except the liquid membrane curing compounds shall be in accordance with Section 1055.4.2.3.4, "High Performance Curing Compound" when reinforced concrete pavement is opened to traffic in three days or less and not subjected to an asphalt overlay. Repair of surface damage shall be in accordance with Section 502. 505.3.1 Aggregate Base. Testing of aggregate base will be completed by the engineer. 505.4 Method of Measurement. Final measurement of the completed reinforced concrete pavement will not be made except for authorized changes during construction, or where appreciable errors are found in the contract quantity. Where required, reinforced concrete pavement areas, including tied shoulders, will be computed to the nearest 0.1 square yard. The revision or correction will be computed and added to or deducted from the contract quantity. 505.4.1 Irregular areas of reinforced concrete pavement or pavement areas not identified by a typical section, will be field measured and the area calculated to the nearest 0.1 square yards for payment. 505.5 Basis of Payment. The accepted quantity of reinforced concrete pavement will be paid for at the contract unit price and will be considered full compensation for, all labor, equipment, and material to complete the described work. 505.5.1 No direct payment will be made for the welded wire or Grade 60 epoxy coated reinforcing steel and all appurtenances and incidental work to construct the reinforced concrete pavement. 505.5.2 If pavement is found to be deficient in thickness, the Department will pay a reduced price according with Section 502. There is no additional payment for any pavement constructed and found to have an average thickness in excess of the thickness specified. 505.5.3 No direct will be made for repair of marred surface areas or slightly damaged concrete. Deductions as a percentage of the contract unit price shall be in accordance with Section 502.
1/1/2016
505-4
Reinforced Concrete Pavement
Section 507
Strength of Concrete Using the Maturity Method
507.1 Description. This specification covers the maturity method as non-destructive means of determining the in-place concrete compressive strength for pavement or structural applications. The concept of the maturity method is based on the combined effects of concrete age and temperature, during hydration, on the rate of strength gain for a specific concrete mix. This method requires the establishment of a relationship between compressive strength and calculated maturity (time-temperature factor based on Nurse-Saul function) indices for a specific concrete mixture prior to placement of the mixture in the field. The Contractor shall use the maturity method in accordance with this specification to estimate the compressive strength of inplace concrete for early release or early opening to traffic. 507.2 Procedure. In-place concrete strength determined by the maturity method shall be in accordance with ASTM C 1074, except as noted herein. 507.2.1 Maturity Meter. The battery-operated maturity meter shall have a secure means of collecting data that is unalterable; use maturity loggers that can provide a maturity value based on Temperature Time Method as detailed in ASTM C 1074; continuously log and store maturity data; is accurate to within ±1°C when operating in the range of -5°C to 85°C and when the meter is calibrated as per the manufacturer's instructions; have a reader operating temperature range from -5°C to 50°C; continuously take readings every hour at a minimum; and print data and/or download it into a spreadsheet. The same brand and type of maturity meter used to develop and verify the strength-maturity relationship shall be used in the field. 507.2.1.1 Maturity Logger Requirements. When concrete maturity testing is used, the contractor shall supply the Engineer with maturity loggers to develop the strengthmaturity curve, to verify the maturity curve and for monitoring concrete maturity during each placement. Maturity Logger Part numbers are MAT-02-1H28D-XX. The cable length (XX) ordered will depend on the location of the pour and the location of where the hand held reader will be operated. The acceptable loggers required are the IntelliRock II system manufactured and supplied by Engius, LLC, P.O. Box 188, Stillwater, Oklahoma 74076. IntelliRock II loggers are currently available with the following cable lengths: 4 feet; 8 feet*; 15 feet*; 30 feet*; 50 feet*; and 100 feet* (* denotes loggers with tough "yellow wire" cables). Cables longer than 100 feet are available by special order (Maximum wire length: 50 feet (wire in concrete or water), 200 feet (wire in air)). The Contractor shall determine the proper length of cable when ordering the loggers. The Contractor is responsible for providing the proper number of maturity loggers for building the maturity curve, verifying the maturity curve and providing the minimum required sensors for each concrete pour. No direct payment will be made for assistance in development of the strength-maturity relationship and provision of sensors with appropriate length sensor cables. All costs involved will be completely incidental to other items included in the contract.
1/1/2016
507-1
Strength of Concrete Using the Maturity Method
507.2.2 Maturity Function Values. The datum temperature is dependent on type and dosage of cement and of accelerating or retarding admixtures used. The maturity datum temperature can be determined in one of two ways: mortar cubes or concrete cylinders. Mortar cubes or concrete test cylinders can be tested by isothermal curing over a range of temperatures following the procedures laid out in ASTM C 1074 Annex A1. Determination of Datum Temperature or Activation Energy. In lieu of the above procedure, the following datum temperature values may be used: 507.2.2.1 Datum Temperature (T0). In the absence of testing for datum temperature (the temperature below which no active hydration of cement is considered to take place), use the following datum temperatures for the concrete mix meeting the most appropriate of the following conditions. Expected curing temperature is to be at least 40°F. Datum Temperature, T0 (°C)
Description of Use
6
Very early or high early concrete mixes with accelerating or water-reducing admixtures or additions
0
Concrete mixes with Type I/II cement without retarding or accelerating admixtures or additions
-10
Concrete mixes that use 15 percent or greater supplementary cementitious material, are cured at low temperatures, or contain admixtures to gain strength slowly
507.2.3 Standardization. The calibration of systems used for monitoring the maturity of concrete shall be verified as a minimum on an annual basis, in accordance with AASHTO T 325, Section 9.1 at 5°C; 25°C; and 45°C. 507.2.4 Development of the Strength-Maturity Relationship. The Contractor shall assist in the development of the strength-maturity relationship prior to use on the project and shall notify the Engineer prior to development of the maturity curve. The development of the strength-maturity relationship shall be done in the field using project equipment and materials. A strength-maturity relationship shall be valid for concrete placement at the ambient temperature at the time the strength-maturity relationship is developed ± 25°F, but no lower than 40°F. Compression testing of the cylinders will be performed by the County. 507.2.4.1 Preparing Test Specimens. When the strength-maturity relationship is developed, compressive strength specimens shall be fabricated from a 4 (±1) cubic yard batch of concrete, cured and tested for entrained air, slump, and temperature at the plant or job site. Air and concrete temperature, entrained air content and slump of the fresh concrete shall be measured and recorded. Prepare at least 17 cylindrical specimens that shall be fabricated and cured in accordance with ASTM C 31, with the following exceptions: 1) The concrete mixture shall meet the specification requirements in order to determine the strength-maturity relationship.
1/1/2016
507-2
Strength of Concrete Using the Maturity Method
2) Specimens shall be cured for the first 24 hours (or until the first approximate age specified under Section 507.2.5) under similar or like conditions anticipated during construction. 3) Specimens, including the cylinders used to monitor temperature, shall be demolded at approximately 24 hours (or until the first approximate age specified under Section 507.2.5) and cured in accordance with ASTM C31. 4) Embed two maturity loggers, in accordance with Section 507.4.3, in two cylindrical specimens. 5) Immediately connect the sensors to maturity instruments and activate in accordance with manufacturer's instructions as soon as the logger makes contact with the concrete. 507.2.4.2 Limitations. The concrete mixture's entrained air shall be no less than the target air content established by mix used. Fluctuations in entrained air content shall be avoided. The concrete mixture water / cement ratio shall be no less than specified by the concrete mix design and should be at the production target value ±0.02. Cement, Class or Type of cementitious material, admixtures, water or aggregate used in production that is not from the same type, brand and sources as used in the test specimens shall not be used. During field placement of concrete the contractor shall ensure that proper consolidation, placement, curing and protection of concrete shall be made. 507.2.4.3 Required Documentation. The Engineer shall obtain the following information prior to placing any production concrete on the project:
1/1/2016
1)
The concrete testing technician’s name and MoDOT Concrete Field (for making and curing samples) and MoDOT Concrete Strength (for compression testing of samples) certification number(s);
2)
The County and applicable Federal Project numbers, concrete mix number and date of testing;
3)
The ambient temperature range the maturity curve is valid;
4)
The air temperature, entrained air content, slump and water content from the batch of concrete tested;
5)
The source, amount and type of aggregate, cementitious materials, and water;
6)
The manufacturer, type and dosage amount of each admixture used in the concrete mix;
7)
The compressive strength of each test specimen, and the average strength of test specimens at each test age used to develop the maturity curve;
8)
Maturity index (°C-Hours) for each instrumented test specimen and the average maturity index for the instrumented specimens at each test age;
507-3
Strength of Concrete Using the Maturity Method
9)
The datum temperature and required maturity index (TTFreq) for the desired opening compressive strength; and
10) A graph of the average compressive strength versus the average value of the maturity index as described in the strength-maturity relationship section of ASTM C 1074. Use Microsoft® Office Excel logarithmic trendline function, showing the predictive equation for the maturity method applied to the concrete and the coefficient of determination (R-squared). The R-squared value shall exceed 0.950 to be considered a valid maturity curve. 507.2.5 Compressive Strength Testing. Perform compression testing at the ages specified in accordance with ASTM C 39. The Engineer may request up to two additional sets (six 4" x 8" specimens) for maturity testing. 28-day compressive strength tests shall be performed for all opening strengths. Develop data points for the strength / maturity relationship of roughly 30 percent, 60 percent, 90 percent, 120 percent, and 240 percent of the maturity values corresponding to the anticipated required strength level for each mix design. To achieve equal increments of strength gain between test ages, the Engineer may alter the compressive strength frequencies listed below to account for differences in materials, curing temperature or testing manpower. 507.2.5.1 Normal Opening Strength Testing. For concrete that is to be placed in service in more than 72 hours, normal opening strength testing is at the contractor's option. At a minimum, compressive strength tests shall be performed on three 4" x 8" specimens (a minimum of 15), and the average strength computed at 1, 2, 3, 4 and 7 days. Production may start after the 4-day compressive strengths have been determined with approval from the Engineer. 507.2.5.2 Early Opening Strength Testing. For concrete that is to be placed in service in 48 to 72 hours, early opening strength testing is required. At a minimum, compressive strength tests shall be performed on three 4" x 8" specimens (a minimum of 15), and the average strength computed at 12, 24, 36, 72 and 96 hours. Production may start after the 72-hour compressive strengths have been determined with approval from the Engineer. 507.2.5.3 High Early Opening Strength Testing. For concrete that is to be placed in service in less than 48 hours, early opening strength testing is required. At a minimum, compressive strength tests shall be performed on three 4" x 8" specimens (a minimum of 15), and the average strength computed at 6, 12, 18, 36, and 48 hours. Production may start after the 36-hour compressive strengths have been determined with approval from the Engineer. 507.2.5.4 Very Early Opening Strength Testing. For concrete that is to be placed in service in less than six hours, early opening strength testing is required. At a minimum, compressive strength tests shall be performed on three 4" x 8" specimens (a minimum of 15), and the average strength computed at 4, 5, 6, 7, and 8 hours. Production may start after the 7-hour compressive strengths have been determined with approval from the Engineer.
1/1/2016
507-4
Strength of Concrete Using the Maturity Method
507.2.6 Placement of Maturity Loggers. For pavement and pavement repairs, maturity loggers shall be embedded at approximately mid-depth and 18 inches from the edge of the pavement. For determination of compressive strength for saw cutting of pavement joints, maturity loggers shall be embedded at approximately one-third the slab depth as determined from the surface of the finished pavement and 18 inches from the edge of the pavement. For other applications, maturity loggers shall be embedded in locations considered critical in terms of exposure conditions and structural requirements, (bottom portion of drilled shafts and top portion of columns). The loggers shall be placed in formed structures (walls, columns, footings, column caps and diaphragms) and within two to four inches from formed surfaces. Do not disable logger until the required maturity values are achieved, as data collection must be uninterrupted. The maturity logger may be tied to reinforcing steel, but shall not be in contact with formwork or reinforcing steel. Maturity loggers shall be placed at the following frequency: Structure Component Frequency Pavement
1 maturity logger per 3,750 square yards, with a minimum of 1 per day in the last 50 feet of pavement.
Pavement Sawing
1 maturity logger per 750 linear feet, with a minimum of 1 per day in the first 15 feet of pavement.
Pavement Repair
1 maturity logger per 10 patches, with a minimum of 1 sensor per day in the last pavement repair.
Structural
A minimum of 1 maturity logger for each pour, with 3 other sensors available to be placed as directed by the Engineer.
507.3 Proportioning, Mixing, Placing and Curing Field Placed Concrete. The maturity method does not account for strength variations due to proportioning, mixing, placing and curing of concrete. Proper methods shall be followed at all times during proportioning, mixing, placing and curing the field placed concrete. 507.3.1 Field Placed Concrete Mix Requirements. Mix constituents of the field placed concrete shall not change, and mix proportions of the field placed concrete shall not vary more than 5.0 percent from the concrete mix used to develop the strength-maturity relationship. The water / cementitious ratio shall not vary more than 0.02. The Engineer may determine the water content of freshly mixed concrete using the microwave oven drying test method in accordance with AASHTO T 318. 507.3.2 Requiring Immediate Validation of Strength-Maturity Relationship. If the mix constituents change more than 5.0 percent, the water / cementitious ratio changes more than 0.02, the material sources change or the mixing operations change, an immediate validation of the strength-maturity curve shall be done in accordance with Section 507.4. 507.4 Validation of Strength-Maturity Relationship. At a minimum every seventh day of concrete placement, a validation test shall be conducted to verify that in-place concrete strength is accurately represented by the strength-maturity relationship. The Engineer shall be notified at least one business day in advance of when and where the validation test will be done.
1/1/2016
507-5
Strength of Concrete Using the Maturity Method
507.4.1 Documentation for Validation. The Engineer shall document the material proportions, entrained air, slump, and water content from the batch of concrete tested and any deviations from the original job mix in the presence of the Contractor. Specimens shall be cast in accordance with ASTM C 31. 507.4.2 Specimens for Validation. During placement of the field placed concrete, a minimum of four 4" x 8" compressive strength cylinders shall be fabricated and cured as specified in Section 507.2.4.1. 507.4.3 Maturity Logger Location for Validation. After a cylinder has been fabricated, a maturity logger shall be inserted. A maturity logger shall be embedded from 2 inches to 4 inches deep and to within ½ inch of the center of one cylinder for computing the maturity index from the measured temperature history as specified in Section 507.2. After the maturity logger is inserted into the cylinder, connect the meter to the logger, set the datum temperature as required, and activate the logger. The side of the cylinder mold is then tamped with a rubber mallet to ensure the concrete comes in contact with the maturity logger. Disconnect the meter and finish the cylinder surface in accordance with ASTM C 31. 507.4.4 Test Specimens for Validation. Once the maturity index, according to the temperature monitored cylinder, is achieved which corresponds to the maturity index desired for the first critical action such as opening pavement to traffic or removing formwork, three cylinders shall be tested for compressive strength. Maturity readings shall be taken immediately after the corresponding specimens are tested for strength. 507.4.5 Strength-Maturity Relationship Validated. The average compressive strength of the three cylinders shall be compared to the compressive strength as determined by the strength-maturity relationship. If the predicted strength is within 10 percent of the actual compressive strength, then the strength-maturity relationship will be considered validated. 507.4.6 Strength-Maturity Relationship Acceptable. If the actual compressive strength is more than 10 percent above the compressive strength as determined by the strengthmaturity relationship, then a new strength-maturity relationship may be developed. 507.4.7 Strength-Maturity Relationship Not Validated. If the actual compressive strength is more than 10 percent below the compressive strength as determined by the strength-maturity relationship, the Engineer shall make cylinders to determine compressive strengths until a new strength-maturity relationship has been developed. 507.5 Field Documentation. The Engineer shall have the following information prior to taking any field action based on the strength-maturity strengths: 1) County and applicable Federal Project Number and date tested; 2) A list of each concrete section or structure evaluated; 3) Station Number(s) and offset(s) or street address; 4) Item Number;
1/1/2016
507-6
Strength of Concrete Using the Maturity Method
5) Quantity of Concrete; 6) Logger location; 7) Datum Temperature and Maturity index determined for each maturity logger location; 8) Estimated strength determined for each maturity logger location. 507.5.1 Calibration and Verification Records. The Engineer shall record all test results for equipment calibration and verification, and shall maintain all results in an organized format. 507.5.2 Availability of Test Results. Test results shall be available to the contractor and material supplier at all times. 507.6 Basis of Payment. No additional payment will be made for compliance with this specification. Failure to provide adequate type and amount of loggers will result in the use of concrete cylinder compressive strength to determine release or opening compressive strength.
1/1/2016
507-7
Strength of Concrete Using the Maturity Method
(This Page Intentionally Left Blank)
1/1/2016
507-8
Strength of Concrete Using the Maturity Method
Section 508
Subdivision Concrete Replacement
508.1 Maintenance of Traffic. In accordance with Section 104.6.4, the Contractor will be required to maintain all traffic, through and local, as defined in Sections 104.6.1 and 104.6.2, respectively. All signing must be in place with proper weighting and functional before any work may be started. Accordingly, the Contractor will be required to pave no more than ½ of any roadway at any given time. The Engineer reserves the right to limit the pavement closed to traffic to 400 linear feet per run if conditions warrant and may require a gap of up to 400 linear feet between adjacent closed sections totaling 400 linear feet or more. 508.1.1 Temporary Closure Request. If any of the Contractor's operations necessitate periodic temporary closing of any portion of the existing roadways, the work schedule shall so indicate. A request for all closures must be submitted for approval a minimum of 2 weeks prior to closure date. 508.1.2 Driveway Closure. No private driveway on this project shall be closed for more than 3 calendar days unless in the opinion of the Engineer, delays beyond the control of the Contractor justify extensions of time. The Contractor is cautioned that premature closing of driveways will not be considered as justification for an extension. Commercial, industrial, and street entrances must be built in stages so that at no time will access be denied to any commercial establishment. Driveway closures will be limited to a maximum of 3 concurrent closures. 508.1.3 Pavement Closure. The closure of pavement slabs for removal and replacement shall be limited to a maximum of 7 days with 5 days of curing inclusive in this total closure time, unless specifically extended by the Resident Engineer. The Contractor is cautioned to arrange equipment, labor and materials with work schedule so as to comply fully with this provision. 508.1.4 Pavement Slab Adjacent to Drive Approach. The Contractor shall also arrange equipment, labor and materials with work schedule so as to remove and replace the pavement slab adjacent to drive approaches to be removed and replaced prior to any work on the drive approach being commenced. 508.1.5 Condition Before Opening. In all cases, before any new or replaced pavement, drive approach or sidewalk may be opened; it must be swept and placed in a condition free of debris, loose stone or other objectionable materials. 508.1.6 Roadways to Remain Open to Traffic. All existing roadways in the area shall remain open to traffic at all times during the execution of the work. Proposals for various paving arrangements to handle traffic shall be submitted to the Engineer for approval prior to implementation. 508.1.7 Payment for this work will be made at the contract unit prices bid for each of the pay items included in the contract. No direct payment will be made for any inconvenience or time lost because of the interference of traffic.
9/1/2023
508-1
Subdivision Concrete Replacement
Section 508.10
Subdivision Concrete Pavement Replacement (Bonus Penalty)
508.10.1 Description. This work will consist of removal and replacement of Portland Cement Concrete (PCC) pavement (full or partial slab) of various thicknesses, in accordance with this specification or as otherwise directed by the Engineer. The removal and replacement of the pavement items will be considered to include the mountable or vertical curbs attendant to the pavement slabs, and no separate payment will be made for removal and replacement of such curbs. 508.10.2 Material. 508.10.2.1 Concrete Requirements. All material, proportioning, air-entrainment, mixing, slump and transporting for Portland cement concrete shall be in accordance with Section 501. Coarse aggregates for all concrete use shall consist of crushed limestone. All materials shall conform to Division 1000, Material Details, and specifically as follows: Item
Section
Strength of Concrete Using the Maturity Method
507
Reinforcing Steel for Concrete
1036.4
Concrete Curing Material
1055
Material for Joints
1057
508.10.2.1.1 Concrete Pavement Mix Design. The design 28-day concrete pavement compressive strength, f´c for this project will be 4,000 psi. The minimum concrete pavement compressive strength at the time of single slab opening to PVehicle traffic only shall be in accordance with the table below. The minimum compressive strength at the time of single slab opening to mixed traffic shall be 3,000 psi and for slab sections greater than 15 feet shall be in accordance with the table below. The 28-day compressive strength and thickness of concrete pavement will be determined from cores taken and tested in accordance with County Test Method QA2, "Obtaining and Testing Drilled Cores of Concrete". Mixed Traffic, Slab Section > 15 feet in Length Opening To Traffic Pavement Thickness (T), inches Minimum Compressive Strength, psi T=6 3,500 T≥7
2,500 P-Vehicle 1 Opening To Traffic Minimum Compressive Strength, psi 1,100
Pavement Thickness (T), inches All 1
9/1/2023
P-Vehicle - The passenger car design vehicle as defined by AASHTO. Also includes minivans, pick-up trucks, sport utility vehicles (SUV's), and standard size vans.
508-2
Subdivision Concrete Replacement
508.10.2.1.2 Warnings. The wear and use of personnel protective equipment shall be in accordance with Section 502.2.1. 508.10.2.1.3 Allowance for Testing. The Contractor shall make allowance for Engineer sampling of concrete for quality control testing purposes. 508.10.2.1.4 Production Notification. The Engineer shall be notified by the Contractor in accordance with Section 501.3.1.7 when production inspection is needed.
9/1/2023
508-3
Subdivision Concrete Replacement
508.10.2.2 Failure to Meet Early Opening Compressive Strength. Portland cement concrete pavement that does not meet the required early opening compressive strengths as specified in Section 508.10.2.1.1 will result in suspension of use of the mix design. The Contractor shall submit a mix design for evaluation by the Engineer with an explanation in changes of production, transportation, placement, consolidation, and curing that will ensure compliance. When conditional approval is granted, the Engineer will then evaluate field production for specification compliance. Mix Design Submittal. The Contractor shall submit all mix designs for Engineer review and approval, in accordance with Section 501. 508.10.2.3 Dowels and Bent Bars. Materials for dowel bars shall be in accordance with Section 1057.3. Materials for tie (bent) bars shall be in accordance with Section 1057.4. All dowels and bent bars for pavement and curbs shall be epoxy coated in accordance with Section 1036.6.1. The cost of the epoxy coated dowels and bent bars shall be incidental, and no direct payment will be made. 508.10.2.4 Aggregate Base. Aggregate base material shall be in accordance with Section 1007. 508.10.3 Equipment. Except as revised in Section 508.10.4 the equipment requirements of Section 502, "Portland Cement Concrete Pavement", including field laboratory, shall apply to the construction of this work. 508.10.4 Construction Requirements. 508.10.4.1 Clearing Vegetation from the Pedestrian Access Route. This work shall consist of clearing and disposing of vegetation within the limits of the pedestrian access route. The pedestrian access route shall be defined as all sidewalks and curb ramps within the project limits. 508.10.4.1.1 Construction Requirements. All tree limbs, bushes, and other vegetation encroaching upon the pedestrian access route shall be trimmed horizontally to the edge of sidewalk and vertically to a minimum height of 80 inches. All cut surfaces over 1 inch in diameter shall be painted with tree paint or tar. 508.10.4.1.1.1 Disposal of vegetative material shall be in accordance with Section 201 of the St. Louis County Standard Specifications for Road and Bridge Construction.
9/1/2023
508-4
Subdivision Concrete Replacement
508.10.4.1.1.2 Exclusions. When no pay item for Clearing Vegetation from the Pedestrian Access Route is included in the contract, Clearing Vegetation from the Pedestrian Access Route will be considered incidental and no direct payment will be made. 508.10.4.1.2 Tree Trimming to Prevent / Correct Damage During Construction. Prior to work on any subdivision street or arterial road where construction activity will result in construction equipment, garbage trucks or any other vehicle making contact with trees, it will be the contractor's responsibility to trim the trees to prevent damage. The limits and extent of tree trimming shall be discussed with and agreed to by the Engineer before work proceeds. 1) The Contractor will be responsible for the timely removal of any additional branches that have been damaged as a result of the construction activities, as directed by the Engineer. 2) When branches are removed, either after damaged or in advance of construction activities, they shall be cut off flush with the parent branch. All cut surfaces over 1 inch in diameter shall be painted with tree paint or tar. 3) Disposal of vegetative material shall be in accordance with Section 201. This work will include disposition of removed branches by the Contractor. 4) Tree trimming to prevent/correct damage during construction will be considered incidental and no direct payment will be made. 508.10.4.1.3 Tree Removal. This work shall consist of removing and disposing of trees and tree stumps. This work shall be performed prior to removal of pavement, paved approach or sidewalk. Work shall be performed in accordance with Section 201.2.1. Stumps and roots shall be grubbed to a depth of not less than 12 inches below the finished earth grade. All exposed roots within the drip zone of the tree shall be ground to a depth of not less than 12 inches below the finished earth grade. Grubbing of Osage orange shall include complete removal of roots. Stump holes shall be backfilled with suitable material and compacted to the approximate density of the adjacent area. The disturbed area shall be seeded or sodded as determined by the Engineer. 508.10.4.1.4 Removal of Existing Stumps. This work shall consist of removing existing stumps, as authorized by the Engineer. Work shall be performed in accordance with Section 201.2.1 of the St Louis County Standard Specifications for Road and Bridge Construction. Stumps and roots shall be grubbed and area restored in accordance with Section 508.10.4.1.3. 508.10.4.2 Removals. The pavement removal operation will conform to the requirements of Section 202.30 or as directed by the Engineer. Pavement removal will extend to an existing joint or to a saw cut joint as hereinafter provided. Pavement in front of paved approaches shall be removed and replaced prior to replacement of paved approaches.
9/1/2023
508-5
Subdivision Concrete Replacement
508.10.4.2.1 Concrete Removal and Replacement Adjacent to Asphaltic Concrete Pavement and Appurtenances. When removing and replacing concrete pavements abutting asphaltic concrete drive approaches and driveways, the following provisions will apply: 508.10.4.2.1.1 If sidewalk does not exist, the approach will be removed to a saw cut line established by the Engineer. All such approach removal will be made to a saw cut line. The excavation necessary for the forms will be backfilled with granular material and maintained by the Contractor to make the driveway safe and usable. Contractor will schedule the restoration of the driveway with asphaltic concrete materials as time permits. The Contractor shall be responsible for the removal of the temporary aggregate material in advance of the restoration operation. 508.10.4.2.1.2 No direct payment will be made for removing the asphaltic concrete pavements covered under this provision, or for furnishing, placing, compacting, and maintaining the aggregate materials to restore the driveways to a safe and usable condition or for the removal of the aggregate material preparatory to the restoration of the driveways by the Contractor. 508.10.4.2.2 Removal of Damaged Pavement Adjacent to Joints. The Engineer may order additional pavement removal where adjoining pavements not scheduled for removal and replacement exhibits spalling and cracking at or near the transverse joint area. Such removals will normally extend 12 inches to 18 inches beyond the joint line. The additional removal will be made to a full depth saw cut line parallel with the transverse joint. 508.10.4.2.3 Removal of Damaged Pavement Adjacent to Grated Troughs. Where a pavement slab is being removed adjacent to an existing grated trough, the pavement replacement portion of the item will terminate 3 feet from the edge of the grated trough. The unpaved area will be finished to a level 8 inches below the level of the pavement with compacted granular material as directed by the Engineer. Contractor will place and compact asphaltic concrete material in this area to complete the pavement section. 508.10.4.3 Excavation of Unsuitable Material and Backfill of Resulting Excavation. 1) Removal of Unsuitable Material and Backfill shall be performed in accordance with Section 203.2.6. 2) Soft or wet areas resulting from inclement weather or the sequence of the Contractor's operations shall not constitute unsuitable material. 3) Payment for authorized excavation of unsuitable material, furnishing and placement of the backfill material and disposal of the unsuitable material will be made in accordance with Section 203.7.3.
9/1/2023
508-6
Subdivision Concrete Replacement
508.10.4.4 Aggregate Base. Under all new/replaced concrete base and pavement, paved approaches and driveways, curb and gutter, exposed aggregate concrete, 6-inch sidewalk, 7-inch sidewalk, and curb ramps, install, fine grade and compact 4 inch thick base of Type 5 Aggregate. Aggregate base material shall be in accordance with Section 1007. Placement, shaping, compaction and surface tolerance shall be in accordance to the applicable provisions of Section 304. Prior to installation of the aggregate, contractor shall compact the subgrade in accordance with Section 209.3.1 using equipment specified in Section 304.3.5.2. 508.10.4.4.1 This work shall include any earthwork (excavation and/or borrow) for the aggregate base construction. 508.10.4.5 Replacement of Concrete Pavement. Except as modified herein, pavement replacement construction will conform to the requirements of Section 502, "Portland Cement Concrete Pavement", with the following modifications: 1)
Forms for Concrete Replacement. This work shall consist of placing and removing any forms for concrete replacement. Work shall be performed in accordance with Section 502.3.4.2 for pavement and Section 608.3.1 for concrete median, median strip, sidewalk, steps and paved approaches. The removal of a form resulting in a gap of less than 3 inches at the back of curb, edge of sidewalk, approaches and curb ramps shall be backfilled, compacted, and seeded. Unless otherwise directed by the Engineer, any gap consistently greater than 3 inches shall be sodded.
9/1/2023
2)
Reinforcement. When reinforcement is required it shall be performed in accordance with Section 505.
3)
Final Strike-Off. Final strike-off shall be made with a vibratory screed for continuous pavement pours greater than 200 feet in length. For all other conditions the hand finishing requirements of Section 502.4.7.2 shall apply.
4)
Consolidation. The placement and finishing of the concrete pavement must conform to the provisions of Section 502.4.7.3 regarding handwork. Proper consolidation and screeding of the concrete will be required at all times. The use of a spud-type vibrator will be required for all items except vertical curb and 4-inch sidewalk. The use of water to aid in finishing the concrete will not be permitted unless specifically authorized by the Engineer. When so authorized, finish water may only be placed in accordance with Section 502.4.7.4.
5)
Floating. Floating shall be in accordance with Section 502.4.7.6, "Hand Method".
6)
Straight Edge and Surface Correction. Straight edge and surface correction shall be in accordance with Section 502.4.7.7. The surface of the pavement replacement shall be finished so that it will not vary more than ¼ inch from a 10-foot straightedge and have a smooth transition to adjacent slab edges the does not vary by more than ⅛ inch.
508-7
Subdivision Concrete Replacement
7)
Surface Texture. The surface shall be finished in accordance with Section 502.4.7.8.4, Broom finish.
8)
Jointing of Concrete Pavement. Transverse contraction joints will be spaced to match existing roadway joints or on 15 foot to 20 foot intervals where the entire pavement surface is to be replaced. Contraction joints will extend full width across the pavement and through all monolithic curbs. Transverse contraction joints will be grooved with a suitable finishing tool or saw cut that will produce, at a minimum, a 2 inch deep by ⅜ inch wide joint. All joints are to be open, straight, continuously uniform, and neatly finished. All tooled joints that fail to have the required 2-inch depth will be sawed in accordance with Section 502.5.7, to the 2-inch depth within 12 hours of tooling. All grooved and sawcut joints will be properly cleaned and sealed in accordance with Section 502.9. In areas where pavement removal and replacement is to extend across the entire roadway width, or where a saw cut is to extend across the entire roadway width and the nearest expansion joint is more than 400 feet away, the Engineer may order the construction of an expansion joint. Such joints will be placed in accordance with Section 502.5.2.
9)
Expansion Joint Filler Strip. This item has been added to the Summary of Quantities and the Itemized Bid and is intended to provide the Engineer with the capability of ordering the installation of joint filler. The actual locations for this item have not been identified, and the quantity given is for establishing a unit price for this item. Final payment will be based on the actual quantities measured. The filler material shall be in accordance with Section 1057.7.4. The filler material shall extend to the base of the new pour with the top held ½ inch below the pavement surface to form a reservoir for joint sealant material. The filler material shall be held securely in place with keyway pins or galvanized nails. The fasteners shall be located approximately 2½ inches above the base of the slab on 3-foot centers.
10) Preformed Fiber Expansion Joint Filler. Preformed Fiber Expansion Joint Filler shall be in accordance with Section 1057.5.2. The joint filler material thickness shall be 1 inch across the intersection of concrete sidewalk and concrete entrances and at Type A or AA expansion joints not specified by item 9 (above), ¾ inch across street inlet sumps, ½ inch across concrete sidewalk or of the joint thickness specified. The joint filler material shall be of a depth equal to the full depth of the pavement less the depth of the joint sealer and of a length no less than across the width of the face of the inlet, sidewalk, paved approach or no less than the pavement section width. This material is incidental to the concrete being placed and will not be paid for directly. 11) Box-Outs for Utility Access. Necessary box-outs for utility access shall be constructed in accordance with Section 502.5.10 and will not be paid for directly. 12) Curing. Membrane curing methods permitted by Section 502.6.2 shall be used. Polyethylene sheeting may be used and shall be applied in accordance with Section 502.6.3. When weather conditions require thermal protection for pavement to be opened in three days or less, use shall be in accordance with Section 502.6.6, Thermal Curing Blankets.
9/1/2023
508-8
Subdivision Concrete Replacement
508.10.4.6 Adjustment of Appurtenances. 508.10.4.6.1 The work will include the cleaning and straightening of tie bars, saw cutting, and removal of dowel basket bars. If during the removal of a slab 7 inches or greater in thickness, or during the cleaning or straightening of the tie bars, the tie bars are broken off where more than two are missing in a continuous run, the Contractor shall drill, epoxy grout and replace the tie bars. No direct payment will be made for any labor, equipment, or material necessary to accomplish this work. 508.10.4.6.2 No direct payment will be made for labor, equipment, or materials necessary for readjustment of disturbed street inlets associated with the removal and replacement of pavement slabs. If required, removal and replacement of inlet stones, sills, and adjustment of manhole frames to grade will be paid at the contract unit price or as included as a contingent item in the contract documents. Adjustments and materials shall be in conformance with the requirements of the latest edition of the standard details and the standard specifications of the Metropolitan St. Louis Sewer District (MSD). 508.10.4.7 Concrete Placement Requirements. 508.10.4.7.1 Mixing and Placement Limitations. Mixing and placing limitations shall be in accordance with Section 502.4.1, with the following modifications: 508.10.4.7.1.1 Cold Weather. Cold weather concreting shall be in accordance with Sections 502.4.1.1 through 502.4.1.6. The use of a non-corrosive strength accelerator (NCA) is required if the projected low temperature for the night after paving is below 35°F. NCA shall be dosed in accordance with Section 502.4.1.3. Warm water may also be required so that plastic concrete temperature at the time of placement is between 55°F and 80°F. This requirement may be waived by the Engineer if favorable atmospheric conditions (warm ground temperature, calm wind, etc.) dictate. In accordance with Section 502.4.1.6, the Contractor shall apply special thermal curing efforts that ensure the concrete temperature is maintained at or above 55°F for at least 5 calendar days after placement or when the concrete has reached a compressive strength of at least 3,000 psi as determined by field cured cylinders or by maturity testing. 508.10.4.7.1.2 Hot Weather. Hot weather concreting of pavement, sidewalks and approaches shall be performed in accordance with Section 502.4.1.7 to control evaporation and maintain concrete temperature within specified limits. 508.10.4.7.2 Job Site Inspection. Testing shall be performed at least once per lot. A lot is defined as 1,000.0 square yards or fraction thereof (i.e., 1,000.1 square yards would require 2 sets of tests). 508.10.4.7.2.1 Slump. The Department at random intervals on the job site shall test and report the concrete slump at the time of placement at least once per lot. Slump may be tested and report by Department personnel at the job site at the Engineer's discretion. After water addition in accordance with Section 502, the maximum allowable slump of concrete at the time of placement, without water reducer or with mid-range water reducer shall not exceed 4 inches. Concrete with high range water reducer shall have no job site water addition and have a
9/1/2023
508-9
Subdivision Concrete Replacement
maximum allowable slump that shall not exceed 6 inches. A slump test shall be performed and reported when an entrained air test is performed. Additional cement shall not be added to reduce slump. Concrete exceeding the maximum allowable slump shall be rejected. 508.10.4.7.2.2 Entrained Air. The Department at random intervals on the job site shall test and report the entrained air content at the time of placement at least once per lot. After air entrainment admixture is added in accordance with Section 502, the minimum entrained air content shall be 5.5 percent as determined at the time of placement. For concrete pavement, the specified air content will apply to the measurements taken after consolidation and strike-off or to measurements taken before consolidation and strike-off minus the established air loss through consolidation. Concrete with less than the minimum specified entrained air will be rejected. 508.10.4.7.2.3 Concrete Temperature. Plastic concrete temperature shall be tested at the time of placement and reported by the Engineer on the job site for each lot when: 1) Slump and entrained air tests are performed; and 2) The ambient air temperature is 80°F or above. Plastic concrete temperature shall be taken at a frequency that will ensure concrete will be rejected when the plastic concrete temperature exceeds 100°F (the rejection maximum allowable temperature shall be reduced to 90°F when thermal cracking is evident); or 3) The ambient air temperature is 40°F or below. Plastic concrete temperature shall be taken at a frequency that will ensure concrete will be rejected when the plastic concrete temperature is below 55°F or above 80°F. 508.10.4.8 Curing and Weather Protection. Concrete pavement will be cured in accordance with Section 502.6. When polyethylene is used for curing, it should be of the color in accordance with Section 502.6.3. Concrete sidewalk and approaches will be moist cured with material in accordance with Section 1055.4.2.3.1 and applied with equipment at the application rate in accordance with Section 502.3.3.8.1. Weather protection for thermal curing will be required in accordance with Section 508.10.4.7.1. 508.10.4.9 Backfill of Completed Pavement. Backfill for pavements and curbs, where required, shall consist of compacted clean earth backfill and shall be completed in a timely manner. Backfill shall be placed within 15 calendar days after the construction of the pavement and curbs. The upper 6 inches of backfill material shall meet or exceed the requirements specified for Topsoil in Section 804 and shall not contain more than 5% (by weight) of grass, rock, gravel, slag, roots or other deleterious materials as designated by the Engineer and shall be a suitable material for a sod bed. Payment for the affected items may be removed from the Engineer's pay estimate if the required backfill has not been satisfactorily placed within the 15-day period. Required barricades shall remain in place until the backfill is placed.
9/1/2023
508-10
Subdivision Concrete Replacement
508.10.4.9.1 The backfill will be compacted to an elevation at which sod or seed can be placed level with the adjacent grass and the curb line. 508.10.4.9.2 No direct payment will be made for furnishing, placing, and compacting backfill. 508.10.4.10 Opening to Traffic. Traffic is not to be allowed on new concrete pavement earlier than 14 days after concrete placement, unless concrete compression tests or maturity testing indicate that one of the following conditions is obtained: 1) The concrete pavement shall not be opened for construction traffic until the concrete is at least 72 hours old and has attained a minimum compressive strength: a) At the time of single slab opening to traffic shall be 3,000 psi; and b) For multiple slab sections greater than 15 feet shall be 3,500 psi. 2) The pavement shall not be opened to all types of traffic until the concrete is at least 120 hours old and has attained a minimum compressive strength of 3,000 psi as determined by field cast and cured cylinders or maturity method; or 3) When directed by the Engineer. 508.10.4.11 Joint and Crack Sealing. Joint sealing shall be performed in accordance with Section 502.9. 508.10.4.12 Strip Sodding. Following the completion of the backfilling and final grading operations, all disturbed areas shall be sodded in accordance with Section 508.30.4.9. 508.10.5 Acceptance and Payment. Damaged pavement shall be repaired in accordance with Section 502.13, "Repairing Defects", prior to acceptance. 508.10.5.1 Acceptance of concrete pavement will be made solely by the results of thickness and compressive strength testing of concrete cores drilled from the new concrete pavement. 508.10.5.2 Acceptance by cores is intended to represent not only the quality of concrete delivered to the job site, but also to represent the quality of grading, concrete placement, consolidation and curing procedures. 508.10.5.3 3 cores will be extracted from the day's placement for every 1,000.0 square yards of pavement placed each day, or fraction thereof (i.e., over 1,000.1 square yards would require six 6 cores). However, if an individual day’s production is less than 200.0 square yards, it will be combined with the next day where production is 200.0 square yards or more. No more than 1 core will be extracted from an individual slab, however, cores may be chosen from adjacent slabs in a continuous placement at any time. When identifying a slab for drilling, the engineer shall mark the top of curb with the core number in white paint. No core shall be extracted less than 2 feet from either the edge of pavement; adjacent to a utility appurtenance; or previously drilled core. The slabs to
9/1/2023
508-11
Subdivision Concrete Replacement
be cored will be selected by the Engineer and may not necessarily be chosen at random. The location of the core to be taken in the selected slabs will be determined by the Engineer. Samples shall not be taken until the concrete has cured a minimum of 21 days. Average values for the strength of the cores and the deviation from design thickness will be determined for each day using the procedures outlined below. 508.10.5.4 The cores will be drilled, measured for thickness and compression tested in accordance with ASTM C42 or as modified herein. Cores will be compression tested after a 7-day air cure. Core length will be determined by the average of 9 measurements and measured to the nearest 0.1 inch. The cores will then be sawed to the appropriate l/d ratio and have a strength correction factor applied. The corrected compressive strength for each core will then be rounded to the nearest 50 psi. This number will be referred to as the adjusted core strength. The adjusted core strengths will then be averaged and again rounded to the nearest 50 psi. This average will be referred to as the daily adjusted average core strength. Rounding will be performed in accordance with ASTM E 29. Cores will not be compression tested for strength before the concrete reaches 28 days of age. Cores will generally be compression tested for strength within 42 days of placement. 508.10.5.5 The thickness of all cores taken for a day's production will be measured to the nearest 0.1 inch. The core thicknesses will then be subtracted from the design thickness to determine the deviation from design thickness. The deviation from design thickness for each core will be averaged to determine the daily average deviation from design thickness. 508.10.5.6 The daily average deviation from design thickness and the daily adjusted average core strength will be applied to the chart included in this specification to determine the pay factor (percentage of unit prices bid for pavement items) for the pavement placed that day. Bonuses and penalties for the day's work will be determined from this pay factor and assessed in the method prescribed in the Section 508.10.8.1. 508.10.5.7 The County reserves the right to have the Contractor remove and replace any slab from which a core measuring 1.0 inch or more thinner than the plan thickness was extracted or from which a core with an adjusted core strength of less than 3,300 psi was extracted. In addition, the County may also have the Contractor remove and replace any slab that is represented by a zero pay factor. 508.10.5.8 Multiple Slab Placements. Multiple slabs are defined as two or more slabs placed adjacent to each other. When the measurement of any core (original core or additional cores taken to calculate the average) is less than the plan thickness by more than 1.0 inch or the adjusted core strength is less than 3,300 psi, the extent of the removal area due to deficiency will be determined by taking additional exploratory cores at each adjacent slab or series of slabs in each direction from the deficient core until an exploratory core is found in each direction which is both less than 1.0 inch deficient of the plan thickness and has an adjusted core strength of greater than or equal to 3,300 psi. The pavement between these exploratory cores will be removed full lane width wide and replaced with concrete of the thickness shown on the plans. Exploratory cores for deficient thickness and compressive strength will not be used in averages for adjusted unit price.
9/1/2023
508-12
Subdivision Concrete Replacement
508.10.5.9 The Department will not generally perform any cylinder or core testing prior to the 28-day tests, however, the Department reserves the right to perform such tests for informational purposes. The Contractor will be responsible for performing any additional testing necessary to verify that the desired level of quality control is being achieved. Any costs involved with this additional testing will be the responsibility of the Contractor. 508.10.5.10 The Department will perform periodic testing of fine and coarse aggregate from the Contractor's concrete supplier to verify that the producer has adequate supplies of Department approved aggregates on hand. The Department also reserves the right to observe the concrete supplier's operations to verify that only Department approved water, admixtures, cement, fly ash and aggregates are being incorporated into the mix and that the approved mix proportions are being used. 508.10.5.11 Pay Factor Challenge Requirements. The Contractor would be permitted to challenge the pay factor determined by the Department for a given day's production under the following conditions only: 1) The Contractor shall have the same number of cores extracted from the day's production as originally taken by the Department. A testing company hired by the Contractor at his own expense will extract these cores. Cores will be spotted by the Engineer and will be marked within a 3-foot radius (but not within 2 feet of the edge of the pavement slab) of the Department's cores for that day's production. The company performing extraction must be listed in the most recent AASHTO Accreditation Program Directory of Accredited Labs for ASTM Test Method C 42 (Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete). A Department representative must witness extraction by the testing company hired by the Contractor. Accordingly, the Contractor must inform the Engineer 24 hours in advance of performing this work. 2) Cores must be measured and compression tested by the Contractor at his own expense. The Contractor shall furnish all tools, labor and materials for traffic control, cutting and extracting samples, filling the cored hole with non-shrink grout, compression testing the prepared core, and reporting the results. The company performing measuring and compression testing must be listed in the most recent AASHTO Accreditation Program Directory of Accredited Labs for ASTM Test Method C 174 (Standard Test Method for Measuring Length of Drilled Concrete Cores) and for ASTM Test Method C 39 (Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens), respectively. Testing must be witnessed by a Department representative and must be scheduled with the Engineer at least 24 hours in advance. Each core is required to be neatly cut with a 4-inch (nominal) diameter core drill bit for the full depth of the pavement. Core holes shall be filled by the Contractor with MoDOT FS-1066 approved non-shrink grout at the time of drilling. 3) Challenges of individual cores will not be permitted. The Contractor will be required to take the same number of cores taken by the Department (as prescribed above) for a given day's production. The core results obtained for the Contractor will then be converted to a pay factor using the procedure specified herein. The pay factor determined from the Contractor's results will then be averaged with the pay factor determined from the Department's results to
9/1/2023
508-13
Subdivision Concrete Replacement
determine the pay factor for that day. Both the thickness and strength of the cores will be averaged, regardless of which area the Contractor is challenging. 4) Cores drilled to challenge the Department's strength results must be drilled and compression tested within 14 days of the Department’s compression test. 508.10.5.12 Surface Tolerance Testing. The Department will perform periodic surface tolerance testing in accordance with Section 502.8.2, Subdivision Pavements. Pavement surface correction shall be accomplished by grinding the pavement in accordance with Section 502.8.1. 508.10.6
Repairing Defects. Repairing defects shall be in accordance with Section 502.13.
508.10.7 Method of Measurement. Quantities for the removal and replacement of concrete pavement will be measured and computed to the nearest 0.1 square yard. The Department will include fillets for widened sections, or at drain basins and similar locations, placed monolithic with the pavement. The Department will not deduct for fixtures with an area of one square yard or less as measured in the plane of the pavement surface. 508.10.7.1 Tree Removal. Trees to be removed will be measured per unit of diameter where one unit is equal to 1 inch. The diameter will be measured at a point 4.5 feet above the highest ground level at the base of the tree and will be determined by dividing the measured circumference of the tree by π or pi (3.1416). A multiple stem tree's branches having a diameter of 6 inches or more at a point 4.5 feet above the highest ground level at the base of the tree will be measured for payment as individual trees. The accumulated total number of units will be the pay quantity. 508.10.7.2 Removal of Existing Stumps. Stumps 3 inches in diameter or greater will be counted. The diameter, measured in inches, will be determined by dividing the measured circumference of the tree by π or pi (3.1416). Measurement for removal of existing stumps, removal, site restoration and clean-up will be made by the Engineer for each. Payment for stumps less than 3 inches in diameter will be considered incidental to the work and no direct payment for the removal will be made. 508.10.7.3 Aggregate Base. Payment for all labor, material, and equipment necessary to accomplish this item will be considered included in the contract unit price for "Type 5 Aggregate Base, 4 Inches Thick". 508.10.7.4 Joint and Crack Sealing. Measurement of individual joints and cracks will not be made. The ordered and accepted cleaning, separating, or blocking media, and sealing of pavement joints and cracks will be measured along the centerline roadway surface to the nearest 0.01 mile. 508.10.7.5 Expansion Joint Filler Strip (1 Inch Thickness). Measurement of expansion joint filler strip (1 inch thickness) will be measured to the nearest linear foot.
9/1/2023
508-14
Subdivision Concrete Replacement
508.10.7.6 Strip Sodding. Measurement of strip sodded areas shall be in accordance with Section 508.30.4.9. 508.10.8 Basis for Payment. 508.10.8.1 Bonus / Penalty. The cost of all labor, equipment, and materials necessary to complete the construction shall be included in the contract unit price for the following items: 1) Item No. 508-99.96 - Remove and Replace Concrete Pavement (6" Non-reinforced), Includes Curb (Bonus/Penalty). 2) Item No. 508-99.97 - Remove and Replace Concrete Pavement (7" Non-reinforced), Includes Curb (Bonus/Penalty). 508.10.8.1.1 The replacement of the above items will be made at the contract unit price for said item. In addition, the item shall include construction of mountable or vertical curbs and curb transitions on the replacement pavements. No direct payment will be made for pavement grinding and for furnishing and backfilling the completed replacement with topsoil material in accordance with Section 804, suitable as a sod bed. 508.10.8.1.2 The Contractor is cautioned that all work included in the item, including backfill, must be completed in its entirety before the value of the item will be included in the Engineer's monthly payment estimate as provided for in Section 109.5. 508.10.8.1.3 The Daily Pavement Pay Factor Percentage Chart. The Daily Pavement Pay Factor Percentage Chart is for the purpose of determining Bonuses and Penalties will be based on the unit price of $20 per square yard for Items No. 50899.96 and No. 508-99.97 regardless of the low bidder's contract unit price for this item. Therefore, the contract unit price will be adjusted by the Daily Pavement Pay Factor (PFcomposite) multiplied by the unit price of $20 per square yard. The actual pay adjustment (PAYADJLot) for the as-constructed day's work is computed using the lot composite pay factor as follows: =
$20.00/ yd2 * AREALot * (PFcomposite - 100) / 100
PAYADJLot
=
Pay increase (+) or decrease (-), $ for the day's work.
AREALot
=
Measured actual area, yd2, of the as-constructed day's work.
PFcomposite
=
Composite pay factor based on core strength and deviation from thickness for the day’s work (from Table), percent (e.g., 101 percent is expressed as 101.0).
PAYADJLot Where:
9/1/2023
508-15
Subdivision Concrete Replacement
Daily Pavement Pay Factor (Percent of Base Unit Price ($20 Per Square Yard) for Determination of Adjustments to the Contract Unit Price for Pavement Items) Daily Adjusted Average Core Strength, psi
Daily Average Deviation From Design Thickness More than +0.2"
+0.2"
+0.1"
0.0"
-0.1"
-0.2"
-0.3"
-0.4"
-0.5"
-0.6" to -0.9"
-1.0" or More
6,300 or above
105
104
104
103
100
100
100
80
80
60
0*
5,950 to 6,250
104
104
103
102
100
100
100
80
80
60
0*
5,600 to 5,900
104
103
102
101
100
100
100
80
80
60
0*
4,000 to 5,550
103
102
101
100
100
100
100
80
80
60
0*
3950
100
100
100
100
100
100
100
80
80
60
0*
3900
100
100
100
100
100
100
100
80
80
60
0*
3850
100
100
100
100
100
100
100
80
80
60
0*
3800
100
100
100
100
100
100
100
80
80
60
0*
3750
80
80
80
80
80
80
80
64
64
48
0*
3700
80
80
80
80
80
80
80
64
64
48
0*
3650
80
80
80
80
80
80
80
64
64
48
0*
3600
60
60
60
60
60
60
60
48
48
36
0*
3550
60
60
60
60
60
60
60
48
48
36
0*
3500
60
60
60
60
60
60
60
48
48
36
0*
3450
60
60
60
60
60
60
60
48
48
36
0*
3400
60
60
60
60
60
60
60
48
48
36
0*
3350
60
60
60
60
60
60
60
48
48
36
0*
3300
60
60
60
60
60
60
60
48
48
36
0*
less than 3,300
0*
0*
0*
0*
0*
0*
0*
0*
0*
0*
0*
9/1/2023
508-16
Subdivision Concrete Replacement
508.10.8.1.4 Bonuses and Penalties for Pavement Items. Payment for any amount in excess of 100% of the contract unit price for pavement items will be paid for under the contingent item "Bonus Payment for Pavement Items". The amount of payment will be calculated using the methods described in Section 508.10.8.1.3. Penalties will be listed in the "Deductions" section of the Payment Estimate. Bonus and penalties will be itemized on a daily basis. 508.10.8.2 Tree Removal. The cost of all labor, equipment and materials necessary to complete the work shall be included in the contract unit price for Bid Item No. 201-20.14, "Tree Removal". If no pay item exists in the contract, payment for Tree Removal will be made per inch at the fixed cost specified in section109.4.5. 508.10.8.3 Removal of Existing Stumps. The cost of all labor, equipment and materials necessary to complete the work and restore the site will be made at a unit price of %25 of bid item 201-20.14 Tree Removal per inch.No additional payment will be made for removing existing stumps with a diameter less than 3 inches. 508.10.8.4 Expansion Joint Filler Strip. Payment for furnishing and placing expansion joint fill material will be made at the contract unit price for Bid Item No. 508- 90.00, "Expansion Joint Filler Strip (1 Inch Thickness)". The unit price is for one linear foot at a thickness of 1 inch. The contract length will be doubled where the 2 inch thickness is installed. No additional payment will be made for securing the joint filler material to the abutting pavement sections. If no pay item exists in the contract, payment for Expansion Joint Filler Strip will be made per linear foot at the fixed cost specified in section109.4.5. 508.10.8.5 Adjusting Manholes to Grade. This work shall consist of adjusting manholes to grade, as authorized by the Engineer. Work shall conform to the requirements of the latest edition of the standard details and the standard specifications of the Metropolitan St. Louis Sewer District (MSD). The cost of all labor, equipment and materials necessary to complete the work will be made at bid item “604-20.30 Adjusting Manhole to Grade”. If no pay item exists in the contract, payment for Adjusting Manhole to Grade will be made per each at the fixed cost specified in section109.4.5. 508.10.8.6 Remove and Replace Inlet Sills. This work shall consist of removing and replacing inlet sills, as authorized by the Engineer. Work shall conform to the requirements of the latest edition of the standard details and the standard specifications of the Metropolitan St. Louis Sewer District (MSD). The cost of all labor, equipment and materials necessary to complete the work will be made at bid item “604-90.52 Replace Inlet Sill”. If no pay item exists in the contract, payment for Replace Inlet Sill will be made per each at the fixed cost specified in section109.4.5. 508.10.8.7 Remove and Replace Inlet Tops. This work shall consist of removing and replacing inlet tops, as authorized by the Engineer. Work shall conform to the requirements of the latest edition of the standard details and the standard specifications of the Metropolitan St. Louis Sewer District (MSD). The cost of all labor, equipment and materials necessary to complete the work will be made at bid item “604-21.95 Replace Precast Inlet Top”. If no pay item exists in the contract, payment for Replace Precast Inlet Top will be made per each at the fixed cost specified in section109.4.5. 508.10.8.8 Strip Sodding. Payment of strip sodded areas shall be in accordance with Section 508.30.4.9. 9/1/2023
508-17
Subdivision Concrete Replacement
Section 508.20
Subdivision Concrete Pavement Replacement 6 to 13 Inch Thickness (Non-Bonus / Penalty)
508.20.1 Description. When this item is added to the Summary of Quantities and the Itemized Bid, it is intended to provide the Engineer with the capability of ordering removing and replacing concrete pavement adjacent to areas where expansion joints are to be constructed. The actual locations for this item have not been identified, and the quantity given is for establishing a unit price for this item. Final payment will be based on the actual quantities measured. Removal, replacement and backfill of the completed 6-inch to 13-inch pavement shall be accomplished in the same manner specified in Section 508.10 (without the bonus penalty specification in Section 508.10.8.1) and shall conform to the dimensions shown in the project plans. Concrete for 6 inch to 13 inch pavement will be accepted in accordance with the applicable portions of Sections 501 and 502 of the "Standard Specifications for Road and Bridge Construction". 508.20.1.1 Excess Variation in Concrete. Additional air entraining, slump and temperature tests shall be made at the time of placement when excessive variation in concrete workability is reported by the placing foreman or the Engineer. If results are out of tolerance, the placing foreman shall be notified and the Contractor shall take appropriate action to have the air content, slump, or temperature corrected at the plant. Additional tests for air content, slump or temperature will be performed by the Engineer on each truckload of material until such time as the plastic concrete air content, slump or temperature is within the tolerance specified. 508.20.2 Thickness and compressive strength shall be determined in accordance with Section 502.15. Opening to traffic will be in accordance with Section 508.10. 508.20.4 Method of Measurement. Quantities for the removal and replacement of concrete pavement will be measured and computed in accordance with Section 508.10.7. 508.20.4.1 Strip Sodding. Following the completion of the backfilling and final grading operations, all disturbed areas in excess of three inches from the back of pavement, shall be sodded, measured in accordance with Section 508.30.4.9. 508.20.5 Basis for Payment. The cost of all labor, equipment, and materials necessary to complete the construction shall be included in the contract unit price for the following item: 1) Item No. 508-11.99 - Remove and Replace 6-inch to 13-inch Non-Reinforced Concrete Pavement (Includes Curbs). 508.20.5.1 No direct payment will be made for the additional excavation required or for backfilling the completed replacement with Section 804, material suitable for sod bed. Payment for all labor, material and equipment necessary to accomplish this item will be considered to be completely included in the contract unit price for "Remove and Replace 6-inch to 13-inch Non-reinforced Concrete Pavement (Includes Curbs)". 508.20.5.2 Strip Sodding. Payment of strip sodded areas shall be in accordance with Section 508.30.4.9.
9/1/2023
508-18
Subdivision Concrete Replacement
Section 508.30
Remove and Replace Paved Approach and Sidewalk
508.30.1 Description. This work will consist of removal and replacement of concrete paved approaches and concrete sidewalks in accordance with this specification or as directed by the Engineer. 508.30.2 Materials. All material, proportioning, air-entrainment, mixing, slump and transporting for Portland cement concrete shall be in accordance with Sections 501 and 505. All materials shall conform to Division 1000, Material Details, and specifically as follows: Item
Section
Reinforcing Steel for Concrete
1036
Concrete Curing Material
1055
Material for Joints
1057
508.30.2.1 Concrete Requirements. Concrete shall be in accordance with Section 508.10.2.1.1 and shall be made with lignite-free fine aggregate. Class B or PCCP concrete for approach and sidewalk items will be accepted in accordance with the applicable portions of Sections 501, 502 and 608 of the "Standard Specifications for Road and Bridge Construction". 508.30.2.2 Curb, Sidewalk, and Paved Approaches Mix Design. Curb, sidewalk and paved approaches require the use of Class B concrete with lignite-free sand in accordance with Section 501. The design 28-day concrete curb, sidewalk, and paved approach compressive strength, f´c, for this project will be 3,000 psi. The minimum compressive strength at the time paved approach is opened to P-Vehicle traffic only, in accordance with Section 508.10.2.1.1, shall be 1,100 psi. The minimum compressive strength of paved approach at the time of opening for all other vehicle types shall be 2,500 psi. The opening strength and 28-day compressive strength of concrete pavement will be determined by either concrete maturity or from concrete cylinders, field cured or lab cured, respectively. 508.30.2.3 Allowance for Testing. The Contractor shall make allowance for Engineer sampling of concrete for quality control testing purposes. Additional air entraining, slump and temperature tests shall be made by the Engineer at the time of placement when excessive variation in concrete workability is reported by the placing foreman or the Engineer in accordance with Section 508.20.1.1, "Excess Variation in Concrete".
9/1/2023
508-19
Subdivision Concrete Replacement
508.30.2.4 General. The resulting opening strength, after Engineer verification, will apply to concrete on the same project conforming to the following criteria: 1) Of the same mix design as the test location; 2) Cured under similar or more desirable conditions; 3) Placed on or before the test location. If direct productions compressive strength test results, cylinders, or maturity data, are not available, the Engineer may estimate compressive strength based on test results of concrete of the same mix design placed contiguously under similar conditions on the same project.
9/1/2023
508-20
Subdivision Concrete Replacement
508.30.2.5 Concrete Mix Design Submittal. Concrete mix design submittal shall be in accordance with Section 501.3.1. 508.30.2.6 Aggregate Base. Aggregate base material shall be in Section 1007.
accordance with
508.30.3 Equipment. Except as revised in Section 508.10.4, the equipment requirements of Section 502, "Portland Cement Concrete Pavement", shall apply to the construction of this work. 508.30.4 Construction Requirements. 508.30.4.1 Clearing Vegetation from the Pedestrian Access Route. This work shall consist of clearing and disposing of vegetation within the limits of the pedestrian access route. The pedestrian access route shall be defined as all sidewalks and curb ramps within the project limits. 508.30.4.1.1 Construction Requirements. All tree limbs, bushes, and other vegetation encroaching upon the pedestrian access route shall be trimmed horizontally to the edge of sidewalk and vertically to a minimum height of 80 inches. Work shall be performed before removal of any existing or construction of any new sidewalk. All cut surfaces over 1 inch in diameter shall be painted with tree paint or tar. Disposal of vegetative material shall be in accordance with Section 201. Tree and stump removal shall be performed in accordance with Sections 508.10.4.1.3 and 508.10.4.1.4, respectively. 508.30.4.2 Removals. No direct payment will be made for saw cutting and / or removing the paved approaches and sidewalks covered under this provision; for furnishing, placing, compacting, and maintaining the aggregate materials to a safe and usable condition (for temporary driveway access as needed); or for the removal of the aggregate material in preparation for the new paved approach. Removals will conform to the requirements of Section 202.30 and will extend to an existing joint or to a saw cut joint as hereinafter provided. 508.30.4.2.1 Concrete Removal and Replacement Adjacent to Asphaltic Concrete Pavement and Appurtenances. When removing and replacing concrete pavements and appurtenances abutting asphaltic concrete pavement and appurtenances, the following provisions will apply: 1) If sidewalk does not exist, the approach will be removed in accordance with Section 508.10.4. 2) When the pavement slab and / or sidewalk is being replaced, part of the driveway necessary for the placement of sidewalk forms will be removed to a saw cut line established by the Engineer. Both the approach and the portion of the driveway excavated to allow for forms will be backfilled with granular material and maintained by the Contractor to provide a safe, usable driveway. Contractor will schedule the restoration of the driveway with asphaltic concrete materials as time permits. The Contractor shall be responsible for the removal of the temporary aggregate material in advance of the restoration operation. The Engineer will coordinate the operations with the Contractor.
9/1/2023
508-21
Subdivision Concrete Replacement
508.30.4.2.2 Replacement of Concrete Paved Approaches and Sidewalks. Except as modified herein, paved approach and sidewalk construction will comply with the requirements of Sections 508.10.4 and 608. 508.30.4.3 Adjustment of Appurtenances. No direct payment will be made for the adjustment of street inlets associated with the removal and replacement of paved approaches and sidewalks. If required, removal and replacement of inlet stones, sills, and adjustment of manhole frames to grade will be paid at the contingent unit price included in the contract documents. 508.30.4.4 Mixing and Placement Requirements. 1) Placement of sidewalks and approaches may commence when the air temperature is 35ºF and rising with a projected high temperature above 40ºF. Placement of sidewalks and approaches will discontinue when the ambient temperature falls to 40ºF. Sidewalks and approaches may not be placed on days when the projected overnight low air temperature following the placement is below 25ºF. 2) The placement and finishing of the sidewalk and approaches must conform to the applicable provisions of Sections 502 and 608 regarding handwork. Proper consolidation and screening of the concrete will be required at all times. The use of a spud-type vibrator will be required for all items except 4-inch sidewalk. The use of water to aid in finishing the concrete will not be permitted unless specifically authorized by the Engineer. When so authorized, finish water may only be applied by use of a fine misting device, such as a Hudson sprayer. 508.30.4.5 Jointing of Concrete Sidewalks and Approaches. Concrete sidewalks and approaches will be jointed in accordance with the applicable provisions of Section 608 of the Standard Specifications. As directed by the Engineer, joint filler material and sealant for concrete approaches, sidewalks, and ramps shall meet the requirements of Section 1057. No direct payment will be made for joint fillers or sealants. 508.30.4.6 Curing and Weather Protection. Concrete sidewalk and approaches will be cured with material in accordance with Section 1055.4.2.3.1 and applied with equipment at the application rate in accordance with Section 502.3.3.8.1. Weather protection will be required per Section 508.10.4.7.1. When polyethylene sheeting is used, it should be the color specified in Section 502.6.3. 508.30.4.7 Backfill of Completed Approaches and Sidewalk. Completed approaches and sidewalks are to be backfilled with clean dirt, in accordance with Section 508.10.4.9. 508.30.4.8 Paved Approach and Sidewalk Opening. The paved approach or sidewalk shall not be opened for light traffic until the concrete is at least 24 hours old, reached a minimum compressive strength of 1,100 psi (as determined by field cast and cured cylinders or maturity method) or as directed by the Engineer.
9/1/2023
508-22
Subdivision Concrete Replacement
508.30.4.9 Strip Sodding. Following the completion of the backfilling and final grading operations, all disturbed areas 3 inches or more behind the form line shall be sodded. Sodding shall conform to Section 803 except as noted below. 1) Sod replacement shall be made to a straight line where it abuts existing grass areas. The straight line shall be produced by using a sod cutter. 2) Areas excavated during the period from June 1 to September 1 shall be sodded prior to October 31. Areas excavated at other periods shall be sodded within 30 calendar days after the completion of the adjacent improvements. 3) All disturbed areas shall be maintained by the contractor as directed by the Engineer until sodded. All disturbed areas shall be sodded by the end of the construction season. 4) Method of Measurement. Pay line limits will be 18 inches from form line on concrete paved approaches and 9 inches from form line on concrete sidewalks. No measurement will be made for areas disturbed beyond the limits specified. Quantities for strip sodding will be measured and computed to the nearest 0.1 square yard. 5) The contractor shall immediately water the newly transplanted sod and shall keep sod wet for 5 weeks (35 days), which may require daily watering. The engineer may elect to install a rain gauge in order to determine the amount of water supplied to the new sod. Sod shall be thriving and rooted at the time of acceptance. 6) Basis of Payment. The cost of all labor, equipment, and materials necessary to complete the work shall be included in the contract unit price for Bid Item No. 80320.00, "Strip Sodding". Payment for strip sodding with Zoysia sod will be made at twice the contract unit price, unless a unit bid item is so provided for Zoysia sod. Sodding beyond the specified limits will be considered incidental and no direct payment will be made. 508.30.5 Method of Measurement. Quantities for the removal and replacement of concrete sidewalk and paved approaches will be measured and computed to the nearest 0.1 square yard. 508.30.5.1 Clearing Vegetation from the Pedestrian Access Route. No separate measurement will be made for clearing vegetation The cost of all labor, equipment, and materials necessary to complete Clearing Vegetation from the Pedestrian Access Route shall be included in the contract unit bid price, per lump sum. 508.30.5.2 Aggregate Base. Payment for all labor, material, and equipment necessary to accomplish this item will be considered included in the contract unit price for "Type 5 Aggregate Base, 4 Inches Thick".
9/1/2023
508-23
Subdivision Concrete Replacement
508.30.6 Basis for Payment. 508.30.6.1 The cost of all labor, equipment, and materials necessary to complete this work shall be included in the contract unit price for the following items: 1) Item No. 304-05.04 - Type 5 Aggregate Base (4 Inches Thick) 2) Item No. 608-50.96 - Remove and Replace Paved Approach (6 Inches) 3) Item No. 608-60.94 - Remove and Replace Concrete Sidewalk (4 Inches Thick) 4) Item No. 608-60.96 - Remove and Replace Concrete Sidewalk (6 Inches Thick) 5) Item No. 608-60.93 - Remove and Replace Concrete Curb Ramp 508.30.6.2 The removal and replacement of each of the above items will be considered single bid items with both removal and replacement operations included in the contract unit price. Any required excavation and compaction of the subgrade shall be incidental to the item. No additional payment will be made for aggregate base in excess of four inches thick base placed under concrete channelization islands or medians. 508.30.6.3 No direct payment will be made for any saw cutting; it will be considered incidental. No direct payment will be made for furnishing and backfilling the completed replacement with Section 804, material suitable as a sod bed. No direct payment will be made for joint sealing. 508.30.6.4 The Contractor is cautioned that all work included in the item, including backfill must be completed in its entirety before the value of the item will be included in the Engineer's monthly payment estimate as provided for in Section 109.5. 508.30.6.5 Strip Sodding. Payment of strip sodded areas shall be in accordance with Section 508.30.4.9.
9/1/2023
508-24
Subdivision Concrete Replacement
Section 508.50
Sidewalk Grinding
508.50.1 Description. This item has been added to the Summary of Quantities and the Itemized Bid and is intended to provide the Engineer with the capability of directing the repair of sidewalk displaced 1 inch or less by grinding. The actual locations for this item have not been identified, and the quantity given is for establishing a unit price for this item. Final payment will be based on the actual number of locations ground. 508.50.2 Equipment. The equipment shall be a walk-behind gas powered scarifier no smaller than 190 lbs., 9 HP, 2-inch cutter, 8-inch widths, that shall be dry-cutting. The cutter shall be outfitted with tungsten carbide spike cutters to quickly reduce the raised sidewalk panel level through the pulverizing scarification process that tapers down the hard risers into fine concrete powders. No more than ¼ inch of material may be removed per pass. The final surface will have a smooth "non-slip" textured surface finish without any rough edges. The completed panel will have a surface color shaded lighter than the adjoining section. The Engineer may approve a hand-held scarifier no smaller than 15 lbs., 1.3 HP, 1¼ inch cutter, 2-inch widths, when working in tight locations and for squaring-up the scarifier's finishes. 508.50.3 Construction. The Engineer will approve all grinding locations. All work shall be compliant with ADA standards (See ADA Post Inspection Checklist). The finished surface shall have a clean, non-slip and broom-like appearance with no grinding transition exceeding a 1:12 (V:H) ratio in accordance with the following limits: Horizontal (H) Grinding Limits, Inches Vertical Rise (V), Inch Minimum
Maximum
½
6
12
¾
9
18
1
12
24
508.50.3.1 Any remaining concrete powders shall be collected from the sight by broom or vacuum and disposed of by a method approved by the Engineer. Grinding shall not result in water ponding. 508.50.4 Method of Measurement. The accepted sidewalk grinding will be measured per each location ground (may include portions of two abutting sidewalk slabs). 508.50.5 Basis of Payment. Payment for the above described work including all materials, equipment, labor, and any other incidental work necessary to complete this item shall be completely covered by the contract unit price for Bid Item No. 412-20.00, "Sidewalk Grinding". Payment shall be made per each location ground (includes the abutting sidewalk slab). If no pay item exists in the contract, payment for Sidewalk Grinding will be made per each at the fixed cost specified in section109.4.5.
9/1/2023
508-25
Subdivision Concrete Replacement
Section 509
Portland Cement Concrete Base
509.1 Description. This work shall consist of placement, finishing, and curing a Portland cement concrete base, with or without reinforcement as specified, on a prepared base (aggregate or hot mix asphalt) and subgrade in accordance with these specifications and in conformity with the lines, grades, thicknesses, and typical cross sections shown on the plans or established by the Engineer. 509.2 Materials. All material, proportioning, water-to-cementitious ratio, air-entrainment, mixing, slump, air entrainment, and transporting for Portland cement concrete base shall be in accordance with Section 501and Division 1000, Materials Details, and specifically as follows: Item
Section
Reinforcement for Concrete Pavement
1036.4
Concrete Curing Material
1055
Materials for Joints
1057
Emulsified Asphalt (SS-1, SS-1H, CSS-1, or CSS-1H)
1015
Compressive Strengths. Portland cement concrete base pavement shall have a minimum 28-day compressive strength as specified in accordance with Section 501. 509.2.1 Allowance for Testing. The Contractor shall make allowance for sampling of concrete for quality control testing purposes. 509.2.1.1 The Engineer shall reject any Very Early Opening Strength base area that develops 1 or more transverse cracks within 21 days after placement. The contractor shall remove and replace this concrete base with Very Early Opening Strength concrete that complies with the specifications. A transverse crack is a crack running from one longitudinal edge of the panel to the other. 509.3 Equipment. Except as revised in Section 509.4, the equipment requirements of Section 502, "Portland Cement Concrete Pavement", shall apply to the construction of this work. Approved sliding form construction methods may be used at the contractor's option. 509.4 Construction Requirements. The construction of concrete base shall be performed in accordance with the requirements of Section 502, "Portland Cement Concrete Pavement", with the following modifications: 1) Surface Finish. The surface shall be finished in accordance with Section 502.4.7.8.3 "Artificial Turf", Section 502.4.7.8.1 "Texturing with Wire Comb", or Section 502.4.7.8.4 "Wet Burlap or Broom". Mechanical floating will not be required for the surface finish. The surface of the base shall be finished so that it will not vary more than ¼ inch from a 10-foot straightedge.
9/1/2023
509-1
Portland Cement Concrete Base
2) Curing. Membrane curing shall not be used. In addition to any of the other methods permitted by Section 502.6.3, emulsified asphalt used in accordance with Section 502.6.2.1 "Concrete to be Overlaid with Hot Mix Asphalt", may be used to cure the concrete base if the surface course is to be of a bituminous type. When weather conditions require thermal protection, use shall be in accordance with Section 502.6.6 "Thermal Curing Blankets". Application of curing blankets for Very Early Opening Strength base concrete shall be based on ambient temperature and desired opening time in accordance with the following table:
4-6 Hour Very Early Strength Opening to Traffic Temperature Retention Requirements * Minimum Ambient Temperature Range in Curing Period
Opening Time (T), (Hours)
≤ 80°F **
Yes
> 80°F
No
4≤T≤6
* To reduce thermal cracking thermal curing shall be removed when the concrete temperature reaches 140°F. Moist curing shall continue through to the time of opening.
** Concrete exposed to temperatures below 40°F will require a minimum of 2 curing blankets.
3) Sawing of Joints. Joints shall be sawed in accordance with Section 502.5.7 "Sawing of Joints” and shall not be sealed with joint sealing material. 4) Widening an Existing Pavement 8 Feet or Less in Width. Either mechanical or approved manual methods may be used in preparing the subgrade and for grading and tamping the forms. The type and spacing of transverse joints will be designated in the contract. A batch-type mixer having a rated capacity of not less than 10 cubic feet of mixed concrete may be used when approved by the Engineer. Either manual or mechanical methods may be used for finishing the concrete after thorough consolidation by vibrating. 5) Jointed Concrete Pavement to Jointed Concrete Pavement Transition. The transition between two jointed concrete pavements that have different thicknesses involves a tapered section that is approximately 2 feet-6 inches in length along the length of the poured slab. Tie bar and dowel bar diameter is determined by the thicker slab and shall be drilled at the mid-depth of the thinner slab.
9/1/2023
509-2
Portland Cement Concrete Base
509.5 Material Acceptance. Pavement shall be constructed strictly in accordance with the thickness, entrained air and compressive strength shown in the contract documents. The thickness and compressive strength of the pavement will be measured in accordance with Section 502.12, and where any pavement is found deficient in thickness, it may be compensated for at an adjusted unit price per square yard or shall be removed and replaced with satisfactory pavement in accordance with Section 502.15. 509.5.1
Repairing Defects. Repair defects in accordance with Section 502.13 "Repairing Defects”.
509.6 Method of Measurement. Final measurement of the completed concrete base will not be made except for authorized changes during construction, or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. Concrete base areas will be computed to the nearest 0.1 square yard. 509.7 Basis of Payment. The basis of payment shall be in accordance with Section 502.15 "Basis of Payment" and specifically as follows: 509.7.1 The contract unit bid price for Portland Cement Concrete Base will be considered as full compensation for all materials and other items including reinforcement entering into the construction of the base, and no additional compensation will be allowed for any excess thickness. No direct payment will be made for emulsified asphalt used as a curing agent.
9/1/2023
509-3
Portland Cement Concrete Base
(This Page Intentionally Left Blank)
9/1/2023
509-4
Portland Cement Concrete Base
Division 600
INCIDENTAL CONSTRUCTION
9/1/2023
600-1
Incidental Construction
(This Page Intentionally Left Blank)
9/1/2023
600-2
Incidental Construction
Standard Specifications for Road and Bridge Construction Division 600 - Incidental Construction Section
Description
Revision Date
601......Field Laboratories .....................................................................................................1/1/2016 602......Markers and Monuments..........................................................................................1/1/2016 603......Miscellaneous Water Equipment ..............................................................................1/1/2016 603.10.......Water Main Installation (Greater than 2 Inches) ......................................... 603-1 603.20.......Water Service Connections ...................................................................... 603-10 604......Miscellaneous Drainage ...........................................................................................9/1/2023 604.10.......Concrete Headwalls, Drop Inlets and Manholes ........................................ 604-1 604.20.......Adjusting Drainage Facilities ...................................................................... 604-6 604.30.......Adjusting House Sewer Connections ......................................................... 604-7 604.40.......Pipe Collars ................................................................................................ 604-8 604.50.......Connecting Pipe to Existing Structures ...................................................... 604-9 605......Underdrainage ..........................................................................................................1/1/2016 605.10.......Class A Underdrain .................................................................................... 605-1 605.20.......Class B Underdrain .................................................................................... 605-3 605.30.......Class C Underdrain .................................................................................... 605-4 606......Guardrail and Roadway Barriers ..............................................................................1/1/2016 606.10.......Guardrail ..................................................................................................... 606-3 606.20.......Guard Fence .............................................................................................. 606-7 606.30.......Crashworthy End Terminals ....................................................................... 606-8 606.40.......One-Strand Access Restraint Cable........................................................... 606-9 606.50.......Three-Strand Guard Cable ....................................................................... 606-10
9/1/2023
600-3
Division 600 - Index
Section
Description
Revision Date
607......Fencing .....................................................................................................................1/1/2016 607.10.......Chain-Link Fence ....................................................................................... 607-1 607.20.......Woven Wire Fence ..................................................................................... 607-3 607.30.......Handrails .................................................................................................... 607-5 608......Concrete Medians, Median Strips, Sidewalks, Curb Ramps, Steps and Paved Approaches ...................................................................................................9/1/2023 609......Paved Drainage ........................................................................................................9/1/2023 609.10.......Concrete Curb, Gutter and Paved Ditch ..................................................... 609-1 609.20.......Integral Curb ............................................................................................... 609-3 609.30.......Asphalt Curb ............................................................................................... 609-5 609.40.......Drain Basin ................................................................................................. 609-7 609.60.......Ditch Liner .................................................................................................. 609-8 609.70.......Rock Lining ................................................................................................. 609-9 610......Masonry Construction...............................................................................................1/1/2016 611......Embankment Protection ...........................................................................................1/1/2016 611.10.......Rock Fill ...................................................................................................... 611-1 611.20.......Fully Grouted Rock Fill ............................................................................... 611-2 611.30.......Rock Blanket .............................................................................................. 611-3 611.40.......Grouted Rock Surface ................................................................................ 611-4 611.50.......Revetment .................................................................................................. 611-5 611.60.......Concrete Slope Protection.......................................................................... 611-6 611.70.......Gabions ...................................................................................................... 611-7 612......Traffic Control Devices .............................................................................................1/1/2016 612.30.......Standard Traffic Control Devices................................................................ 612-3 612.40.......Detour Lighting ........................................................................................... 612-6 612.50.......Project Information Signs ........................................................................... 612-7 612.60.......Temporary Excavation Fencing .................................................................. 612-8 612.70.......Advanced Warning Arrow Panel ................................................................ 612-9 612.80.......Nighttime Worksite Lighting Requirements .............................................. 612-10 613......Pavement Repair ....................................................................................................3/15/2022 614......Drainage Fittings ......................................................................................................1/1/2016 614.10.......Grates and Bearing Plates ......................................................................... 614-1 614.20.......Automatic Floodgate................................................................................... 614-2 614.30.......Gray Iron Castings for Manhole or Inlet Frame, Cover and Gratings ......... 614-3
9/1/2023
600-4
Division 600 - Index
Section
Description
Revision Date
615......Office for Engineer....................................................................................................1/1/2016 616......Traffic Control Plan ...................................................................................................1/1/2016 617......Concrete Median Barrier ..........................................................................................1/1/2016 618......Mud Jacking .............................................................................................................1/1/2016 619......Mobilization...............................................................................................................1/1/2016 620......Inlaid Pavement Markers ..........................................................................................1/1/2016 621......Temporary Pavement Markings ..............................................................................9/1/2023 622......(Removed) ................................................................................................................9/1/2023 623......Concrete Bonding and Epoxy Mortar .......................................................................1/1/2016 623.10.......Concrete Bonding Compound .................................................................... 623-1 623-20 ......Epoxy Mortar .............................................................................................. 623-2 624......Geotextile Construction ............................................................................................1/1/2016 625......Flowable Fill (Controlled Low-Strength Materials) ....................................................1/1/2016 625.10.......Excavatable Flowable Fill ........................................................................... 625-1 625.20.......Non-Excavatable Flowable Fill ................................................................. 625-10 626......Temporary Steel Plate Trench Bridging ...................................................................1/1/2016 627......Diamond Grinding of Portland Cement Concrete or Bituminous Pavement .............9/1/2023 628......Keyhole Coring and Repair ......................................................................................1/1/2016
9/1/2023
600-5
Division 600 - Index
(This Page Intentionally Left Blank)
9/1/2023
600-6
Division 600 - Index
Section 601
Field Laboratories
601.1 Description. This work shall consist of providing one or more field laboratories at the quarry or manufacturing plant site designated by the Engineer. 601.1.1 Laboratory Requirements. A laboratory shall be furnished for each item of work that requires inspection at a quarry or manufacturing plant. Separate laboratories will not be required for successive items of work when any preceding item has been completed, provided that the laboratory complies with the requirements for specific work. Additional laboratories may be required for the proper control of the work when simultaneous operations on the same item of work are being carried on at more than one location separated by a distance of one mile or more and separate testing operations are necessary. The Engineer will specify the number of laboratories required based on the operations of the Contractor. 601.1.2 The laboratory shall be located and maintained at the site of current operations by the Contractor's material supplier. Work that requires the use of a field laboratory will not be permitted until a laboratory is provided. This requirement also applies to job-site portable manufacturing plants. The laboratory shall remain the property of, and shall be disposed of by the Contractor upon completion of the work requiring the laboratory. 601.2 Type 1 Field Laboratory. The laboratory shall be substantially constructed and weatherproof with wood or concrete floors, windows on at least two sides and at least one outside door. Windows and doors shall be equipped with screens and locks, and the necessary keys shall be furnished to the Engineer. The laboratory shall have a minimum of 120 square feet of floor space. The ceiling shall be no less than 7 feet high. The laboratory shall have at least one worktable 30 inches high with a smooth one-piece top, no less than 8 feet long and 30 inches wide. The laboratory shall be equipped with a storage shelf, a fire extinguisher having a minimum underwriter's laboratory rating of 4A60BC, a desk and chair. An operational electric hot plate or gas burner, having no less than two burners with adjustable temperature controls, and capable of accommodating two 14" x 20" sample pans shall be provided. A faucet equipped sink capable of accommodating a 14" x 20" sample pan and connected to an operating potable water source of at least 50-gallon capacity shall be provided. The Contractor shall keep an adequate supply of potable water available at all times. Lighting facilities shall be located to adequately illuminate all work in the interior of the laboratory. A minimum of three grounded electrical outlets with 110-120 volts, 60-Hertz continuous current and a climate control capable of maintaining an ambient temperature range of 72°F to 80°F shall be provided. Suitable on-site sanitary facilities meeting Federal, State and local health department requirements shall be provided and maintained clean and in good working condition and stocked with laboratory and sanitary supplies at all times material is being tested by the Department. Laboratories shall be relocated on the manufacturing site as directed by the Engineer. 601.2.1 Mobile Units. Mobile units used with the approval of the Engineer, shall be tied down near the four corners at each end of the mobile unit with tie-down equipment of the type commonly sold by mobile home equipment suppliers and made to the satisfaction of the Engineer. Mobile units shall be adequately blocked and leveled. A landing of minimum 3' x 3' dimension shall be provided at each doorway with integral steps and railing.
1/1/2016
601-1
Field Laboratories
601.3 Type 2 Field Laboratory. The laboratory shall have a minimum of 200 square feet of floor space. The laboratory shall be constructed with a dividing wall and doorway to allow for a separate testing work area and an office area suitable for computer operation meeting the Engineer's approval. The laboratory shall be provided with an exhaust fan capable of moving a volume of air equal to at least ten times the volume of the laboratory each hour. When required by Section 502, at least one window shall provide a direct view of plant operations. 601.4 Type 3 Field Laboratory. The laboratory shall be in accordance with Section 601.3, except as follows. At least one window shall provide a direct view of plant operations. The laboratory shall have a minimum of 200 square feet of floor space. 601.4.1 When required by Sections 404 or 405, a thermostatically controlled operating oven, capable of maintaining a minimum temperature of 230°F and having a capacity to accommodate at least one standard gallon can, shall be furnished. The laboratory required in Sections 404, 405, and 1001 shall contain a sieve shaker in accordance with AASHTO T 27, including time controls, a minimum sieve stacking height of 28 inches, platform adapters to accommodate 8 or 12 inch sieves, and a sample splitter meeting AASHTO T 248 requirements, having a minimum length of 20 inches with 2 inch maximum opening size and complete with a minimum of three pans. 601.4.2 When required by Sections 404, 405 and 1001, the laboratory shall have a minimum of two outside doors and four windows. The outside doors shall be located so as to permit ingress and egress from opposite ends of the building. Each window shall provide at least 4 square feet of glazed area. The laboratory shall have a minimum of 200 square feet of floor space with a minimum width of 8 feet. An exhaust fan will be provided that is capable of moving a volume of air each hour equal to at least ten times the volume of the laboratory. Anchored tables of adequate dimensions shall be furnished. All tables shall have smooth one-piece tops. The laboratory shall be equipped with storage shelves, a minimum of four chairs, and a two-drawer filing cabinet. Circuitry shall be such that all indicated equipment can be used without disruption. 601.5 Basis of Payment. Unless otherwise specified, no direct payment will be made for Type 1, 2 or 3 Field Laboratories. No direct payment will be made for furnishings, systems or laboratory maintenance, utilities, heating and cooling facilities, repairs or replacement, for damage due to vandalism, theft or other criminal activities, and other operation expenses including laboratory operation and fuel, laboratory mobilization and final removal of the laboratory.
1/1/2016
601-2
Field Laboratories
Section 602
Markers and Monuments
602.1 Description. This work shall consist of constructing markers, of the type required by the contract, at the locations shown on the plans or as directed by the Engineer. Markers will be as follows: 1)
Drain Marker
2)
Steel Right-of-Way Marker
3)
Concrete Right-of-Way Marker
602.1.1 Monuments shall be installed, where required, in accordance with the Subdivision Ordinance of St. Louis County. 602.2 Materials. 602.2.1 All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Steel Post for Marker ............................................................1044.2.2 602.2.2 Right-of-way and drain marker plaques and fasteners will be furnished at the job site by the County at no cost to the Contractor. 602.2.3 Concrete for setting drain markers and steel right-of-way markers shall be subject to the approval of the Engineer and shall have a cement content of not less than 470 pounds per yard of concrete. Concrete right-of-way markers shall be constructed of Class A, A-1, B, or B1 concrete. 602.3 Construction Requirements. 602.3.1 Steel markers shall be set with the legend facing the centerline of the highway. Posts may be driven, set in concrete, or set with a quick setting polyurethane foam in accordance with Section 607.23.3. Posts having battered or mushroomed tops will not be accepted. Posts shall be set vertical at locations shown on the plans or as designated by the Engineer and the plaques firmly attached. 602.3.2 Concrete right-of-way markers shall be constructed to the design and dimensions shown on the plans. Markers shall be set vertical, with the top flush with the finished ground surface or pavement surface. Where markers are located within or adjacent to an area paved with Portland cement concrete, the marker shall be separated from the paved area with ¼ inch preformed bituminous filler extending the full depth of the paved area. 602.4 Basis of Payment. The accepted quantity of markers will be paid for at the unit bid price for each of the pay items included in the contract. No direct payment will be made for concrete, polyurethane, or for grout when required.
1/1/2016
602-1
Markers and Monuments
(This Page Intentionally Left Blank)
1/1/2016
602-2
Markers and Monuments
Section 603
Miscellaneous Water Equipment
Section 603.10 Water Main Installation (Greater than 2 Inches) 603.10.1 Description. This work shall consist of furnishing materials for, and installing water lines and appurtenances in conformity with the lines and grades shown on the plans or established by the Engineer. 603.11 Adjusting Water Service Main, Meters and Valve and Pyramid Meter Boxes. The tops of all valve and meter boxes shall be adjusted to the finished grade. Meters and meter boxes located within the limits of roadways and ditches shall be relocated outside the right-of-way as directed. 603.12 Materials. 603.12.1 All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Portland Cement Concrete ...........................................................501 Reinforcing Steel for Concrete .................................................. 1036 Item
Specification
Cast Iron Pipe 3 to 24 Inch Diameters ........................................... AWWA C106 3 to 48 Inch Diameters ........................................... AWWA C108 Gate Valves ............................................................ AWWA C500 Butterfly Valves....................................................... AWWA C504 Hydrants ................................................................. AWWA C502 Item
Specification
Ductile Iron Pipe 3 to 48 Inch Diameters ........................................... AWWA C511 Cast Iron and Ductile Iron Fittings ................................ AWWA C110 Rubber Gasket Joints ................................................... AWWA C111 Cement Mortar Lining ................................................... AWWA C104 Seamless Copper Water Tube ...........................ASTM B 88, Type K
1/1/2016
603-1
Miscellaneous Water Equipment
603.12.2 Pipe and fittings shall be lined, cast iron or ductile iron, bell and spigot with mechanical or push-on joint. Cast iron pipe shall have a minimum working pressure of 150 pounds per square inch. Pipe 3 to 20 inch diameter, inclusive, shall be thickness Class 22 or higher, and pipe 24 to 48 inch diameter, inclusive, shall be thickness Class 23 or higher. 603.12.3 Service connections greater than 2 inch inside diameter shall be cast iron or ductile iron. 603.12.4 The Contractor shall furnish manufacturers' certifications in triplicate certifying that all of the specified tests have been made and that the materials and fittings comply with the requirements of the specifications. 603.13 Construction Requirements. 603.13.1 Materials furnished by the Contractor shall be distributed along the site of the work, with each section of pipe unloaded opposite or near the place where it is to be laid in the trench. Pipe, fittings, valves, hydrants, and other heavy accessories shall be carefully handled by the use of hoists or skidways to avoid shock or damage. Pipe handled on skidways shall not be skidded or rolled against pipe already on the ground. 603.13.2 Service shall not be interrupted without the approval of the Engineer and of the proper utility official. The Contractor shall arrange his work to interrupt services the shortest possible time. Prior notice of at least 24 hours shall be given the proper utility official and the Engineer before any main is shut off. In no case shall a valve or hydrant be opened or shut without proper authorization. 603.13.3 Trenches shall be excavated so that the pipe can be laid to the alignment and minimum depth designated on the plans, except that approved changes may be made to avoid obstructions or to connect to an existing line. The width of the trench shall be sufficient to permit the pipe to be laid and joined properly and the backfill to be placed and compacted as specified. The Contractor shall carefully expose existing water, gas, and sewer services, and other underground structures for a sufficient distance ahead of pipe laying to determine the grade and alignment of the pipe to be laid. 603.13.3.1 The trench shall be prepared to provide a uniform and continuous support for the pipe between bell holes, except that the finished pipe grade may be disturbed by the withdrawal of pipe slings or other lifting tackle. Ledge rock, boulders, and large stones shall be removed to provide a clearance below and on each side of all pipe and pipe appurtenances of at least 6 inches for pipe 24 inches or less in diameter, and 9 inches for pipe larger than 24 inches in diameter. If other unsuitable material is encountered at the pipe grade, the trench shall be excavated to at least 3 inches below the grade. Before the pipe is laid, any part of the trench excavated below grade shall be backfilled, at the Contractor's expense, with an approved material, placed in thoroughly compacted layers not more than 3 inches thick.
1/1/2016
603-2
Miscellaneous Water Equipment
603.13.4 Pipe fittings, valves, and hydrants shall be carefully lowered into the trench to prevent damage to water main materials and to protective coatings and linings. Water main materials shall not be dropped or dumped into the trench. The pipe and fittings shall be inspected for defects, and while suspended above grade shall be rung with a light hammer to detect cracks. Precautions shall be taken to prevent foreign material from entering the pipe while it is being placed in the line. An approved plastic sleeve shall completely cover the pipe and shall be connected to adjoining sleeves to produce a uniform waterproof barrier. 603.13.4.1 After placing the length of pipe in the trench, the spigot end shall be centered in the bell and the pipe forced home and brought to correct line and grade. The pipe shall be temporarily secured in place with approved, thoroughly tamped backfill material, except at the bells. Cutting of the pipe for inserting valves, fittings, or closure pieces shall be done in a neat and workmanlike manner without damage to the pipe or lining. Cut ends and rough edges shall be ground smooth, and for push-on joint connections, the ends shall be beveled. Gray cast iron pipe may be cut using a hydraulic squeeze cutter, abrasive pipe saw, rotary wheel cutter, guillotine pipe saw, or milling wheel saw. Ductile iron pipe may be cut using an abrasive pipe saw, rotary wheel cutter, guillotine pipe saw, milling wheel saw, or oxyacetylene torch. Unless otherwise permitted by the Engineer, pipe shall be laid with the bell ends facing in the direction of the laying. Where the pipe is laid on a grade of 10 percent or greater, the laying shall start at the bottom. If necessary to deflect the pipe from a straight line either in the vertical or horizontal plane, the deflections shall not exceed that shown in Tables I or II. The open ends of the pipe shall be closed by a watertight plug or other suitable means when pipe laying is not in progress. If water is in the trench, the seal shall remain in place until the trench is pumped completely dry. No pipe shall be laid in water.
1/1/2016
603-3
Miscellaneous Water Equipment
TABLE 1 Maximum Deflection Full Length Pipe-Mechanical Joint Pipes Size of Pipe (in.)
1/1/2016
Deflection Angle, (deg-min)
Max Deflection (in.)
Approx. Radius of Curve Produced by Succession of Joints (ft.)
18 ft. Length
20 ft. Length
18 ft. Length
20 ft. Length
3
8-18
31
35
125
140
4
8-18
31
35
125
140
6
7-7
27
30
145
160
8
5-21
20
22
195
220
10
5-21
20
22
195
220
12
5-21
20
22
195
220
14
3-35
13.5
15
285
320
16
3-35
13.5
15
285
320
18
3-0
11
12
340
380
20
3-0
11
12
340
380
24
2-23
9
10
450
500
30
2-23
9
10
450
500
36
2-5
8
9
500
550
42
2-0
7.5
8
510
570
48
2-0
7.5
8
510
570
603-4
Miscellaneous Water Equipment
TABLE II Maximum Deflection Full Length Pipe-Push-on Joint Pipes Size of Pipe (in.)
Deflection Angle, (deg-min)
Max Deflection (in.)
Approx. Radius of Curve Produced by Succession of Joints (ft.)
18 ft. Length
20 ft. Length
18 ft. Length
20 ft. Length
3
5
19
21
205
230
4
5
19
21
205
230
6
5
19
21
205
230
8
5
19
21
205
230
10
5
19
21
205
230
12
5
19
21
205
230
14
3
11
12
340
380
16
3
11
12
340
380
18
3
11
12
340
380
20
3
11
12
340
380
24
2
11
12
340
380
30
2
7.5
8
510
570
36
2
7.5
8
510
570
42
2
7.5
8
510
570
48
2
7.5
8
510
570
603.13.4.2 Bends deflecting 22½ degrees or more, and all plugs, caps, and tees, shall be provided with a reaction backing. Concrete backing shall be placed between solid ground and the fitting to be anchored. The bearing area of the reaction backing shall be as shown on the plans or as authorized by the Engineer. The backing shall be so placed that the pipe and fitting joints will be accessible for repairs. Concrete for reaction backing shall be any of the mixtures specified in Section 501. No direct payment will be made for reaction backing.
1/1/2016
603-5
Miscellaneous Water Equipment
603.13.5 Mechanical and Push-on Joints. 603.13.5.1 Mechanical Joint Pipe. The last 8 inches outside of the spigot, and the inside of the bell of mechanical joint pipe shall be thoroughly cleaned to remove oil, grit, excess coating, and other foreign matter from the joint, and then painted with an approved commercial lubricant. The cast iron gland shall then be slipped on the spigot end of the pipe with the lip extension of the gland toward the socket or bell end. The rubber gasket shall be painted with an approved commercial lubricant and placed on the spigot end with the thick edge toward the gland. The pipe shall be pushed forward to seat the spigot end in the bell. The gasket shall then be pressed into place within the bell. Care shall be taken to locate the gasket evenly around the entire joint. The cast iron gland shall be moved into position for bolting. All nuts shall be tightened with a torque-limiting wrench. The torque for various sizes of bolts shall be as follows: Size (Inch)
Range of Torque (Foot Pounds)
⅝ inch ....................................................................................45 to 60 ¾ inch ....................................................................................75 to 90 1 inch ...................................................................................85 to 100 1¼ inch ..............................................................................105 to 120 Nuts spaced 180 degrees apart shall be tightened alternately in order to produce an equal pressure on all parts of the gland. 603.13.5.2 Push-on Joint Pipe. The inside of the bell and the outside of the spigot end shall be thoroughly cleaned to remove oil, grit, excess coating, and other foreign matter. The circular rubber gasket shall be flexed inward and inserted in the gasket recess of the bell socket. A thin film of gasket lubricant shall be applied to either the inside surface of the gasket or the spigot end of the pipe or both. Gasket lubricant shall be as supplied by the pipe manufacturer and approved by the Engineer. The spigot end of the pipe shall be entered into the socket with care to keep the joint from contacting the ground. The joint shall then be completed by forcing the plain end to the bottom of the socket with a forked tool or jack-type tool or other device approved by the Engineer. Pipe that is not furnished with a depth mark shall be marked before assembly to insure that the spigot end is inserted to the full depth of the joint. Field-cut pipe lengths shall be filed or ground to resemble the spigot end of such pipe as manufactured. 603.13.5.3 A special adapter shall be used for joining two lines having the same inside diameter and different outside diameters. 603.13.6 Valves shall be set and jointed to the pipe at the locations shown on the plans, or as directed by the Engineer, in the manner specified for cleaning, laying, and jointing pipe fittings. A valve box shall be provided for every valve. The valve box shall not transmit shock or stress to the valve and shall be centered and plumb over the wrench nut of the valve, with the box cover flush with the finished surface.
1/1/2016
603-6
Miscellaneous Water Equipment
603.13.6.1 Tapping and inserting valves shall be installed in existing mains under pressure, as shown on the plans or as directed by the Engineer in accordance with instructions furnished by the manufacturer of the drilling machine, valves, and sleeves. 603.13.7 Hydrants shall be located as shown on the plans, or as directed by the Engineer, to provide complete accessibility, and to minimize the possibility of damage from vehicles or injury to pedestrians. Hydrants shall be plumb, with the nozzles at least 12 inches above the finished surface. Each hydrant shall be connected to the main with a 6-inch branch controlled by an independent 6-inch gate valve. A drainage pit 2 feet in diameter and 3 feet deep shall be excavated below each hydrant. The pit shall be backfilled with coarse gravel or crushed stone, mixed with sand, under and around the elbow of the hydrant to a level 6 inches above the waste opening. 603.13.8 If necessary to join pipe of dissimilar metals, a method of insulation against the passage of electric current shall be provided as approved by the Engineer. 603.13.9 All dead ends on new mains shall be closed with cast iron plugs or caps with suitable blow off assemblies. 603.13.10 Existing service connections to any portion of a main to be retired shall be transferred by relocating and connecting to the new main. The relocated portion shall not be smaller than that originally in place. Service connections to be disconnected shall be shut off at the corporation cock and the corporation cock rendered unusable. 603.13.11 In relocating meters, the Contractor shall furnish and install new pyramid meter boxes, and covers or vaults, meter yokes, and such fittings as may be required to complete the relocation. 603.13.12 Connections between new mains and existing mains shall be made only after the new mains have been tested, chlorinated, and flushed. 603.13.13 Hydrostatic Tests. After installation of the pipe, the trench shall be partially backfilled having the joints exposed for examination. The pipe shall then be subjected to hydrostatic tests performed in accordance with Section 4 of the American Water Works Association Specifications, Designation AWWA C 600. Water used in this test shall be furnished by the Contractor and shall be of satisfactory bacteriological quality for drinking purposes. No pipe installation will be accepted until favorable test results have been achieved. Any defective joints and any defects in pipe, fittings, valves, or hydrants revealed during this test shall be repaired or replaced and again tested until the work is satisfactory, at the Contractor's expense. The equipment required for hydrostatic testing shall be furnished by the Contractor. 603.13.14 Abandoned water mains shall be plugged and sealed watertight by means of a cast iron plug or cap, or by covering the end of the pipe with concrete of any of the mixtures specified in Section 501. The concrete cover shall provide a minimum of 6 inches cover around the outside of the pipe and shall extend a minimum of 6 inches in each direction from the end of the pipe. All existing valves, which will have pressure on one side and an abandoned main on the other side, shall be closed with a cast iron plug and blocked with reaction backing on the side where the main has been abandoned. A portion of the abandoned pipe shall be removed to allow clearance for the plugging and backing. No direct payment will be made for this work. 1/1/2016
603-7
Miscellaneous Water Equipment
603.13.15 Material placed around and 12 inches above the top of the pipe shall be free from cinders, ashes, refuse, boulders, rocks, or other unsuitable material. The remainder of the trench shall be backfilled in accordance with the applicable provisions of Section 726.6. 603.13.16 Encasement, if required, shall be one of the following types as specified in the contract: a) Conduit which will permit the removal and replacement of the water pipe. b) Reinforced concrete placed around the water pipe as shown on the plans. Concrete shall be Class B. 603.13.17 The completed water line installation shall be disinfected in accordance with the provisions of the St. Louis County Department of Health. No direct payment will be made for disinfecting water lines. 603.14 Method of Measurement. 603.14.1 Measurement of pipe complete in place, including joint accessories and service connections greater than 2 inch inside diameter, will be made to the nearest linear foot along the geometrical center of the pipe with no exceptions for valves or fittings. Contract quantities will be used for final payment except as hereinafter provided. 603.14.2 Rock encountered in trenching will be measured to the nearest cubic yard and paid for only when pay item 603-80.00, "Rock Excavation", is included in the contract. Measurement of the volume to be paid for in rock excavation will be a width 18 inches greater than the inside diameter of the pipe and a depth from the surface of the rock as determined by the Engineer to a plane 6 inches below the outside bottom of the pipe or to the bottom of the rock, whichever is higher. The term "Rock Excavation" is defined as that excavation which would be classified as Class C, Sandstone, or Igneous Rock Excavation in Section 203. It shall be the Contractor's responsibility to notify the Engineer before removing any such material. Any rock excavation removed before the Engineer has been notified and has established lines of demarcation will not be measured or paid for. 603.14.3 Measurement of fittings will be the theoretical weight to the nearest 5 pounds, regardless of type of fitting used, as determined in accordance with AWWA Standards. Accessories required for fittings will be considered as part of the fitting. Contract quantities will be used for final payment except as hereinafter provided. 603.14.4 Measurement for relocating water main connections over 2 inch inside diameter will be made to the nearest linear foot. Contract quantities will be used for final payment except as hereinafter provided. 603.14.5 Measurement of encasement conduit will be made to the nearest linear foot along the geometrical center of the conduit. Contract quantities will be used for final payment except as hereinafter provided. 603.14.6 Measurement of reinforced concrete encasement, including reinforcing steel, will be made to the nearest 1/10 cubic yard. Contract quantities will be used for final payment except as hereinafter provided. 1/1/2016
603-8
Miscellaneous Water Equipment
603.14.7 Measurement for relocating water service meter and pyramid meter, and valve box or vault will include all hardware, fittings, main meter yokes, and appurtenances necessary to complete this item, and will be made per each. 603.14.8 For those items on which final payment is based on contract quantities, final measurement will not be made except for authorized changes during construction, or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. 603.15 Basis of Payment. Accepted water main installation will be paid for at the unit bid price for each of the pay items included in the contract. No direct payment will be made for any incidental items necessary to complete the work unless specifically provided as a pay item in the contract. No direct payment will be made for excavation or backfill except as noted in Section 603.14.2. In relocating service connections with 2 inch inside diameters or less payment will be made in accordance with Section 603.20. 603.15.1 Rock excavation in trench will be paid at the contract unit bid price when a part of the contract, or if not so included, in accordance with Section 726. 603.15.2 Payment for relocating meter and pyramid valve box or vault will be at contract unit bid price. No payment will be made for adjusting pyramid meter valve box or vault to grade when such adjustments are less than 3 inches vertically. When such adjustment exceeds 3 inches, it will be paid as a separate item.
1/1/2016
603-9
Miscellaneous Water Equipment
Section 603.20 Water Service Connections 603.21 Description. This work shall consist of furnishing materials for, and installing water lines and appurtenances in conformity with the lines and grades shown on the plans or established by the Engineer. 603.22 Materials. 603.22.1 All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Portland Cement Concrete ...........................................................501 Reinforcing Steel for Concrete .................................................. 1036 Specification Copper Water Tube ............................... ASTM B 88M (B88), Type K 603.22.3 Service connections 2 inch inside diameter or less shall be seamless copper water tube. 603.22.4 The Contractor shall furnish manufacturers' certifications in triplicate certifying that all of the specified tests have been made and that the materials and fittings comply with the requirements of the specifications. 603.23 Construction Requirements. 603.23.1 All work shall conform to the requirements of the County Plumbing Code as shown on Standard Drawing 603.10. Separate pay items are included in the bid for "Expose Water Service House Lead"; "Relocation of Water Service House Lead"; "Relocating Service Valve and Box to Grade"; "Adjust Water Service Valve Box to Grade"; "Adjust Water Service Meter Box to Grade"; "Adjust Water Service Meter" and "Water Service Appurtenance Installation." Separate payment for excavation and backfill will not be made. 603.23.2 Service shall not be interrupted without the approval of the Engineer and of the proper utility official. The Contractor shall arrange his work to interrupt services the shortest possible time. Prior notice of at least 24 hours shall be given the proper utility official and the Engineer before any main is shut off. In no case shall a valve or hydrant be opened or shut without proper authorization.
1/1/2016
603-10
Miscellaneous Water Equipment
603.23.3 Expose Water Service House Lead. Will consist of the excavation necessary to expose the individual water service lead from the corporation valve to the limit of construction. The overall depth of the water service lead will be determined from this exposure. Regardless of the number of times or locations along a single service lead an exposure is required by the Engineer, only one payment per service lead will be made. When it is determined that the service lead is usable at its existing location, the excavation will be backfilled in accordance with Section 726.6. Construction or detour phasing will provide no basis for claim for any exposures on a single service lead which must be made at different time intervals during construction. 603.23.4 Relocation of Water Service House Lead. Will include both new construction and the relocation in grade or alignment or both of the existing water service lead or portions thereof. Regardless of the condition of the existing water service lead, new copper lead and fittings will be required from the corporation valve to the limit of construction. The use of a minimum number of fittings in each lead run will be required. When the house service lead or any portion thereof will not be covered by 42 inches of material below finish grade, the water service lead must be relocated. 603.23.4.1 If necessary to join pipe of dissimilar metals, a method of insulation against the passage of electric current shall be provided as approved by the Engineer. 603.23.4.2 Trenches shall be excavated so that the pipe can be laid to the alignment and minimum depth designated on the plans, except that approved changes may be made to avoid obstructions or to connect to an existing line. The width of the trench shall be sufficient to permit the pipe to be laid and joined properly, and the backfill to be placed and compacted as specified. The Contractor shall locate and carefully expose existing water, gas, and sewer services, and other underground structures for a sufficient distance ahead of pipe laying to determine the grade and alignment of the pipe to be laid. 603.23.4.3 The trench shall be prepared to provide a uniform and continuous support for the pipe. Ledge rock, boulders, and large stones shall be removed to provide a clearance below and on each side of all pipe and pipe appurtenances of at least 6 inches. 603.23.4.4 Material placed around and 12 inches above the top of the pipe shall be free from cinders, ashes, refuse, boulders, rocks, or other unsuitable material. The remainder of the trench shall be backfilled in accordance with the applicable provisions of Section 726.6. 603.23.4.5 Where the water main is less than 42 inches below grade, that portion of the water service connection not meeting the cover requirement of Section 603.23 shall be insulated from the main to a point where the cover requirement can be met. Insulation shall be a commercially available product such as Arma-flex rubber insulation material or an approved equal with a factor of R-1.4. Installation methods shall be in accordance with the manufacturer's instructions and shall meet the approval of the Engineer.
1/1/2016
603-11
Miscellaneous Water Equipment
603.23.5 Relocating House Water Service Valve and Box. Will include the horizontal relocation of the water service shut off valve and the vertical stack which forms the box over the valve to a location designated by the Engineer within the right-of-way. Any material required to perform this operation will be new and the final product will be accessible and at finished grade. Any final adjustment of the box to grade will be considered as a part of the item regardless of the number of times required and will not be a basis for claim. The valve box shall not transmit shock or stress to the valve and shall be centered and plumb over the wrench nut of the valve. 603.23.6 Relocate Water Service Meter and Box. Will consist of the horizontal relocation of the water service meter and box to a location designated by the Engineer. Included in this relocation will be any new fittings, copper lead, meter yoke, new box, frame and cover as may be required to complete the relocation from the water service house lead grade to the finished grade. Existing meter yokes and frames and covers in same as new condition may be reused. The tops of all meter boxes shall be adjusted to the finished grade. Meters and meter boxes located within the limits of roadways and ditches shall be relocated outside the right-ofway as directed. 603.23.7 Adjust Water Service Valve and Box to Grade. Will consist of the vertical adjustment of the existing water service valve and/or box as determined by the Engineer. Vertical adjustment of the water service valve will include any and all fittings and new copper lead required to complete the item from the existing lead elevation to the designated elevation. Adjustment of the water service valve box will be accomplished by utilizing standard adjustable valve box extensions as needed to obtain final grade. Any final adjustment of the valve box cover to grade will be considered a part of this item regardless of the number of times required and will not be a basis for claim. 603.23.8 Adjust Water Service Valve Box to Grade. Will consist of the vertical adjustment of the existing valve box as designated by the Engineer to match the final grade. This item will include new material in the form of adjustable valve box extension, cover, and bolt. Also included in this item is the cleanout of the vertical stack above the wrench nut to provide access to the shut off valve. 603.23.9 Adjust Water Service Meter Box to Grade. Will consist of the vertical adjustment of an existing meter box to grade provided by the Engineer. This item will include the adjustment or replacement of the existing meter box to the finished grade with materials, as approved, as conditions warrant. Nonstandard meter boxes will be replaced to conform to the County Plumbing Code. 603.23.10 Adjust Water Service Meter. Will consist of the vertical adjustment of the existing meter yoke within the meter box to conform to the standard drawing. This item will include any new fittings, new copper lead, meter yoke, or appurtenance necessary to complete the adjustment. Should it become necessary to remove the meter box to facilitate this adjustment no additional cost will be allowed for removal or replacement of the meter box.
1/1/2016
603-12
Miscellaneous Water Equipment
603.23.11 Water Service Appurtenance Installation. Will consist of the tapping and placing of the corporation valve on the water main together with any cost of acquisition of the necessary permits, tap fees, or inspections as required. The Contractor will be solely responsible for acquiring any and all such permits and inspections. Tapping and inserting valves shall be installed in existing mains under pressure, as shown on the plans or as directed by the Engineer in accordance with instructions furnished by the manufacturer of the drilling machine, valves, and sleeves. Manifold valves to produce a sufficient water volume will be considered as a single unit. Existing service connections to any portion of a main to be retired shall be transferred by relocating and connecting to the new main. The relocated portion shall not be smaller than that originally in place. Service connections to be disconnected shall be shut off, disconnected, and the existing corporation valve rendered unusable. 603.23.12 Final Inspection of Water Valves and Water Meters. Following the sodding or seeding operations, but before final payment is made, a final inspection of all adjusted and relocated water service valves and meters will be made by the Engineer accompanied by the Contractor's superintendent. This inspection is to insure that these facilities have not been covered over or otherwise disturbed by other construction in the vicinity and that work has been properly done. Meter boxes shall be level and plumb. There shall be adequate space between the meter box and the meter yoke to allow for the use of a wrench. The meter yoke shall be 14 inches to 16 inches below the lid. Valve boxes shall be plumb and free of dirt and debris that might obstruct access to the valve. Each valve shall be fully opened and closed during the inspection. Any defects in the valve or meter boxes, joints, pipe fittings, valves, or meters revealed during the inspection shall be repaired or the defective material replaced until the work is satisfactory, all at the Contractor's expense. Valves and meters found to be at the wrong location or elevation shall be relocated or adjusted as directed by the Engineer. 603.24 Method of Measurement. 603.24.1 Expose Water Service House Lead. Will be measured on a per each basis at the contract unit bid price. 603.24.2 Relocating House Water Service Lead. Will be measured to the nearest foot along the geometrical centerline of the lead from corporation valve to construction limit for leads 2 inches in diameter and less, and will include all fittings in the measurement. 603.24.3 Relocating Water Service Valve and Box. Will be measured on a per each basis at the contract unit bid price. 603.24.4 Relocating Water Service Meter and Box. Will be measured on a per each basis at the contract unit bid price. 603.24.5 Adjust Water Service Valve and Box to Grade. Will be measured on a per each basis at the contract unit bid price. 603.24.6 Adjust Water Service Valve Box to Grade. Will be measured on a per each basis at the contract unit bid price.
1/1/2016
603-13
Miscellaneous Water Equipment
603.24.7 Adjust Water Service Meter Box to Grade. Will be measured on a per each basis at the contract unit bid price. 603.24.8 Adjust Water Service Meter. Will be measured on a per each basis at the contract unit bid price. 603.24.9 Water Service Appurtenance Installation. Will be measured on a per each basis at the contract unit bid price. 603.24.10 When a contract bid item, rock excavation in trench will be measured to the nearest cubic yard. Rock excavation will be measured at a width of 18 inches and to a depth of 6 inches below the bottom of the lead. The lead will be bedded in sand or clean dirt, the cost of which will be incidental. The term "Rock Excavation" is defined as that excavation which would be classified as Class C, Sandstone, or Igneous Rock Excavation in Section 203. It shall be the Contractor's responsibility to notify the Engineer before removing any such material. Any rock excavation removed before the Engineer has been notified and has established lines of demarcation will not be measured or paid for. When not a bid item, rock removal from the trench will be paid in accordance with Section 726, Rock Excavation in Trench. No payment will be made for backfilling, rock overbreak, or for bedding through the rock excavation area. 603.25 Basis of Payment. 603.25.1 No direct payment will be made for the Contractor's cooperation in the final inspection or for replacing or repairing defective valves or meters or their appurtenances. No direct payment will be made for further adjusting or relocating facilities as directed. All costs involved therewith are considered to be completely covered by the unit prices bid for the water service appurtenance adjustment and relocation items included in the itemized bid. 603.25.2 Accepted water service connection items will be paid for at the unit bid price for each of the pay items included in the contract. No direct payment will be made for any incidental items necessary to complete the work unless specifically provide as a pay item in the contract. No direct payment will be made for excavation or backfill, except for rock excavation in trench in accordance with Section 603.24.10.
1/1/2016
603-14
Miscellaneous Water Equipment
Section 604
Miscellaneous Drainage
Section 604.10 Concrete Headwalls, Drop Inlets and Manholes 604.11 Description. This work shall consist of the construction of headwalls, drop inlets, and manholes in accordance with these specifications, and in conformity with the lines and grades shown on the plans or established by the Engineer. Drop inlets and manholes may be constructed of brick masonry, poured concrete, or precast concrete. 604.12 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Reinforcing Steel for Concrete ........................................................... 1036 Mortars and Grout ................................................................................ 1066 Sewer Brick; Grades SM conforming to ASTM C 32 Unless otherwise specified, concrete for precast items will be class A1 concrete producing 4000 pounds per square inch (psi) in 28 days. All other concrete for this work is to be MSD Class A concrete (air entrained) with 3500-psi minimum compressive strength at 28 days. Materials, proportioning, mixing slump and transporting shall be in accordance with Section 501. Concrete shall be placed, finished, and cured in accordance with the applicable provisions of Section 703. Sewer brick shall be grade SM. 604.12.1 All brick shall be new and whole of uniform standard size and with substantially straight and parallel edges and square corners. Bricks shall be of compact textures, burned hard entirely through, tough, and strong, free from injurious cracks and flaws, and shall have a clear ring when struck together. No soft or salmon brick shall be used in any part of the work. Brick shall be culled after delivery, if required, and no culls shall be used except at such places, to such extent, and under such conditions as may be approved by the Engineer. The Contractor may be required to furnish the County with at least five (5) bricks of the character and make he proposes to use at least one week before any bricks are delivered for use. All brick shall be of the same quality as the accepted samples. 604.12.2 Steps for concrete manholes and drop inlets shall be co-polymer polypropylene plastic manufactured in accordance with MSD specifications. The portion of the step to be embedded in the concrete shall have a configuration such that it will prevent any pullout. The steps shall have properties such that they will withstand a single concentrated load of 300 pounds without distortion on that portion protruding from the wall. The minimum width of rungs or cleats shall be 10 inches and shaped to prevent the foot from slipping off the side. The step shall project a minimum distance of 4½ inches from the wall of the riser or cone section measured from the point of embedment. The steps shall be embedded a minimum distance of 5½ inches and shall be spaced vertically at a maximum distance of 16 inches.
9/1/2023
604-1
Miscellaneous Drainage
604.13 Construction Requirements. 604.13.1 Concrete Structures. Where concrete structures are permitted or required by the project plans, they shall be built of Class A concrete (MSD) as shown on the project plans. The structure shall be built on prepared foundations, conforming to the dimensions and shapes shown on the plans. The construction shall conform to the methods, forms, mixture, placement, and curing for concrete as detailed in the specifications, the Standard Drawing, and the project plans and specifications. Any required reinforcement shall be of the kind, type, and size, and shall be located, spaced, bent, and fastened as shown in the project plans. Concrete reinforcing in place shall be approved by the Engineer before any concrete is placed. All invert channels shall be accurately constructed and shaped so as to be smooth, uniform, give minimum resistance to flow, and shall slope downward toward the outlet. Inlet and outlet pipes shall extend through the walls of structures only a sufficient distance beyond the outside surface to allow for connections and shall cut off flush with inside the surface of the walls as shown in the project plans, or otherwise directed. Concrete or brick masonry or mortar shall be so placed around the pipes as to provide full continuous contact between masonry and outside of pipe, to prevent leakage, and to form a neat connection. Adequate water stops, approved by the Engineer shall be used with all plastic inlet and outlet pipes. In brick manholes and inlets, a rowlock arch shall be placed over all incoming and outgoing pipes. The pipes for a precast manhole base shall be placed as an integral part of the base or the connections may be of any approved patented compression type joint. Precast manholes will be utilized on sanitary or combined sewers only, 8 inches to 12 inches, and will require Type II cement. Precast manholes will be utilized only with the permission of the Director u p o n request of the Contractor unless specified as a bid item. Steps shall clear all pipes and shall be built on an unobstructed wall as designated by the Engineer. Steps shall be installed as shown in the Standard Drawing. When the steps are set in concrete, they shall be placed and secured in position before the concrete is placed. When the steps are installed in brick masonry, they shall be placed as the masonry unit is being built. The steps shall not be disturbed or used until the concrete or mortar has set and cured for at least seven days. Forms on cast-in-place construction will not be removed for 24 hours or backfilled for 72 hours. 604.13.2 Manholes, Inlets, Junction Chambers and Headwalls. The Contractor shall build manholes, inlets, junction chambers, headwalls, culverts, and other such miscellaneous structures as are required at the locations shown on the project plans, or as otherwise directed. The structures will be either of concrete, plain or reinforced as required, or of brick masonry. Where the top elevation is not shown on the plans, the structure or appurtenance shall be built to conform to the elevation ordered by the Engineer. Manholes shall not be out of plumb more than 1 foot in 30 feet. No precast manholes or inlets will be constructed within the right-of-way of the roadway, unless approved by the Director. Detailed shop drawings must be submitted and accepted prior to approval for inclusion in the contract. The various structures shall be built as the pipe laying or sewer construction progresses. The Engineer, at his discretion, may stop the laying of pipe or building of other structures until the structure just passed has been completed. Completion of the structure shall include the installation of fittings and connections to pipes and other construction as shown on the plans.
9/1/2023
604-2
Miscellaneous Drainage
604.13.2.1 Brick Masonry Construction. All materials used in brick masonry construction shall conform to the requirements of Division 1000. Mortar for sewer construction shall consist of a uniform mixture of Portland cement and masonry sand with the minimum amount of water necessary to produce the desired consistency. No admixtures shall be used without the approval of the Engineer. Mortar for brick masonry and plastering shall consist of one volume of cement and three volumes of sand. Mortar shall be prepared in suitable mixing equipment, or for small amounts, on a hard impervious surface. It shall be kept free at all times of earth, debris, contamination, or other deleterious substances. Re-tempered or partially set mortar shall not be used. Mortar required for patching or jointing areas in the vicinity of sanitary sewage shall be of an approved rapid setting variety. A prepared foundation shall be placed for all brick structures after the foundation excavation is completed. This shall be of the materials and dimensions shown in the standard drawing or on the project plans and specifications. All brick shall be thoroughly clean. The bed which is to receive the brick shall be thoroughly cleaned and damp but should be free of water before placing mortar thereon. All bricks shall be laid in courses in freshly made mortar, using the shoved joint method so as to thoroughly bond them into the mortar and always with the joints completely filled with mortar. The bricks shall be laid in a workmanlike manner and true to the lines and grades indicated on the plans. The arrangement of headers and stretchers shall be such as will thoroughly bond the masonry. Unless otherwise indicated, brick masonry shall be of alternate headers and stretchers with consecutive courses breaking joints. In manholes, all bricks in each course shall be headers. The course shall be laid continuously with joints broken or alternating evenly with the joints in the preceding course. Horizontal joints shall average 3/8-inch but shall be not less than ¼ inch nor more than ½ inch in thickness. Face joints shall be flush and neatly struck, and all joints on unexposed faces shall be solidly filled. No spalls or bats shall be used except in shaping around irregular openings or connections, or when unavoidable to finish out a course. In this case, a full brick shall be used at the corner with the bat in the interior of the course. If any brick is moved or a joint broken during laying, the brick shall be removed, the mortar thoroughly cleaned from the brick, bed, and joints and the brick re-laid in fresh mortar. Where required by the Standard Drawings or by the project plans and specifications, the inside and outside surfaces of brick masonry shall be neatly plastered with mortar to a thickness not less than ½-inch, and be finished to a true, uniform, continuous, smooth surface. All plastering shall be applied as the manhole or brick structure is constructed, as opposed to plastering upon completion. On completion of each brick structure, all waste mortar and debris shall be immediately removed from the structure and any necessary repairs or required pointing shall be completed. Brick masonry, plastering, and mortar shall be protected from freezing or lack of moisture. Brick masonry shall not be constructed when the temperature is 40°F or lower without the permission of the Engineer, nor without adequate approved means for protection against freezing. Brick masonry shall have sufficient moisture for proper curing and be protected from drying. Requirements for protection of brick masonry and masonry materials are the same as required for concrete structures.
9/1/2023
604-3
Miscellaneous Drainage
604.13.3 New Manhole on Existing Sewer. If a new manhole must be constructed for the connection, the new manhole and invert shall be constructed over and around the existing sewer pipe to the elevation shown on the project plans. The work shall be done carefully to avoid breaks in the existing sewer until the manhole is completed. Any joints in the existing sewer shall be pointed upon with a 1-3 cement-sand mortar, if necessary to stop leakage before building the manhole. After construction of the manhole, the top half of the existing pipe shall be carefully cut and removed to be flush at each end with the inside wall and pointed up to present a neat smooth surface at the junction of the cut pipe with the invert and wall. The newly placed concrete mortar or plastering at the connection shall be protected from sanitary sewage or foul water by completely covering with a thick coat of emulsified asphalt applied after the initial set of the mortar or concrete. No sewage or water shall be permitted to touch the protected surfaces until the emulsion has set and properly hardened. Any portion of an existing sewer that is damaged in constructing the new manhole shall be repaired with new material of a type matching the old, at the Contractor's expense. 604.13.4 Pipe Connection to Existing Manhole or Stub. The Contractor will verify the exact location and elevation of existing sewers immediately prior to actual construction. Any differences should then be brought to the attention of the County. If a bulkhead opening of adequate size or a stub of proper size, elevation, location, and direction exists at the manhole, the pipe connection will be made as required for pipe laying. The cost of removing the bulkheads and making the pipe connection is included in the cost of laying the new pipe sewer. If the existing stub is not suitable for use, or if no stub exists, a new connection must be made to the manhole. The stub shall be removed, or a hole shall be cut in the manhole wall to permit inserting the pipe at the required flowline elevation, horizontal angle, and slope, and to allow 2 inches of space around the pipe for bedding and filling solidly with 1-3 cement-sand mortar. Care shall be used to avoid unnecessary damage to the masonry. All loose material shall be removed from the cut surfaces, which shall be completely coated with mortar before setting the pipe. Before inserting the pipe, a sufficient thickness of mortar shall be placed at the bottom and sides of the opening for proper bedding of the pipe. After setting, all spaces around the pipe shall be solidly filled with mortar, and neatly pointed up on the inside to present a smooth joint, flush with the inner wall surface. Any necessary revisions in the existing invert shall be made to provide a smooth plastered surface for properly channeled drainage from the new connection. Particular care shall be given to ensure that the earth sub- base and bedding adjacent to the manhole will provide firm solid support to the pipe. 604.14 Basis of Payment. All manholes will be paid for at the contract unit bid price, per each. 604.14.1 No direct payment will be made for: a) Maintaining service, or for cutting the existing sewer. b) Weep holes, including excavation, permeable granular backfill, 4-inch drain tile, screen for inlet, or any other work incidental thereto. c) Manhole steps. 604.14.2 Payment will be made for constructing a new manhole over an existing sewer at the bid price as described for manhole construction. The cost of cutting and removing the pipe and pointing up are included in the payment made for manhole construction.
9/1/2023
604-4
Miscellaneous Drainage
604.14.3 New connections at levels above the manhole flowline for invert lines will be made similarly except for the requirements of invert adjustment, unless otherwise required in the project plans and specifications. 604.14.4 Inlets. Payment will be made for each type of inlet per each at the bid price for the type of inlet required by the project plans and specifications and shown in the Standard Drawings. Such payment shall include all costs of the base, walls, tops, sill, blocks, angle seats, cement mortar, plaster, pipe specials for the trap when a trapped inlet is required, steps, grates and covers, and all costs for the construction of the required gutter sump, including the removal and replacement of the pavement and curbing required for construction of the inlets. 604.14.5 Junction Chambers. Payment will be made for each junction chamber completed as required by the project plans and specifications at the lump sum bid price for constructing the junction chamber. Such payment shall include all cost of masonry, forms, concrete, reinforcing steel, steps, manhole construction above the top of the chamber, and making pipe connections. 604.14.6 No separate payments will be made for backfill around manholes, catch basins, inlets, junction chambers, or other structures. 603.14.7 No direct payment will be made for excavation, in accordance with Section 726.3.11.12. Excavation will be considered a portion of the various items. 604.15 Tuckpointing and Plastering Existing Structures. 604.15.1 Description. The interiors of all existing manholes and inlets within the construction limits shall be restored by tuckpointing and replastering as necessary to meet the requirements of the Metropolitan St. Louis Sewer District (MSD). 604.15.2 Tuckpointing shall be in accordance with accepted practices and shall be applied to the inner faces of all structures. Plastering shall consist of the addition of a ½-inch thick 1-3 cement-sand mortar to the inner faces of the structures to insure complete coverage of the surfaces from the invert to the level of the crown of the largest pipe in the structure. Materials shall be in accordance with Metropolitan St. Louis Sewer District (MSD) specifications. Other details shall be in accordance with MSD Standard Plans. It is intended that all existing drainage structures located within the right-of-way and easement areas be inspected and receive this treatment if necessary. The quantities shown on the plans for this item include only existing drainage structures that are also scheduled to be adjusted to grade or otherwise altered under other pay items. Existing manholes and drop inlet structures within the right-of- way, outside the construction limits, whether or not shown on the plans, shall also be inspected, and repaired if necessary. It will be the Contractor's responsibility to investigate the condition of the existing drainage works and determine the extent of work necessary due to this requirement and to base his bid accordingly. 604.15.3 Final measurement for payment will be made along the vertical axis of the affected structure from the invert to the base of the manhole frame, or to the base of the cover stone in the case of inlets. Actual measured quantities will be paid.
9/1/2023
604-5
Miscellaneous Drainage
Section 604.20 Adjusting Drainage Facilities 604.21 Description. This work shall consist of adjusting manholes, catch basins, inlets, and similar items in accordance with the details shown on the plans or as approved by Metropolitan St. Louis Sewer District (MSD). Existing frames and covers shall be salvaged and reused if required by the contract. New manhole steps shall be provided as necessary. New manhole adjusting rings (adapters) shall be provided when required in the contract. Frame and covers shall be positioned so as to be flush with the finished roadway grade. 604.22 Basis of Payment. The accepted adjustments of manholes, and catch basins and inlets, will be paid for at the unit bid price for each of the pay items included in the contract. No direct payment will be made for steps or adjusting rings, unless specified in the contract.
9/1/2023
604-6
Miscellaneous Drainage
Section 604.30 Adjusting House Sewer Connections 604.31 Description. This work shall consist of laying or relaying sanitary sewer house connections which may be any part of the sanitary waste disposal system between the trunk line or lateral sewer to the construction limits which are to be relocated to clear new construction or which are to be reconnected to new sewers or temporarily removed to permit installation of other items in the contract. Septic tanks and absorption fields when encountered in construction shall be reconstructed in accordance with local codes. 604.32 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Vitrified Clay Products ......................................................................... 1030 Material for Joints ................................................................................. 1057 Mortars and Grout ................................................................................ 1066 Sewer and Stormwater Pipe Joints ................................................... 1057.8 The size and class of pipe to be used shall meet the requirements of the local authority having jurisdiction over the installation of sewer connections. The Contractor will be responsible for acquisition of all permits required. 604.33 Construction Requirements. The excavation for the laying of the pipe, and backfilling of the trench shall be in accordance with the applicable portions of Section 726. The adjustment shall be made to the line and grade shown on the plans or as directed by the Engineer. When a house sewer connection is relocated or re-laid within a minimum of 2 linear feet above a water main, Class A (MSD) concrete meeting current MSD specifications, shall be used to encase the sewer line to a minimum thickness of 6 inches. The encasement shall extend to a point where the normal distance from the sewer to the water main is a minimum of 10 feet. 604.34 Method of Measurement. Measurements of adjusting house sewer connections will be made to the nearest foot along the geometrical center of the adjusted pipe. 604.35 Basis of Payment. 604.35.1 Payment for adjusting house sewer connections, complete in place, including all necessary pipe, tees, bends, wyes, the cutting of and joining of new pipe to old pipe or structure, excavation, backfill, traps, fittings, and items incidental thereto including permits, will be considered as completely covered by the contract unit bid price per linear ft. for each house sewer connection. 604.35.2 Payment for encasement, complete in place, will be made at the contract unit bid price. If no pay item exists in the contract, payment for MSD Class "A" Concrete for Encasement will be made per cubic yard at the fixed cost specified in section 109.4.5
9/1/2023
604-7
Miscellaneous Drainage
Section 604.40 Pipe Collars 604.41 Description. This work will consist of metal or concrete collars constructed around a pipe joint in accordance with the plans. 604.42 Materials. All material shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Corrugated Metallic-Coated Steel Culvert Pipe, Pipe-Arches, and End Sections ..................................................1020 Reinforcing Steel for Concrete ...........................................................1036 Metal pipe for pipe collars shall be of the same gage and have the same corrugation dimensions as the corrugated metal pipe to be connected. Concrete used for collars shall be Class A (MSD), meeting the requirements of Section 501. 604.43 Construction Requirements. Pipe collars will be required for the purpose of (1) extending existing pipes where the pipe required for the extension will not form a normal joint with the pipe in place; (2) connecting two different sizes of pipe; (3) connecting corrugated metal pipe to concrete pipe; (4) connection of concrete pipe to box culvert. If the pipe collar design is not applicable to the type of pipe being extended, the pipe collar shall be modified to ensure a joint connection that will fit the pipe. 604.44 Basis of Payment. The accepted quantity of pipe collars will be paid for at the contract unit bid price per each. Cost for reinforcing steel where required will be included in the unit price for pipe collar.
9/1/2023
604-8
Miscellaneous Drainage
Section 604.50 Connecting Pipe to Existing Structures 604.51 Description. Connections to existing sewers shall be made as shown in the Standard Drawings or as modified in the project plans. Care shall be used to avoid damage to the adjacent sewer walls or masonry. The opening shall be of sufficient size to permit inserting the pipe at the required flowline elevation, horizontal angle, and slope, and to allow at least 2 inches of space around the pipe for bedding and filling solidly with 1-3 cement-sand mortar. If there are reinforcing bars in the sewer walls, only those preventing insertion of the pipe may be cut. All others shall be bent into the Class A concrete collar at the junction of the connecting pipe and existing sewer. Unless a detail is provided, the collar shall have vertical walls not less than 6 inches thick above, below, and at the sides of the connecting pipe, at least 12 inches from the outside of the existing sewer at the spring line of the connecting pipe. The bottom of the collar shall extend to solid support at its base. All loose material shall be removed from the cut surfaces, and any surfaces to be in contact with newly placed concrete shall be cleaned to the base concrete or masonry, and thoroughly coated with cement grout before placing the concrete for the collar. Before inserting the pipe, a sufficient thickness of mortar shall be placed at the bottom and sides of the opening for proper bedding of the pipe. All spaces around the pipe shall be filled with mortar or concrete and be neatly pointed up on the inside to form a smooth joint that is flush with the inner sewer surface. Any portion of an existing structure that is damaged in joining the new pipe shall be repaired or replaced with new materials of a type matching the old, at the Contractor's expense. These requirements shall also be applicable in joining one new pipe to another when the use of a manufactured connection joint is waived by the Engineer. Any saw cutting or removal of existing reinforcement will be included in bid price. 604.52 Basis of Payment. No direct payment will be made for connecting pipe to existing structures for pipe sizes up to 36-inch diameter. 604.52.1 Connecting 36-inch diameter pipe and larger sizes to existing structures will be paid for at the contract unit bid price. Payment will be made for cutting the opening in the sewer, constructing the concrete collar, and making the completed pipe connection at the bid price for making the completed pipe connection to the existing sewer.
9/1/2023
604-9
Miscellaneous Drainage
Section 605
Underdrainage
Section 605.10 Class A Underdrain 605.11 Description. This work shall consist of pipe placed for sub-drainage purposes in conformity with the lines and grades shown on the plans or as directed by the Engineer, and shall include excavating the trench and backfilling with materials as specified or directed. 605.12 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Corrugated Metallic Coated Steel Pipe Underdrains ................. 1022 Corrugated Aluminum Alloy Pipe Underdrains .......................... 1025 Aggregate for Drainage (Grade 3) ..............................................1009.3.3 Specification PVC ............................................................................. ASTM D 3034 The Contractor may select the type of underdrain pipe he proposes to furnish. 605.12.1 Except as otherwise specified, all underdrain pipes shall have a nominal internal diameter of 6 inches and shall be perforated. All special fittings such as caps, wyes, tees, reducers, elbows, turns, couplings, etc., shall be of standard design and manufacture. All couplings, joints, and all special fittings shall be galvanized after welding, or all welds and metal adjacent to the welds shall be painted after welding with two coats of zinc dust, zinc oxide or zinc rich paint, meeting the approval of the Engineer. Screens shall be of No. 19 gage galvanized wire cloth with approximately ½-inch by ½-inch openings. 605.13 Construction Requirements. 605.13.1 Although probable locations of underdrains are shown on the plans, the Contractor shall perform work only at such locations as are specified by the Engineer. 605.13.2 The trench for underdrains shall be carefully excavated true to line and grade and to the width and depth shown on the plans and special drawings or as directed by the Engineer. 605.13.3 The pipe shall be firmly bedded in the trench with perforations down. Pipe sections shall be joined with approved connecting bands. Dead ends of pipe shall be completely closed by means of caps securely affixed to the pipe. Discharge ends shall be protected with screens securely fastened in place by means of galvanized wire. Where indicated on the plans or directed by the Engineer, the outlet ends shall be connected to drain into the drop inlets or manholes.
1/1/2016
605-1
Underdrainage
605.13.4 Backfilling shall be carefully done so that the pipe will not become displaced. The required porous backfill material shall be placed to the dimensions shown on the plans and/or Special Drawings. 605.14 Method of Measurement. Measurement will be made to the nearest linear foot for each underdrain along the centerline of the drain, center to center of fittings and junctions. 605.15 Basis of Payment. 605.15.1 The accepted quantity of Class A underdrain, complete in place, will be paid for at the contract unit bid price per linear foot. No direct payment will be made for excavating the trench, connecting underdrains to drop inlets or manholes, nor for backfilling and backfill material.
1/1/2016
605-2
Underdrainage
Section 605.20 Class B Underdrain 605.21 Description. This work shall consist of pipe (generally for draining porous or other backfill adjacent to concrete masonry construction) placed in conformity with the lines and grades shown on the plans, or as directed by the Engineer. The underdrain pipe shall be of the size or sizes shown and may be corrugated metal, perforated corrugated metal, PVC, or combinations of such pipe as specified in the contract. Perforated pipe shall be laid in a prepared bed of porous backfill. 605.22 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Corrugated Metallic Coated Steel Pipe Underdrains ................. 1022 Porous Backfill Material (Gradation D) .......................................1005.1.3 Pipe underdrains shall be perforated unless otherwise specified in the contract. 605.22.1 All special fittings such as caps, wyes, tees, reducers, elbows, turns, couplings, etc., shall be of standard design and manufacture. All couplings, joints and all special fittings shall be galvanized after welding or all welds and metal adjacent to the welds shall be painted after welding with two coats of zinc dust, zinc oxide or zinc rich paint, meeting the approval of the Engineer. 605.23 Construction Requirements. The pipe shall be laid to the grade and alignment shown on the plans, with the perforations down. The pipe shall be joined with approved coupling bands. Where a section of pipe is cast into concrete, the remaining pipe shall be joined to these sections with connecting bands. The porous backfill material shall be placed so that the pipe will not become displaced and shall be firmly tamped under and around the entire pipe. Discharge ends shall be protected by approved methods to prevent obstruction until connections to outlets are installed. Trenching, placement and backfill of cross drains shall be performed only after Type 5 aggregate base has been placed, fine grade and compacted. All cross drains shall have a minimum opening of 6 inches. 605.24 Method of Measurement. Measurement will be made to the nearest linear foot for each underdrain along the centerline of the pipe, center to center of fittings and junctions. 605.25 Basis of Payment. The accepted quantity of Class B underdrain, complete in place, will be paid for at the unit bid price for each of the pay items included in the contract. No direct payment will be made for excavating the trench.
1/1/2016
605-3
Underdrainage
Section 605.30 Class C Underdrain 605.31 Description. This work shall consist of either a French underdrain or a drain tile underdrain, or combinations of these types placed in conformity with the lines and grades shown on the plans, or as directed by the Engineer. The kind of underdrain to be constructed at a particular location will be designated on the plans. 605.32 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Porous Backfill Material (Gradation D) .................................1005.1.3 Specification PVC ............................................................................. ASTM D 3034 Concrete Drain Tile…………………………………..AASHTO M 178 605.33 Construction Requirements. 605.33.1 Although probable locations of underdrains are shown on the plans, the Contractor shall install underdrains only at such locations as are specified by the Engineer. 605.33.2 Drain Tile Underdrain. The trench shall be carefully excavated to the width and depth required to permit the tile to be laid to the proper grade. The tile shall be bedded firmly in the trench with ends closely joined and each section of the tile shall have a firm bearing throughout its length. The top of all joints shall be covered with strips of tarpaper not less than 8 inches wide. No joint opening shall be more than ½ inch and any joint opening ¼ inch or more shall have a piece of broken tile placed over the tar paper covering. All junctions, bends, and turns shall be made with fittings of standard manufacture. Suitable caps or plugs shall be provided and installed to close the dead ends of the underdrains. Screens of No. 19 galvanized wire cloth with approximately ½ inch by ½ inch openings shall be provided and securely fastened over the outlet ends by means of galvanized wire. Any tile which is not in true alignment or which shows signs of settlement after it has been laid shall be taken up and re-laid to the proper grade. 605.33.2.1 Backfilling shall be carefully done so that the tile will not be displaced. Porous backfill shall be placed to the dimensions shown on the plans and covered with a layer of tarpaper as indicated. For that part of the trench in shoulders, the trench above the porous backfill shall be filled with suitable backfill, well compacted. Underdrains shall be kept free from accumulations of silt, debris, and other foreign matter during construction. 605.33.3 French Drain. At locations shown on the plans, French drains shall be constructed in the subgrade and through the shoulders to provide drainage. French drains shall have a trench of the dimensions shown on the plans. Two layers of 90-pound tarpaper or filter fabric approved by the Engineer extending 18 inches outside the limits of porous backfill will be placed, filled with porous backfill material. For that part of the trench in shoulders, the trench above the porous backfill shall be filled with suitable earth, well compacted.
1/1/2016
605-4
Underdrainage
605.34 Method of Measurement. Measurement will be made to the nearest linear foot for each underdrain. 605.35 Basis of Payment. The accepted quantity of Class C underdrain, complete in place, will be paid for at the unit bid price for each of the pay items included in the contract. No direct payment will be made for excavating the trench nor for backfilling the trench.
1/1/2016
605-5
Underdrainage
(This Page Intentionally Left Blank)
1/1/2016
605-6
Underdrainage
Section 606
Guardrail and Roadway Barriers
606.1 Description. This work shall consist of furnishing and installing guardrail, guard fence, crashworthy end terminals, one-strand access restraint cable or three-strand guard cable as shown on the plans or as directed by the engineer. 606.2 Material. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Portland Cement Concrete ...................................................................................501 Guardrail, Crashworthy End Terminals, One-Strand Access Restraint Cable, and Three Strand Guard Cable Material..................... 1040 Chain-Link Fence Material...............................................................................1043.2 606.2.1 Concrete. Concrete shall be placed, finished and cured in accordance with Section 703. 606.2.2 Cold Weather. During cold weather, the weather limitations of Section 502 will apply to concrete work. 606.2.3 Aesthetic Guardrail. When specified, aesthetic guardrail shall be in accordance with NCHRP 350, Test Level 3 criteria and shall be of new stock. End terminals and crash cushions for aesthetic guardrail shall be fabricated and installed in accordance with Section 606.30.3. 606.3 Construction Requirements. 606.3.1 General. Work on guardrail or guard cable removal and replacement when the adjacent travel or auxiliary lane is open to traffic during non-working hours shall adhere to the following requirements: a) The contractor shall provide a schedule of work prior to the beginning of work. b) Remove no more guardrail or guard cable than can be replaced in the same day. c) Schedule guardrail and guard cable installation to ensure guardrail beam or guard cable is properly attached to all installed posts at the end of each workday. d) Ensure end sections or terminals exposed to traffic meet current standards. Guardrail or guard cable shall be maintained to within 3 inches of the nominal barrier height shown on the plans. e) Notify the engineer prior to delivery of the material to the project.
1/1/2016
606-1
Guardrail and Roadway Barriers
606.3.1.1 If guardrail or three-strand guard cable cannot be replaced the same day as removal, traffic control measures meeting the approval of the engineer shall be provided. The contractor will not be compensated for any additional traffic control items required to perform this work. In all cases, the contractor shall ensure that the guardrail or guard cable installation is fully anchored before opening the adjacent lane to traffic. 606.3.1.2 The shoulders and slopes shall be in accordance with all standards shown on the plans or shall be as directed by the engineer before the installation of any guardrail, guard cable or end treatments. 606.3.2 Field Repair of Galvanizing. Galvanized material shall be handled in a manner to avoid damage to the surface. No punching, drilling, cutting or welding will be permitted after galvanizing, except as approved by the engineer to provide for lapped beams, or for changes in location of splices necessitated by field clearances. Any galvanized material on which the galvanizing has been damaged will be rejected or may, with the engineer's approval, be repaired in accordance with Section 1080. 606.3.3 Posts for Guardrail and One-Strand Access Restraint Cable. 606.3.3.1 Posts may be wood or steel. The same material shall be used for all new installations within a single project, except for end treatments. If the project requires an extension of existing guardrail, the new post material for the extension shall match the existing material. 606.3.3.2 Wood posts for end anchors shall be installed as shown on the plans. 606.3.3.3 Posts may be installed by either drilling or driving. 606.3.3.3.1 Posts installed by drilling shall have sufficiently sized holes to permit thorough compaction of backfill material around the posts. The backfill material shall be compacted in layers not exceeding 12 inches high. 606.3.3.3.2 Posts installed by driving may be driven by a power hammer or any other method approved by the engineer. Any mushrooming on the top of the post shall be removed. Damaged zinc coating on galvanized posts shall be field repaired in accordance with Section 1081. If, in the judgment of the engineer, the exposed portion of a wood post is split or the driving process noticeably worsens the check cracking, the post shall be replaced by the contractor at the contractor's expense. 606.4 Basis of Payment. The accepted quantities of grading and drainage at barrier locations will be paid for at the contract unit price for each of the pay items included in the contract.
1/1/2016
606-2
Guardrail and Roadway Barriers
Section 606.10 Guardrail 606.10.1 Description. This work shall consist of furnishing and installing guardrail as shown on the plans or as directed by the engineer. 606.10.2 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Guardrail, Crashworthy End Terminals, One-Strand Access Restraint Cable and Three Strand Guard Cable Material......................... 1040 Guardrail beams shall be galvanized steel unless specified otherwise in the contract. The Contractor may select either zinc coated, aluminum coated, or vinyl-coated steel fencing material, except that the same kind of material shall be used throughout the project. 606.10.3 Construction Requirements. 606.10.3.1 Guardrail. Guardrail shall be of the type specified and shall be placed at locations designated on the plans. All guardrail will be firmly attached to the steel posts by means of one or more steel blocks or mounting connectors or brackets. All steel posts, blocks, mounting connectors, mounting brackets, shims, backup plates, bolts, nuts, and accessories shall be hot dipped galvanized coated. Posts may be cut to length, where required, by sawing or flame cutting. Cut ends will be acceptable painted with zinc rich or zinc oxide paints. Bolts for use in guardrail will be button head ⅝ inch diameter with oval shoulder to prevent turning and will be of sufficient length to properly secure the rail to the post or block. Washers shall be used at all post connections, between the bolt head and rail, and shall conform in shape for a snug fit. Backup plates shall be used between rail and post at all non-splice posts. 606.10.3.2 Beams. Beams, channels where required, posts, and appurtenances for guardrail shall not be field punched, reamed, or drilled except as may be approved by the Engineer to provide for lapped beams, or for changes in location of splices necessitated by field clearances. The beams shall be spliced by lapping in the direction of traffic. The use of 25-foot sections of beam rails, and channels if required, will be permitted for terminal sections and bridge anchor sections, and elsewhere where true line and grade can be maintained. Beams for terminal sections may be either shop or field twisted and bent. Deformation shall be such that the beam will retain the required shape in a relaxed condition. Galvanized material shall be handled in a manner to avoid damage to the surfaces. Any galvanized material on which the spelter coating has been bruised or broken will be rejected or may, with approval of the Engineer, be repaired. Unless otherwise shown, rail beam will be maintained at a uniform height of 1'-9" above the surface, at the location installed, to the center of the rail. 606.10.3.3 Guardrail Posts. Guardrail posts will be driven or set in concrete, as necessary, and at the designated locations in a vertical position and true to the line and grade. Posts for Type A guardrail will be 6 feet-9 inches in length, and for Type B will be 5 feet-9 inches in length. When, due to obstructions, it is not possible to drive guardrail
1/1/2016
606-3
Guardrail and Roadway Barriers
posts, the posts may be shortened and set in a concrete anchor 2 feet deep and 3 feet in diameter. If the post must be set in rock, a pocket must be produced in the rock a minimum of 2 feet deep and a minimum of 2 inches larger than the largest diagonal dimension of the shortened post section. This pocket will be filled with concrete. In both cases concrete will meet the requirements of Class B concrete and will be finished to an elevation a minimum of 6 inches below top of ground elevation. Where posts will be surrounded by concrete surfacing at a later date, a 5 inch by 8 inch blockout must be employed. Mushrooming of the end of a driven guardrail post will be cause for rejection. 606.10.3.4 End Anchors. End anchors shall be installed on ends of guardrail runs where crashworthy end terminals are not required. 606.10.3.5 Delineators. Delineators shall be placed on all guardrail located 2 feet or less from the edge of the shoulder. Delineators shall be spaced at 50-foot intervals. 606.10.3.5.1 Material. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Concrete Traffic Barrier Delineators ...................................................... 1065 606.10.3.5.2 Delineator Construction Requirements. 606.10.3.5.2.1 Delineator reflector colors shall correspond with pavement marking. Delineators shall be sheeted on one side, facing oncoming traffic, unless otherwise specified. Where guardrail divides opposing lanes of travel, the delineators shall have retro-reflective sheeting on both sides corresponding to adjacent pavement markings. Guardrail located on ramps shall have red reflective sheeting placed on the reverse side of the reflector. 606.10.3.5.2.2 Delineators will be installed according to manufacturer's recommendations. 606.10.3.5.2.3 Any damaged or missing delineators shall be replaced by the contractor at the contractor’s expense. 606.10.4 Type of Guardrail. The various types of guardrail are defined as follows: Type A Guardrail will consist of 12 gage rail beams mounted with blocks as necessary to steel posts centered at 6'-3" intervals, including all necessary appurtenances. Type B Guardrail will consist of 12 gage rail beams mounted with blocks to both sides of the flanges of the steel posts centered at 6'-3" intervals, including all the necessary appurtenances.
1/1/2016
606-4
Guardrail and Roadway Barriers
606.10.5 Non-Working Hours Requirements. Unless a concrete traffic barrier is provided between the installed posts and the adjacent travel or auxiliary lane, and when that lane will be open to traffic during non-working hours, the Contractor shall schedule guardrail installation or replacement to assure that guardrail beam is fully attached to all installed posts at the end of each workday. 606.10.5.1 In addition to the previously mentioned construction in Section 606.00, appurtenant sections will be used with the various types of guardrail installation. An end section will be required at all rail beam termini on Type A guardrail. The end section will be 12 gage galvanized steel and will be included in the price of the Type A guardrail. A 12 gage galvanized buffer end section will be required at the rail beam termini on all Type B guardrail installations. 606.10.6 Terminal Guardrail Sections. Terminal sections of guardrail will be placed at the locations shown on the plan or designated by the Engineer. These terminal sections will be composed of a minimum of 25 feet of galvanized rail beam of the type specified, a minimum of three line posts and connectors driven to the height necessary to produce the required slope transition and a terminal post driven so that the bottom of the rail beam will contact the ground at the high side of transition slope, an end section at the termini, and such other hardware as may be required. 606.10.7 Bridge Anchor Sections. Bridge Anchor Sections are of three varieties depending on the type of attachment to the structure. The first connection is to a brush curb, the second connection is to an end post, and the third connection is to a safety barrier section. All three varieties utilize an end shoe of 12 gage galvanized steel equipped with slotted expansion connection holes. The end shoe is positively attached to the bridge by a four-bolt connection system composed of ⅞ inch diameter bolts. Holes in the superstructure elements for this connection will be 1 inch in diameter and will be produced by a prefabricated galvanized template unit or other approved forming method. Connections to existing concrete elements in the superstructure will be made by drilling, utilizing a wooden backing plate securely attached to prevent spalling of the back face of the element. 606.10.7.1 The brush curb and safety barrier bridge anchor sections are composed of 2'6" end shoe and 25 feet of Type C guardrail either attached to Type A guardrail or a terminal section at its terminus from the bridge. The end post connection utilizes 25 feet of Type C guardrail and a 2'-6" end shoe to form a terminal section as described previously with the end section positively attached by bolted connection to the curb when greater than or equal to 12 inches wide. 606.10.8 Method of Measurement. 606.10.8.1 Measurement of guardrail will be made to the nearest ½ linear foot for each increment along a line passing through the centerline of each post, and totaled to the nearest linear foot for the sum of the increments on the project. The length will be measured separately for each type from the center of the end post to the center of end post, excluding bridge anchor sections and terminal sections. This item will include all rail beams, posts, brackets, connectors, and other necessary appurtenances.
1/1/2016
606-5
Guardrail and Roadway Barriers
606.10.8.2. No measurement will be made for rock removal in postholes and additional material required or time required to span obstructions or utilities. Special appliances or brackets needed will not be a basis for claim for additional compensation. 606.10.8.3 Terminal sections complete in place will be measured per each in accordance with Section 606.10.7.2. 606.10.8.4 Bridge Anchor Sections complete in place will be measured per each in accordance with Section 606.10.7.2. 606.10.9 Basis of Payment. The accepted quantities of guardrail, bridge anchors, end anchors, transition sections and bull nose guardrail systems, complete in place, will be paid for at the contract unit price for each of the pay items included in the contract. No direct payment will be made for end sections or terminal connectors. No direct payment will be made for setting posts in rock. No direct payment will be made for guardrail delineators provided on new guardrail. Delineators specified for installation on existing guardrail will be measured and paid for per each.
1/1/2016
606-6
Guardrail and Roadway Barriers
Section 606.20 Guard Fence 606.20.1 Guard fence will be constructed at the locations shown on the plans or as established by the Engineer. Guard fence will consist of a standard chain-link fence mounted to posts which are an integral part of a guard cable system. The guard cable system shall consist of an anchor assembly as described in Section 606.50.2.2 or as shown on the plans. When mounted atop a retaining wall, the anchors will be cast into the wall stem. The anchor shall be connected to the cable by means of a 1 inch turnbuckle. Each cable shall have its own anchor and shall be attached to all posts by means of a U-bolt clamp. The fence fabric shall be positively attached to a stretcher bar incorporated into the end posts. Line post connections to fence will be as provided in Section 607. A 1 inch diameter intermediate turnbuckle will be incorporated into the cable to maintain tension in the cable span between end posts. This intermediate turnbuckle will be attached to each of the ¾ inch diameter cables positioned on either side of the line posts and at a height of 2'-6" above the finish grade. A single uninterrupted ¾ inch diameter cable shall be secured to all posts at a height of 9 inches above the finish grade, and a tension wire (9 gage) will be attached to the top of the fence for support. Unless otherwise shown on the plans, the fence fabric will be 9 gage galvanized, knuckled top and bottom, and the posts will be 2 inch x 2¼ inch H-section post weighing 4.10 pounds per foot, mounted on a base plate for retaining walls. 606.20.2 Method of Measurement. Guard fence complete in place will be measured to the nearest linear foot from the center of end post to the center of end post and will include all items necessary to complete the installation. 606.20.3 Basis of Payment. The accepted quantity of guard fence will be paid at the contract unit bid price.
1/1/2016
606-7
Guardrail and Roadway Barriers
Section 606.30 Crashworthy End Terminals 606.30.1 Description. This work shall consist of furnishing and installing crashworthy end terminals as shown on the plans or as directed by the engineer. 606.30.2 Material. 606.30.2.1 Equipment and material shall be of new stock and in accordance with Section 1040. 606.30.2.2 Type A end terminal installations shall be a minimum of 50 feet long. Additional Type A guardrail shall be provided by the contractor, at the contractor's expense, to increase the Type A end terminal to a length of 50 feet. 606.30.3 Construction Requirements. End terminals and crash cushions shall be fabricated and installed in accordance with the manufacturer's approved shop drawings, recommendations and as shown on the plans. Any units damaged during the term of the contract shall be replaced immediately at the contractor's expense. 606.30.3.1 Where a specific end terminal or crash cushion is shown by product name, that unit shall be used as shown on the plans. No substitutions will be permitted without prior approval from the engineer. 606.30.3.2 The contractor shall not install flared Type A end terminals in medians or on curbs. 606.30.3.3 The contractor shall not install Type B end terminals on paved surface locations, unless the location is temporary and the paved area is to be resurfaced after removal of the system. 606.30.3.4 The contractor may use Type C end terminals where Type B units are specified or shown on the plans. 606.30.3.5 Crashworthy end terminals located 12 feet or less from the edge of the traveled way shall be furnished with a modified Type 3 object marker. The marker size, shape, method of attachment and placement shall be approved by the engineer prior to installation. 606.30.4 Method of Measurement. Measurement for crashworthy end terminals will be made for each unit assembled, installed and complete in place. 606.30.5 Basis of Payment. The accepted quantities of Type A, B and C crashworthy end terminals, complete in place, will be paid for at the contract unit price. Payment will be considered full compensation for complete installation including grading, any transition sections, backup assemblies or other items necessary for proper installation of the end terminal or crash cushion as required. If the contractor elects to use a flared Type A crashworthy end terminal, additional embankment as shown on the plans shall be provided at the contractor's expense.
1/1/2016
606-8
Guardrail and Roadway Barriers
Section 606.40 One-Strand Access Restraint Cable 606.40.1 Description. This work shall consist of furnishing and installing one-strand access restraint cable as shown on the plans or as directed by the engineer. 606.40.2 Construction Requirements. The cable shall be strung directly from the reel and pulled tight after the initial anchoring. The cable shall then be attached to the second anchor assembly with all turnbuckles fully opened. The cable shall be completely anchored before attaching to the line posts. Only one splice will be permitted between anchors, located between the line posts. Splices will not be permitted in spans adjacent to the anchor and cable end assemblies. 606.40.3 Method of Measurement. Measurement of one-strand access restraint cable will be made to the nearest ½ linear foot for each increment, from center of end post to center of end post, and totaled to the nearest linear foot for the sum of the increments on the project. 606.40.4 Basis of Payment. The accepted quantities of one-strand access restraint cable, end anchors, posts and hardware, complete in place, will be paid for at the contract unit price for each of the pay items included in the contract.
1/1/2016
606-9
Guardrail and Roadway Barriers
Section 606.50 Three-Strand Guard Cable 606.50.1 Description. This work shall consist of furnishing and installing three-strand guard cable, as shown on the plans or as directed by the Engineer. Guard cable shall consist of expansion or screw anchors, steel line posts, turnbuckles, clamps, cable, appurtenances, aggregate bedding, and all hardware required to complete the installation. All posts, cable, anchors, and hardware shall be hot dipped galvanized coated. 606.50.2 Construction Requirements. 606.50.2.1 Line Posts. Unless otherwise indicated, the standard guard cable installation will consist of 3 inch x 5.7 pound per foot steel posts, 5 feet in length with 2 feet of the post exposed above the finished grade. Posts will be placed on 12'-6" centers either driven or set in concrete, in accordance with the provisions of Section 606.3.3, and will be plumb and true to line and grade. All posts shall be driven unless otherwise directed by the engineer. Driving shall be accomplished with approved equipment and methods that will leave the posts in the final position, free from any distortion, burring or other damage. All posts shall be aligned to a tolerance of ¼ inch for plumb and grade line. If rock is encountered when setting line posts, the contractor may set line posts with or without a soil plate. Line posts set with a soil plate shall be installed by digging or boring a hole into the rock to the required depth and of sufficient size for the post to be set with the soil plate attached. Line posts set without the soil plate shall be installed by drilling a hole to the required depth not to exceed 5 inches in diameter. Following placement of the post, the hole shall be backfilled with a cohesive soil or sand in accordance with Section 1005.2, and thoroughly tamped. 606.50.2.2 Anchor Assemblies. The anchoring device will be of a screw type or expandable type on a 1 inch diameter rod equipped with a standard turnbuckle threaded to provide for post tensioning and plumbing of the end posts. The anchor shall be set to the depth shown on the plans and at each end of cable installations of 300 feet or less. Where cable installations will exceed 300 feet, intermediate anchors will be required. The anchor will be secured to the end post or intermediate post with flat washer and hex nut. The specified type of anchor assembly shall be constructed at each end of a run of guard cable. If intermediate end anchors are required, the cable assembly shall be overlapped as shown on the plans. The location of all intermediate anchor assemblies shall be determined by the contractor and approved by the engineer. The concrete anchor shall be cast in place with the centerline normal to the line of the guard cable. The top 12 inches of the anchor below finished ground line shall be formed, unless the engineer determines soil conditions permit excavation to be made to the neat lines of the anchor and the anchor cast against the undisturbed vertical soil face. Anchors shall be constructed on firm, stable, undisturbed soil to the minimum dimensions shown on the plans. Anchor bolts and anchor post slip bases shall be firmly held in the proper position supported at the top by a template during concrete placement. Backfill shall be thoroughly compacted with mechanical tampers with care taken to prevent damage to the finished concrete. Backfill shall be brought up level with the finished grade line. The anchor may be cast in place or precast as either one or two units.
1/1/2016
606-10
Guardrail and Roadway Barriers
606.50.2.3 Cables. The cable will be ½ inch in diameter and shall be strung directly from the reel and shall be pulled tight after the initial anchoring. The cable shall then be attached to the second anchor assembly with all turnbuckles fully opened. The cables shall be completely anchored before being attached to the line posts. The cable will be anchored to the end or intermediate post by means of a standard, 1 inch diameter turnbuckle secured by flat washer and hex nut. The cable shall be passed through a thimble and attached to the turnbuckle eye by means of a minimum of three cable clamps, securely attached. The cable shall be secured to the line posts by means of a 1¼ in. clamp bolted to each post. One line splice will be permitted between anchors and must be made between line posts only. No splice will be permitted in spans adjacent to an anchor or cable end. Cable line splices will be made by using a minimum of three cable clamps spaced at 8 inch intervals. Individual cables may be spliced with a device approved by the engineer. Cables shall be attached to the line posts, anchor posts, cable transition brackets and anchor brackets as shown on the plans. Where compensating devices or turnbuckles are required, the cables shall be attached to the end anchor with turnbuckles fully opened. Compensating devices and turnbuckles shall be installed such that no interference with the functions of any other part of the system occurs. Each cable shall be stretched taught by mechanical means to eliminate sag between the posts. The contractor may tighten cable hook bolts after final cable tensioning is complete to allow cable slack to be adequately taken up. Prior to final acceptance, the cables shall be tensioned in accordance with the temperature and spring compression table shown on the plans and all cable hook bolts tightened. 606.50.2.4 Aggregate Bedding. Material for aggregate bedding shall consist of a durable crushed stone, shot rock or broken concrete with approximately 20 percent of the pieces being between 1 inch and 3 inches in diameter but none greater than 3 inches. The remainder of the material shall be such that provides a uniform, angular appearance. Acceptance by the engineer will be made by visual inspection. 606.50.2.5 Delineators. Delineator spacing and reflector colors shall be in accordance with Section 606.10.3.5. 606.50.3 Installation Requirements. Unless a concrete traffic barrier is provided between the installed posts and the adjacent travel or auxiliary lane, and when that lane will be open to traffic during non-working hours, the Contractor shall schedule guard cable installation or replacement to assure that guard cable is fully attached to all installed posts at the end of each workday. 606.50.4 Method of Measurement. 606.50.4.1 Three-Strand Guardrail. Measurement of three-strand guard cable will be made from center of line post to center of line post, totaled to the nearest linear foot and will include all items necessary to complete the installation. 606.50.4.2 Anchor Assemblies. Measurement of anchor assemblies will be made per each. 606.50.4.3 Aggregate Bedding. Aggregate bedding material will be measured to the nearest cubic yard of material.
1/1/2016
606-11
Guardrail and Roadway Barriers
606.50.5 Basis of Payment. The accepted quantities of three-strand guard cable, end anchors, posts, hardware and aggregate bedding will be paid for at the contract unit price for each of the pay items included in the contract. No direct payment will be made for setting posts in rock. No direct payment will be made for guard cable delineators provided on new guard cable. Delineators specified for installation on existing guard cable will be measured and paid for per each.
1/1/2016
606-12
Guardrail and Roadway Barriers
Section 607
Fencing
Section 607.10 Chain-Link Fence 607.11 Description. This work shall consist of furnishing and erecting chain-link fence and gates, complete in place, in conformity with the lines shown on the plans, or as established by the Engineer. 607.12 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Chain-Link Fence Material.......................................................1043.2 Posts, Braces, Rails and Gate Frames ................................1043.2.5 Wrought Iron Handrails.................................................... ASTM A 73 The contract will specify either zinc coated steel, aluminum coated steel, aluminum alloy, or vinyl coated steel fencing material, except that the same kind of material shall be used throughout the project. Walk gates and drive gates, if required, shall be of the same kind of material as that selected for the fence. 607.13 Construction Requirements. 607.13.1 The Contractor shall fill, cut, or trench where necessary to produce a smooth and uniform ground surface so the bottom of the fabric is not more than 3 inches above the finished ground line. Posts shall be set plumb, true to line and grade in concrete footings, and shall be located as shown on the plans or as directed by the Engineer. Footings shall be of Class B concrete, concrete of a commercial mixture, or quick setting polyurethane foam. The concrete shall be of a uniform thickness around the post, and the footings shall have cone or dome shaped tops. The Contractor may, at his option, use a quick setting polyurethane foam in accordance with Section 607.23.3 for line posts in lieu of concrete. The Contractor may, at his option, drive line posts in lieu of setting in concrete or polyurethane. If the Contractor elects to drive line posts, they shall be of the length and driven to the depth shown on the plans. If posts cannot be driven to depths indicated because of rocky soils or other conditions, they shall be removed and placed in footings. Post tops shall be protected against damage and all posts damaged during installation shall be removed and replaced. 607.13.2 Fabric shall not be attached to posts until the concrete in the footings is at least 5 days old, and shall be attached to the posts on the side indicated on the plans. Fabric shall be securely attached to end, corner, gate, and pull posts in accordance with manufacturer's recommendations. It shall be attached to top rails and line posts with wire ties or bands, and spaced in accordance with manufacturer's recommendations. All fabric shall be taut before it is attached to line posts or top rails. Top rails shall be continuous from terminal post to terminal post, connected with self-centering couplings, every fifth one of which in any continuous length shall be a slip coupling.
1/1/2016
607-1
Fencing
607.13.3 Walk gates and drive gates complete with hinges, latches, braces, stops, and locking devices shall be installed at locations shown on the plans. Drive gates shall have an approximate 180 degree opening swing. Walk gates shall have positive stops to prevent the gates from swinging into the right-of-way. 607.14 Method of Measurement. Measurement of chain-link fence will be made to the nearest linear ft. measured along the slope of the fabric but shall not include gates. Gates will be paid at contract unit price per each. 607.15 Basis of Payment. The accepted quantity of chain-link fence, complete in place, will be paid for at the unit bid price for each of the pay items included in the contract. No direct payment will be made for concrete footings or for post hole excavation or for excavation and embankment necessary to smooth the area under the fence.
1/1/2016
607-2
Fencing
Section 607.20 Woven Wire Fence 607.21 Description. This work shall consist of furnishing and erecting woven wire fence, complete in place, in conformity with the plans, and at locations as designated on the plans or established by the Engineer. 607.22 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Woven Wire Fence Material ....................................................1043.3 607.23 Construction Requirements. 607.23.1 Wood corner, end, brace, and pull posts shall be set in drilled or dug holes. At the option of the Contractor, steel or wood line posts may be set in drilled or dug holes, or may be driven into place provided the method of driving meets the approval of the Engineer and does not damage the post. All wood posts set in drilled or dug holes shall have the butt end down, and shall be backfilled with suitable material thoroughly tamped. Wood line posts that are to be driven shall have the butt end machine pointed at the plant before being treated. 607.23.2 If surfaces of treated wood posts have been damaged, or if framing at the site is required, such injuries or cuts shall be field treated with two liberal brush coats of commercially available preservative of the same type used for the original treatment. The second coat shall be applied after the first coat is absorbed. 607.23.3 Posts shall be set plumb, true to line and grade. Corner post assemblies shall be set at all horizontal angle points greater than 15 degrees in the line of fence. Pull post assemblies shall be set at all vertical angle points greater than 15 degrees but at not greater than 660 feet intervals. Footings for steel posts and braces shall be of Class B concrete, concrete of a commercial mixture, or, at the Contractor's option, quick setting polyurethane foam for footings. The foam shall have a minimum compressive strength of 80 psi in the direction of rise, when tested in accordance with ASTM D 1621 and shall have a minimum density of 4 pounds per cubic foot when tested in accordance with ASTM O 1622-63. The foam shall not be placed in water. Polyurethane foam, when used, shall be per manufacturer's instructions. 607.23.4 Fabric and barbed wire shall be pulled taut by approved hand powered mechanical means before they are attached to any line post. The bottom of the fabric shall be not more than 3 inches above the ground at any point, and necessary excavation along the fence shall be performed to obtain the specified clearance. Filling of depressions will not be permitted except where old channels are backfilled after drainage has been relocated. Any space left by depressions shall be filled by spacing strands of barbed wire as indicated on the plans.
1/1/2016
607-3
Fencing
607.23.5 Walk gates and drive gates complete with hinges, latches, braces, stops, and locking devices shall be installed at locations shown on the plans. They shall be constructed in accordance with the requirements of gates for chain-link fence, except the filler shall be woven wire fabric of the same kind as used for the fence. Direction of swing of gates shall be as indicated on the plans or as directed by the Engineer. 607.23.6 Water gates shall be installed at locations shown on the plans and the Contractor shall modify the typical installation to fit the conditions encountered. 607.24 Method of Measurement. Measurement of woven wire fence will be made to the nearest linear foot measured along the slope of the fabric, but shall not include gates. Gates will be paid at contract unit bid price per each. 607.25 Basis of Payment. 607.25.1 The accepted quantity of woven wire fence, complete in place, will be paid for at the contract unit bid price per linear foot which will include all materials, excavating for posts, backfilling, clearing of fence row, trenching for fabric, placing extra strands of barbed wire for depressions, and all other incidental work or material. 607.25.2 The accepted walk gates and drive gates, complete in place, will be paid for at the unit bid price for each of the pay items included in the contract. 607.25.3 No direct payment will be made for construction or installation of water gates.
1/1/2016
607-4
Fencing
Section 607.30 Handrails 607.31 Description. This work shall consist of furnishing and erecting galvanized pipe handrails and wrought iron handrails, complete in place, in conformity with the plans and at locations as established on the plans or designated by the Engineer. 607.32 Materials. Pipe shall be galvanized pipe of sizes as detailed. Wrought iron railing shall be constructed of bar sections as detailed. 607.33 Construction Requirements. When anchor bolts are required for handrail posts, they will be poured in place using a template provided by the Engineer; at Contractor's option, holes for rail post may be formed or drilled. Rails shall be installed as detailed using aluminum oxide mortar grout meeting the requirements of Section 1066.2.4. A commercial expansive grout will be permitted with prior approval of the Engineer. 607.34 Method of Measurement. Measurement of handrails will be made to the nearest linear foot measured along the slope of the rail. 607.35 Basis of Payment. The accepted handrail, complete in place, will be paid for at the contract unit bid price per linear ft. which will include all rail, grout, labor, and all other incidental work or material.
1/1/2016
607-5
Fencing
(This Page Intentionally Left Blank)
1/1/2016
607-6
Fencing
Section 608
Concrete Medians, Median Strips, Sidewalks, Curb Ramps, Steps and Paved Approaches
608.1 Description. This work shall consist of constructing concrete medians, median strips, sidewalks, curb ramps, steps, and paved approaches in conformity with the lines, grades, dimensions, and typical sections indicated on the plans, or as directed by the Engineer. Concrete median shall consist of a paved median constructed on a prepared aggregate base over a prepared subgrade. Concrete median strip shall consist of a paved median strip laid over and doweled to a previously constructed pavement. 608.2 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Reinforcing Steel for Concrete Structures .................................. 1036.3 Steel Wire Fabric for Concrete Pavement .................................... 1036.4 Epoxy coated Reinforcing Steel.................................................... 1036.5 Materials for Joints .......................................................................... 1057 608.2.1 Concrete sidewalks and steps shall be constructed of Class B concrete. All other items shall be constructed of concrete using crushed limestone coarse aggregate and shall be either Class B concrete or pavement concrete. Materials, proportioning, air entrainment, mixing, slump, and transporting of Portland cement concrete shall be in accordance with Section 501. Concrete shall be placed, finished, and cured in accordance with the applicable provisions of Sections 502 and 703. Pipe handrails indicated at step locations shall be constructed of 2 inch galvanized schedule 40 pipe and anchored as indicated. 608.3 Construction Requirements. 608.3.1 All items shall be constructed on a subgrade compacted to the required density of the applicable subgrade material. The subgrade shall be checked by means of a template prior to placing concrete. Large rocks and boulders found in the subgrade shall be removed to a minimum of 6 inches below the proposed concrete, and the space shall be refilled with suitable materials. Forms shall be metal or sound, dressed lumber, straight, free from warp, of sufficient strength to resist springing during construction, and of a height equal to the full depth of the item to be constructed. Wood forms shall have a minimum nominal thickness of 2 inches except where flexible forms are used. Flexible metal forms or wood forms having a nominal thickness of 1 inch will be required for all curved form lines, except that straight steel form sections 10 feet or less in length may be used for form lines having a radius greater than 200 feet. Straight steel form sections 5 feet in length will be acceptable for form lines having a radius of not less than 100 feet. The forms shall be thoroughly cleaned, well-oiled securely staked, braced, and held to the required line and grade.
9/1/2023
608-1 Concrete Medians, Median Strips, Sidewalks, Curb Ramps, Steps and Paved Approaches
608.3.2 Required reinforcement and tie bars shall be held in the designated position by bar chairs or other approved devices during the placing of concrete. 608.3.3 Concrete median strip shall be doweled to the pavement with epoxy-coated tie bars as shown on the plans. When the median strip is to be built on pavement constructed on a previous project or on pavement that has been used by traffic before the median strip is placed, the Contractor shall drill 1 inch diameter holes, 6 inches deep on 24 inch centers using 10 inch, No. 5 epoxy-coated dowels grouted in place 24 hours in advance of placing concrete. Where the median strip is included with the paving contract and will be constructed before the pavement is opened to traffic, the Contractor may insert the tie bars into the pavement immediately after it has been finished or may pre-form the holes and grout in the tie bars when the median strip is constructed. The holes shall be thoroughly cleaned just before the tie bars are grouted in place. 608.3.4 Joints for all items shall be constructed at such intervals and locations as shown on the plans or as directed by the Engineer. 608.3.4.1 Transverse joint for concrete median shall be sawed joints of the same dimensions as required for concrete pavement spaced approximately the same as transverse joints in non-reinforced concrete pavement. Load transfer devices will not be required. Longitudinal joints between the median and curb shall be constructed of ½-inch non-extruding preformed joint material. Sawed joints shall be sealed in accordance with Section 502.13.7. 608.3.4.2 Transverse joints in concrete median strip shall be constructed of ½-inch nonextruding preformed joint material extending from top to bottom. Joints shall be constructed over each joint and major crack in the pavement, but at not less than 10 feet intervals. 608.3.4.3 Transverse joints for concrete sidewalks shall be ½-inch deep dummy joints made with a finishing tool. Preformed fiber joints shall be at 20 feet intervals. Regardless of other details and notes shown on the plan, a mastic joint will be required in all new sidewalk construction at the right-of-way line. Other plans and specification requirements regarding joint placement may be varied as directed. 608.3.5 Curb ramps shall be constructed on 4 inches of compacted Type 5 aggregate base. Concrete for all other items shall be placed on the prepared and sprinkled subgrade. Concrete shall be compacted and struck off to the required thickness. Mechanical compacting and finishing equipment may be used provided satisfactory results are obtained. The concrete shall be tamped or vibrated sufficiently to eliminate all voids and to bring the mortar to the top after which the surface shall be uniformly finished. All edges shall be rounded with an edging tool having a ¼-inch radius. After free water has left the surface, a hand broom finish will be applied. After finishing, the concrete shall be cured in the same manner as required for concrete pavement except that transparent membrane shall be used in lieu of pigmented membrane.
9/1/2023
608-2 Concrete Medians, Median Strips, Sidewalks, Curb Ramps, Steps and Paved Approaches
608.3.6 Tinted Concrete. Where the contract requires concrete to be tinted, the tinting materials used shall meet the requirements of Section 1056. 608.3.6.1 Concrete shall be tinted by applying the tinting material uniformly over, and working it into, the surface of the fresh concrete to a depth of ⅛ to ¼ inch in a manner and quantity required to obtain a uniform color density meeting the approval of the Engineer, after which the final finishing operations shall proceed. The tinting mixture shall be a 2 to 1 blend of tinting material to cement. This mixture shall be applied at the rate of approximately 45 pounds per 100 square foot of surface. The actual quantity required to obtain the desired color density may vary from this estimated quantity. Tinted concrete shall be cured in accordance with the curing requirements for the contract item for which tinting is specified, except that white pigmented membrane curing material shall not be used. When the Contractor elects to use membrane curing for those items where its usage is permitted, it shall be of the clear or transparent type. 608.3.7 After the concrete has sufficiently set, the forms shall be removed and where necessary, the area adjacent to the concrete shall be backfilled with suitable material, compacted and finished in a satisfactory manner. 608.3.8 The limitations and protection requirements of Section 502.5, "Weather Limitations", shall apply to this work. 608.3.9 Pedestrian Access Route Requirements. 608.3.9.1 Curb Ramp Segmental Transitions. When a new ADA compliant curb ramp is constructed adjacent to existing pavement, a segmental transition must be constructed. A segmental transition is a warped area of pavement for the connection of the new ADA Compliant curb ramp to the adjacent existing pavement, and shall be constructed as shown in the Standard Drawings. 608.3.9.2 Coordination of Sidewalk Construction. Prior to construction and/or closure of an existing pedestrian access route, the Contractor shall submit a schedule of work which includes the location of work performed, the duration of time the Contractor expects to impact the facility and an accessible signed pedestrian detour during each stage of construction. This plan shall be submitted to the Engineer for review and approval prior to any work being performed in the field. 608.3.9.3 Curb Ramp Design. The Contractor shall use their own survey equipment to verify that the intended ramp design can be constructed to the full requirements as established in the PROWAG. When PROWAG does not give sufficient information to construct the Contract work, the Contractor shall reconstruct the ramp as instructed by the Engineer. It will be the responsibility of the Contractor to determine removal limits based on achieving full ADA compliance. 608.3.9.4 Acceptance of Work. The Engineer will provide the completed ADA Post Construction Checklist to the Contractor prior to scheduling the semi-final inspection. ADA improvements will be accepted upon final inspection and compliance with the ADA Post Construction Checklist. Each item listed in the checklist must receive either a “YES” or a “N/A” score. Any item receiving a “NO” will be deemed non-compliant and shall be corrected at the Contractor’s expense unless deemed otherwise by the Engineer. 608.4 Method of Measurement. 608.4.1 Measurement of concrete median and median strip will be made to the nearest 1/10 square yard or to the nearest linear foot as indicated in the contract. 9/1/2023
608-3 Concrete Medians, Median Strips, Sidewalks, Curb Ramps, Steps and Paved Approaches
608.4.2 Concrete sidewalk will be measured to the nearest 1/10 square yard. 608.4.3 Paved approach will be measured from the beginning of the return on one side of the approach to the end of the return on the other side of the approach to the nearest 1/10 square yard. Integral curb constructed on paved approaches will not be measured and paid for separately but will be included in the contract unit price for paved approaches. 608.4.4 All excavation and all work necessary in preparing the subgrade and backfilling will be paid for as one or more of the classifications of roadway excavation. Final measurement of excavation will not be made except as set out in Section 203.7.1. 608.4.5 Curb Ramps will be measured on a per each basis. When the plans detail a dual ramp or a blended transition that serves two (2) pedestrian crossings at a single location, the Contractor will be compensated for two (2) ramps.
9/1/2023
608-4 Concrete Medians, Median Strips, Sidewalks, Curb Ramps, Steps and Paved Approaches
608.5 Basis of Payment 608.5.1 The accepted quantity of concrete steps will be measured and paid for to the nearest 1 /10 square foot or as: a) Class B concrete which will be constructed in accordance with Section 703 for miscellaneous concrete and paid per cubic yard. b) Reinforcing steel shall be constructed in accordance with Section 706 and paid per pound. 608.5.2 The accepted quantities of concrete median, median strip, sidewalk, and paved approach, complete in place, will be paid for at the unit bid price for each of the pay items included in the contract. No direct payment will be made for furnishing or installing reinforcement. No direct payment will be made for constructing joints in sidewalk. If no Sidewalk pay item exists in the contract, payment for 4” or 6” Sidewalk, as required by the Engineer, will be made per square yard as 6” Sidewalk at the fixed cost specified in section 109.4.5. If no Drive Approach pay item exists in the contract, payment for 6” or 7” Drive Approach, as required by the Engineer, will be made per square yard as 7” Drive Approach at the fixed cost specified in section 109.4.5. 608.5.3 The accepted quantities of curb ramps will be paid for at the unit bid price for each of the pay items included in the contract. No direct payment will be made for the cost associated with removal of existing materials required for curb ramp construction, as well as new construction of landings, ramps, flares, return curbs, additional curbing and/or gutter for grade control (final graded slopes of 3:1 or flatter), raised medians installed for directional delineation, truncated domes, excavation, aggregate base, backfilling, utility adjustments, up to fifteen (15) linear feet in either direction for construction of a compliant ramp, up to five (5) linear feet of sidewalk necessary to transition between newly constructed compliant ramps and adjacent non-compliant sidewalks, and any necessary segmental transitions to the surrounding concrete or asphalt pavement. The segmental transition length included in the per each price shall include an area equal to the size of the opening plus five feet (5’) in any direction to allow for connection to the grade of existing facilities. Where the transitions are in full depth pavement and the Engineer requires a length greater than the five-foot (5’) incidental section, compensation for the additional pavement removal and replacement shall be paid for at the unit price for removal and replacement of concrete pavement in the contract. Where milling and/or overlay operations intersect the newly constructed ramp, no additional pay will be made for constructing a flush connection between the pedestrian access route and the roadway. Retrofit truncated domes will be paid for at the contract unit price. If no retrofit truncated dome item exists in the contract, payment will be made per square foot at the fixed cost specified in Section 109.4.5. 608.5.4 No direct payment will be made to the Contractor to recover the cost of the equipment, labor, materials, or time required to provide an accessible pedestrian signed detour during the various stages and locations of pedestrian access route construction.
9/1/2023
608-5 Concrete Medians, Median Strips, Sidewalks, Curb Ramps, Steps and Paved Approaches
Section 609
Paved Drainage
Section 609.10 Concrete Curb, Gutter and Paved Ditch 609.11 Description. This work shall consist of constructing curb, gutter, or combination curb and gutter, and paved ditches in conformity with the lines, grades, dimensions, and typical sections indicated on the plans, or as directed by the Engineer. 609.12 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Reinforcing Steel for Concrete Structures .................................. 1036.3 Materials for Joints .......................................................................... 1057 Materials, proportioning, air entraining, mixing, slump, and transporting of Portland cement concrete shall be in accordance with Section 501. Concrete shall be Class B and shall be placed, finished, and cured in accordance with the applicable provisions of Section 703. Concrete used for paved ditches and channels shall be MSD Class A and should be placed, finished, and cured in accordance with the applicable provisions of Section 703. 609.13 Construction Requirements. 609.13.1 These items shall be placed on a prepared subgrade of uniform density. Forms shall be metal or sound, dressed lumber, straight, free from warp, of sufficient strength to resist springing during construction, and of a height equal to the full depth of the item to be constructed. Wood forms shall have a minimum nominal thickness of 2 inches except where flexible forms are used. Flexible forms of metal or wood (with a nominal thickness of 1 inch) will be required for all curved form lines, except that straight steel form sections 10 feet or less in length may be used for form lines having a radius greater than 200 feet. Straight steel form sections 5 feet in length will be acceptable for form lines having a radius of not less than 100 feet. The forms shall be thoroughly cleaned, well oiled, securely staked, braced, and held to the required line and grade. Hangers used for face forms on curb must be entirely supported from the back form. 609.13.1.1 In lieu of the forming requirements specified in Section 609.13.1 slip form methods may be used for placement of concrete curb, concrete gutter, curb and gutter, and paved ditch providing proper lines, grades, and typical sections are maintained. Paving requirements will be the same as Section 502.17. 609.13.2 Required reinforcement and tie bars shall be held in the designated position during the placing of concrete by bar chairs or other approved devices. For paved ditch and creek channels, reinforcing steel will be firmly supported on full size concrete brick or block. No additional payment will be allowed for meeting this requirement. Joints shall be constructed at intervals and locations shown on the plans or as directed by the Engineer. ½-inch expansion joints will be provided in curbs or curb and gutter sections at 15 feet centers or as otherwise indicated. 9/1/2023
609-1
Paved Drainage
609.13.3 Concrete shall be placed on the prepared and sprinkled subgrade, compacted, and struck off to the required thickness. Concrete shall be tamped or vibrated sufficiently to eliminate all voids and to bring mortar to the top, after which the surface shall be finished smooth and even. All edges shall be rounded with an edging tool having a ¼-inch radius. Faces of curb shall be rounded at the top and bottom, by means of an approved tool, to the radius shown. The curb face forms will be stripped when the concrete is sufficiently set, and the face of the curb will be rubbed using grout necessary to fill any voids and air bubbles. After the rubbing operation, a brush finish will be applied. After finishing, concrete shall be cured in the same manner as required for concrete pavement except that transparent membrane shall be used on paved ditch. 609.13.3.1 The finished curb shall be true to line, grade, and cross section, with the top and face finished smooth and brushed. The top edges of the curb shall be rounded with an approved edging tool. Curing shall be accomplished in the same manner as required for concrete pavement. At 60 feet intervals, joints of preformed material shall be placed through the curb to within ¼ inch of the top and face of the curb. At all other joint locations, a matching saw joint will be allowed, provided that it is completely sawed through and sealed. 609.13.4 The limitations and protection requirements of Section 502.5, "Weather Limitations", shall apply to this work. 609.13.5 Curb straight edged parallel to the centerline shall not show a variance greater than ½ in. from a 10-foot straightedge. Failure to comply with this provision will require complete removal and replacement of the affected area. No area less than 10 feet will remain in place. 609.14 Method of Measurement. 609.14.1 Curb, gutter, and combination curb and gutter will be measured to the nearest linear foot along the curb face or along the flowline of gutters. Unless otherwise specifically provided for in the contract, the quantities shown for combination curb and gutter have been carried across private and commercial concrete entrances and include the gutter pan shown in the Standard Drawings. However, if the gutter pan section is constructed monolithically with the paved approach, it will be added to the approach quantity for payment with a corresponding amount deducted from the curb, and curb transitions on paved approaches will not be measured nor paid for separately but will be considered a part of the paved approach. Curbs carried full height on paved approaches will be measured and paid for under the applicable curb item. No deductions will be made for wheelchair ramps. 609.14.2 Paved ditches will be computed by measuring from the top of the exposed surface on the slope to the bottom of exposed surface on the slope to the nearest 1/10 square yard. 609.15 Basis of Payment. The accepted quantities of curb, gutter, curb and gutter, and paved ditch, complete in place, will be paid for at the unit bid price for each of the pay items included in the contract. No direct payment will be made for excavation, nor for any work necessary for preparing the subgrade and backfilling the completed item. No direct payment will be made for furnishing or installing reinforcement, nor for excavating toewall. If no Curb and Gutter pay item exists in the contract, payment for vertical/mountable Curb and Gutter of variable width as required by the Engineer will be made per linear foot at the fixed cost specified in section 109.4.5.
9/1/2023
609-2
Paved Drainage
Section 609.20 Integral Curb 609.21 Description. This work shall consist of curb constructed on the edge of concrete pavement in conformity with the typical section shown on the plans. 609.22 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Material for Joints ................................................................................. 1057 Integral curb shall be constructed of Class B concrete conforming to that required for concrete pavement except that coarse aggregate of the classification required for pavement but conforming to the gradation "D" requirements of Section 1005.1.3 may be used. The quantity of coarse aggregate in the mix may be reduced to obtain better workability. 609.23 Construction Requirements. 609.23.1 The curb is to be an integral part of the supporting concrete pavement and may be placed immediately after all slab finishing operations have taken place and before the slab has taken its initial set, or tie bars may be set in the freshly finished slab to serve ultimately as a tie between the slab and the curb, which may be constructed later. When necessary for paving equipment to be backed up near a construction joint, the relatively short distance will be drilled, and curb dowels will be grouted 24 hours prior to placing curb. All curbs will be constructed 6 inches in height unless otherwise specified. 609.23.2 Metal forms joined neatly and tightly, set accurately to alignment and grade, and securely held in place by connections and bracing shall be used for this work. Forms for curved form lines shall be provided in a manner similar to that required for concrete pavement in Section 502.3.4.2 609.23.2.1 In lieu of the forming requirements of Section 609.23.2, slip form methods may be used for placement of integral curb providing all other requirements of Section 609.23 are met. 609.23.3 The finished curb shall be true to line, grade, and cross section, with the top and face finished smooth and brushed. The top edges of the curb shall be rounded with approved edging tools. Curing shall be accomplished in the same manner as required for concrete pavement. At 60-foot intervals, joints of preformed material shall be placed through the curb to within ¼ inch of the top and face of the curb. At all other joint locations, a matching saw joint will be allowed, provided that it is completely sawed through and sealed. 609.23.4 Where the tie bars are set in the freshly finished pavement surface, and membrane curing is used on the pavement, care shall be taken to avoid spraying the membrane on the protruding tie bars or the area on which the integral curb is to be placed. Another of the alternatives of Section 502.14 shall be used for curing this area of the pavement.
9/1/2023
609-3
Paved Drainage
609.23.5 Integral curb straight edged parallel to the centerline shall not show a variance greater than ½ inch from a 10-foot straightedge. Failure to comply with this provision will require complete removal and replacement of the affected area. No area less than 10 feet will remain in place. 609.24 Method of Measurement. Integral curb will be measured to the nearest linear foot along the curb face, exclusive of paved approaches. Final measurement of the completed integral curb will not be made except for authorized changes during construction, or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. 609.25 Basis of Payment. The accepted quantity of integral curb, complete in place, will be paid for at the unit bid price for each of the pay items included in the contract. Payment for curb constructed on paved approaches will be included in the unit bid price for paved approaches. If no Integral Curb pay item exists in the contract, payment for any height of Integral Curb as required by the Engineer will be made for as Remove and Replace Integral Curb (Over 6" Height) per linear foot at the fixed cost specified in section 109.4.5.
9/1/2023
609-4
Paved Drainage
Section 609.30 Asphalt Curb 609.31 Description. This work shall consist of constructing a curb of asphaltic concrete in conformity with the lines, grades, and dimensions shown on the plans or established by the Engineer. All applicable provisions of Section 405, "Bituminous Pavements and Base", shall apply to this construction. 609.32 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Application Temperatures for Bituminous Materials .................. 1015.5 Coarse Aggregate .............................................................................1002.1 Fine Aggregate ..................................................................................1002.2 Mineral Filler ...................................................................................... 1002.4 609.33 Composition of Mixture. The asphaltic concrete mixture shall consist of aggregates, filler if needed, and asphalt cement combined in such proportions that the composition by weight of the finished mixture shall be within the limits specified for Type C or D mixture in accordance with Section 405.3.1. The Contractor shall submit in writing, for approval, the job mix he proposes to use for asphalt curb. The Type C job mix approved for asphaltic concrete pavement shall not be used for asphalt curb. 609.33.1 An approved commercial mixture may be used as approved by the Engineer. If the Contractor elects to use such a mixture, he shall furnish the Engineer, for approval, a statement setting out the source and the job mix formula of the mixture he proposes to furnish. If the proposed mixture and plant are approved by the Engineer, the component materials and the mixture delivered will be accepted or rejected by visual inspection. The supplier shall furnish a certification in triplicate that the material and mixture are in conformance with the approved proposal. 609.34 Construction Requirements. 609.34.1 The curb shall be placed in position on a clean, tacked surface by means of an approved automatic curb machine which shapes and compacts the mixture to the designated cross section. The placement temperature of the mixture shall be approximately 260°F. Any required joints shall be carefully made in such manner as to insure a continuous bond between the old and new sections of the curb. 609.34.2 The newly laid curb shall be protected from traffic by barricades or other suitable methods until the heat of the asphalt mixture has dissipated. Immediately after the asphalt curb has hardened; it shall be backfilled where required with suitable material.
9/1/2023
609-5
Paved Drainage
609.34.3 If painting of the asphalt curb is required by the contract, a light coat of commercial grade asphalt base aluminum paint shall be first applied. 609.35 Method of Measurement. Asphalt curb will be measured to the nearest linear foot. 609.36 Basis of Payment. The accepted quantity of asphalt curb will be paid for at the contract unit bid price. No direct payment will be made for cleaning and priming prior to placing of the curb, nor for painting the completed curb.
9/1/2023
609-6
Paved Drainage
Section 609.40 Drain Basin 609.41 Description. This work shall consist of constructing a drain basin in conformity with the lines, grades, thicknesses, and typical sections shown on the plans or directed by the Engineer. 609.42 Materials. 609.42.1 Drain basins shall be constructed of concrete or bituminous mixtures meeting the requirements of any one of the following specifications: 609.42.1.1 Bituminous. Bituminous mixtures used for construction of drain basins shall meet the requirements of one of the following specifications: Item
Section
Bituminous Pavements and Base (Type C, D or X).....................................405 609.42.1.1.1 The bituminous mixture shall consist of aggregates, filler if needed, and bitumen combined in such proportions that the composition by weight of the finished mixture shall be within the designated limits of the material selected for use, except that if asphalt cement is used the quantity of bitumen shall be increased approximately 2 percentage points above that required for the selected mixture. 609.42.1.1.2 The Contractor shall submit in writing, for approval, the mixing formula he proposes to use. If a commercial mixture is proposed for use, the Contractor shall furnish the Engineer, for approval, a statement setting out the source and the job mix formula. If the proposed mixture and plant are approved by the Engineer, the component materials and the mixture delivered will be accepted or rejected by visual inspection. 609.42.1.2 Concrete. Concrete mixtures used for construction of drain basins will be Class B concrete. 609.43 Construction Requirements. 609.43.1 The excavating shall be done in such manner to permit the placement of the material to the proper section. The surface shall be primed or watered to the satisfaction of the Engineer. The drain basin shall be formed on the surface to the shape shown on the plans and shall be firmly compacted in a neat workmanlike manner to ensure a dense mixture, free from low points, and uniformly shaped to drain properly. 609.43.2 As soon as practicable, the drain basin shall be backfilled around the edges where required with suitable material, and the affected shoulder and slope areas finished to the satisfaction of the Engineer. 609.44 Basis of Payment. The accepted drain basins will be paid for at the contract unit bid price per each. No direct payment will be made for excavating, priming, watering, nor backfilling, nor for the finishing of the affected shoulder or slope.
9/1/2023
609-7
Paved Drainage
Section 609.60 Ditch Liner 609.61 Description. This work shall consist of constructing ditch liner at the locations indicated on the plans, or as directed by the Engineer. 609.62 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Air entrained concrete will be required. Materials, proportioning, air entraining, mixing, slump, and transporting of Portland cement concrete shall be in accordance with Section 501. Concrete shall be Class B and shall be placed, finished, and cured in accordance with the applicable provisions of Section 703. Concrete used for paved ditches and channels shall be MSD Class A and should be placed, finished, and cured in accordance with the applicable provisions of Section 703. Direct placement of concrete by pumping equipment acceptable to the Engineer will be permitted. To facilitate pumping, an increase in the percentage of fine aggregate will be allowed. 609.63 Construction Requirements. 609.63.1 Ditch liners shall be constructed by placing concrete directly on the prepared subgrade. 609.63.2 The ditch liner shall be placed on a subgrade of reasonably uniform density to the thickness shown on the plans. 609.63.3 Forms will not be required. Concrete shall be consolidated and struck off to the required thickness and shape. 609.63.4 The limitations and protection requirements of Section 502.5, "Weather Limitations", shall apply to this work. 609.63.5 Concrete shall be cured in the same manner as required for concrete pavement except that transparent membrane may be used in lieu of pigmented membrane. 609.63.6 After the concrete has sufficiently set the Contractor shall, where necessary, backfill adjacent to the ditch liner with suitable material, compacted and finished in a satisfactory manner. 609.64 Method of Measurement. Ditch liner will be measured to the nearest square yard of surface. 609.65 Basis of Payment. The accepted quantity of ditch liner, complete in place, will be paid for at the contract unit bid price. No direct payment will be made for excavation below the upper surface of the ditch liner, nor for any work necessary for preparing the subgrade and backfilling the completed item.
9/1/2023
609-8
Paved Drainage
Section 609.70 Rock Lining 609.71 Description. This work shall consist of constructing rock lining at the locations indicated on the plans or as directed by the Engineer. 609.72 Materials. The materials for rock lining shall meet the requirements of Section 611.30 for Type 2 rock blanket. 609.73 Construction Requirements. The rock lining material shall be placed by dumping and shall be left in a rough condition to the approximate shape of the channel flow line. 609.74 Method of Measurement. Measurement will be made to the nearest cubic yard of material in place in the completed rock lining. Final measurement of the completed rock lining will not be made except for authorized changes during construction, or where appreciable errors are found in contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. 609.75 Basis of Payment. The accepted quantity of rock lining in place will be paid for at the contract unit price. No direct payment will be made for any excavation required to place the rock lining.
9/1/2023
609-9
Paved Drainage
(This Page Intentionally Left Blank)
9/1/2023
609-10
Paved Drainage
Section 610
Masonry Construction
Section 610.10 Rubble Masonry 610.11 Description. This work shall consist of stone laid in mortar or laid dry as specified in the contract, and in conformity with the lines and grades shown on the plans or established by the Engineer. 610.12 Materials. Stone for rubble masonry shall be sound and durable, and relatively free of shale or other easily disintegrated material. In general, the stone shall be not less than 4 inches thick, however an occasional stone not less than 2 inches thick will be permitted. The stones shall be not less than 12 inches wide, and shall be from 12 inches to 36 inches long. The width shall be not less than the thickness, nor shall the length exceed three times the thickness. The stones shall be roughly squared on joints, beds, and faces. Selected stone shall be used for the ends and angles of walls. Mortar for joints shall meet the requirements of Section 1066.2.3.1. Precast concrete blocks may be substituted for stone for masonry. Such blocks shall be of the size specified above, and shall be made of Class B concrete, proportioned and mixed in accordance with Section 501, and shall be cured by any of the methods specified for concrete pavement, except that transparent membrane shall be used in lieu of pigmented membrane. For dry rubble masonry, the Contractor may use broken concrete in lieu of stone, if approved by the Engineer. The pieces of broken concrete shall be of the size specified above. 610.13 Construction Requirements. 610.13.1 Rubble Masonry Laid in Mortar. All stone or blocks shall be thoroughly wetted and laid upon their natural beds with joints approximately horizontal and vertical. Each stone or block shall be settled into place in a full bed of mortar. In general, the wall shall be laid with face joints not exceeding 1½ inches in thickness and with vertical joints broken not less than 6 inches. The vertical joints in the interior of the wall shall be filled with suitable stone or spalls thoroughly bedded in mortar. Voids will not be permitted. Headers shall be arranged to occupy at least ¼ of the area of the face and back, and shall be evenly distributed. For walls of 2 feet or less in thickness, headers shall extend entirely through the wall. For thicker walls, front, back, and intermediate headers shall be arranged to lap at least 12 inches. 610.13.1.1 All joints on the exposed faces shall be raked out to a depth of approximately 1½ inch and shall be thoroughly wetted. They shall then be filled flush with mortar pressed tightly into place with suitable tools, and cured with transparent curing membrane. 610.13.1.2 The limitations and protection requirements of Section 502.5, "Weather Limitations", shall apply to the grout and concrete. 610.13.2 Rubble Masonry Laid Dry. Dry rubble masonry shall be built with broken joints and placed in a manner forming a solid self-supporting wall. After the stone has been placed, the voids shall be filled with spalls or small stones so that all stones are tightly wedged or keyed. The finished wall shall have a uniform surface.
1/1/2016
610-1
Masonry Construction
610.13.3 Excavation for rubble masonry shall be of sufficient width and depth to permit the proper placing of the stones on a firm, solid foundation or footing. Backfilling shall be done to the finished ground line with suitable material placed in layers, and each layer firmly compacted into place. 610.14 Method of Measurement. Measurement will be made to the nearest 1∕10 cubic yard in accordance with the dimensions shown on the plans or as revised by the Engineer during construction. Copings and footings will generally be made of concrete and will be measured and paid for as concrete masonry. No direct payment will be made for excavation and backfilling for structures. 610.15 Basis of Payment. The accepted quantity of rubble masonry will be paid for at the unit bid price for each of the pay items included in the contract.
1/1/2016
610-2
Masonry Construction
Section 611
Embankment Protection
Section 611.10 Rock Fill 611.11 Description. This work shall consist of constructing fill of rock or broken concrete for protection of embankment. 611.12 Materials. The material for rock fill shall be durable stone or broken concrete containing a combined total of not more than 10 percent of earth, sand, shale, and non-durable rock. It is intended that the material be similar to quarry run stone graded from coarse to fine with a minimum of voids. The coarse stone shall be as large as can be conveniently handled, but at least 25 percent of the weight shall be of pieces having a volume of 1 cubic foot or more. Acceptance of quality and size of material will be made by visual inspection at the job site. 611.13 Construction Requirements. Successive horizontal layers of stone or broken concrete not exceeding 24 inches in thickness shall be spread over the area of the rock fill. The larger pieces shall be well distributed and the interstices filled with smaller pieces. Each layer shall be spread in accordance with the methods specified in Section 203.2.18. Where rock fill is placed as a portion of embankment with controlled density, the material shall be compacted in accordance with the requirements of Section 203.3.5. The fill shall conform to the elevations and dimensions shown on the plans, and the slopes shall present a dense, finished appearance free from segregation and with a proportionate amount of the large pieces showing. 611.14 Method of Measurement. Measurement will be made to the nearest cubic yard of material in place in the completed fill. 611.15 Basis of Payment. 611.15.1 Payment for furnishing and placing rock fill will be made at the contract unit bid price per cubic yard.
1/1/2016
611-1
Embankment Protection
Section 611.20 Fully Grouted Rock Fill 611.21 Description. This work shall consist of furnishing and constructing a fully grouted rock fill as shown on the plans or as directed by the Engineer. This work is not allowed in stream bank stabilization areas. 611.22 Materials. 611.22.1 All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Portland Cement...................................................................1019.2.1 611.22.2 The stone or broken concrete for rock fill shall meet the requirements of Section 611.12. 611.22.3 Grout shall consist of one part Portland cement and five parts of aggregate by volume. The aggregate shall be a mixture of clean sand and gravel, or of crushed stone and sand, or of chat and sand, all of approved quality. The mixture shall be uniformly graded from coarse to fine and meet the following gradation requirements. Sieve Size
Percent Passing
¾ Inch ...........................................................................................100 Number 4...............................................................................40 to 60 611.22.4 Finer aggregate may be used provided the ratio of cement to the material passing the Number 4 sieve is not greater than one to three by volume. 611.23 Construction Requirements. 611.23.1 The rock and grout shall be placed in a manner resulting in a securely bound solid mass with the interstices completely filled. The grout shall have a consistency permitting it to flow readily into the voids. After the interstices have been completely filled with grout, the surface shall be swept clean of all surplus grout with a stiff broom and cured by any one of the methods specified for concrete pavement in Section 502.14, except that transparent membrane shall be used in lieu of pigmented membrane. 611.23.2 The limitations and protection requirements of Section 502.5, "Weather Limitations", shall apply to the grouting. 611.24 Method of Measurement. Measurement of fully grouted rock fill will be made to the nearest ½ cubic yard complete in place. 611.25 Basis of Payment. The accepted quantity of fully grouted rock fill will be paid for at the contract unit bid price. No direct payment will be made for furnishing or placing the rock fill.
1/1/2016
611-2
Embankment Protection
Section 611.30 Rock Blanket 611.31 Description. This work shall consist of constructing a protecting blanket of rock or broken concrete on slopes or stream banks. 611.32 Materials. The material for rock blanket shall be durable stone or broken concrete containing a combined total of not more than 10 percent of earth, sand, shale, and non-durable rock. It is preferable that the material contain a large percentage of pieces as large as the thickness of the blanket will permit, with enough smaller pieces of various sizes to fill the larger voids. For Type 1 Rock Blanket, at least 40 percent of the mass shall be of pieces having a volume of 1 cubic foot or more. For Type 2 Rock Blanket, at least 60 percent of the mass shall be of pieces having a volume of 1 cubic foot or more. Acceptance of quality and size of material will be made by visual inspection at the job site. 611.33 Method of Measurement. Measurement will be made to the nearest ton of material in place in the completed blanket. 611.34 Basis of Payment. 611.34.1 Payment for furnishing and placing rock blanket will be made at the contract unit bid price per ton. No direct payment will be made for excavating the trench nor for backfilling the toe wall and cutoff walls, when required as specified in Section 611.53.2.
1/1/2016
611-3
Embankment Protection
Section 611.40 Grouted Rock Surface 611.41 Description. This work shall consist of surface grouting rock fill or rock blanket as shown on the plans or as directed by the Engineer. This work is not allowed in stream bank stabilization areas. 611.42 Materials. Grout shall meet the requirements of Section 611.22.3 and have a consistency thin enough to permit thorough penetration of the grout into the joints and voids between the stones. 611.43 Construction Requirements. 611.43.1 After completion of the rock fill or rock blanket in accordance with Section 611.10 or Section 611.30, whichever is applicable, the surface shall be grouted at the rate which will fill all voids and secure stone in a stable mass. The surface shall be swept clean of surplus grout with a stiff broom, using the major portion of the grout to fill the voids between stones. The grout shall be cured by any of the methods specified for concrete pavement in Section 502.14, except that transparent membrane shall be used in lieu of pigmented membrane. 611.43.2 The limitations and protection requirements of Section 502.5, "Weather Limitations", shall apply to the grouting. 611.44 Method of Measurement. Measurement will be made to the nearest square yard of grouted surface completed. 611.45 Basis of Payment. The accepted quantity of grouted rock surface will be paid for at the contract unit bid price.
1/1/2016
611-4
Embankment Protection
Section 611.50 Revetment 611.51 Description. This work shall consist of slope or bank protection and drainage ditches constructed at locations shown on the plans or as directed by the Engineer, and shall be of the type or types included in the contract. 611.52 Materials. Acceptance of quality and size of material will be made by visual inspection at the job site. 611.52.1 Stone for light stone revetment shall be sound, durable, and free from cracks and other structural defects that would cause it to deteriorate. It shall not contain any soapstone, shale, or other material easily disintegrated. The stone shall be in blocks at least 7 inches in thickness perpendicular to the slope and have approximately rectangular faces 7 inches or more in width. All blocks shall weigh not less than 25 pounds, and at least 75 percent shall weigh not less than 50 pounds. 611.52.2 The stone for heavy stone revetment shall conform to the requirements of Section 611.52.1, except that the blocks shall be at least 12 inches in thickness perpendicular to the slope and all blocks shall weigh not less than 50 pounds and at least 60 percent shall weigh not less than 100 pounds. 611.52.3 Broken Concrete. When other work included in the contract occasions quantities of broken concrete, the Contractor's may use such material as blocks for revetment, provided minimum size and weight requirements for stone are maintained. 611.53 Construction Requirements. 611.53.1 Unless otherwise approved, the slopes upon which revetment is to be placed shall conform to the section shown on the plans. The slopes shall be compacted to a uniform density as required for adjacent material. The revetment shall be started in a trench below the toe of the slope shown on the plans and shall progress upward. Each stone or broken concrete block shall be laid perpendicular to the slope, shall be firmly bedded against the slope and against adjoining stones or broken concrete, and shall be laid with well broken joints. After revetment has been placed, the voids shall be filled with spalls or small stone in such a manner that all revetment stones or broken concrete are tightly wedged. The finished surface shall present a uniform appearance true to line, grade, and section. 611.53.2 Cut-off Wall Required Around Revetment. Regardless of the details shown on plans, a 2-foot deep cut-off wall, measured from the bottom of the revetment, will be required around the entire perimeter of the revetment blanket except where it abuts headwalls, flared end sections, or inlet sills. No direct payment will be made for construction of the cut-off wall. 611.53.3 The limitations and protection requirements of Section 502.5, "Weather Limitations", shall apply to the grout and concrete. 611.54 Method of Measurement. Measurement will be made to the nearest square yard. 611.55 Basis of Payment. The accepted quantity of revetment will be paid for at the unit bid price for each of the pay items included in the contract. No direct payment will be made for excavating the trench nor for any backfilling required.
1/1/2016
611-5
Embankment Protection
Section 611.60 Concrete Slope Protection 611.61 Description. This work shall consist of constructing a concrete slope protection by depositing concrete on the finished earth slope, in conformity with the lines and grades shown on the plans. 611.62 Materials. Slope protection shall be of Class B concrete with materials, proportioning, mixing, slump, and transporting of concrete conforming to Section 501. Concrete shall be placed, finished, and cured in accordance with the applicable provisions of Section 703. 611.63 Construction Requirements. 611.63.1 Concrete slope protection shall be 8 inches in thickness and reinforced with No. 4 reinforcing steel on 12 inch centers each direction unless specified otherwise in the contract. The concrete shall be placed on a prepared compacted subgrade of uniform density, and shall be consolidated and struck off to the required thickness. Joints shall be the full depth of the concrete and shall consist of ½-inch material conforming to Section 1057.6. Joint spacing will be in accordance with Standard Drawings. 611.63.2 The surface of the paved slope shall have a broom or burlap drag finish and shall be cured in the same manner as required for concrete pavement, except that transparent membrane shall be used in lieu of pigmented membrane. 611.63.3 The limitations and protection requirements of Section 502.5, "Weather Limitations", shall apply to this work. 611.64 Method of Measurement. Measurement will be made to the nearest 1/10 square yard. Final measurement of the completed slope protection will not be made except for authorized changes during construction or when appreciable errors are found in contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. 611.65 Basis of Payment. The accepted quantity of concrete slope protection will be paid for at the contract unit bid price. No direct payment will be made for any excavating or for other work necessary in preparing the subgrade or for any backfilling required.
1/1/2016
611-6
Embankment Protection
Section 611.70 Gabions 611.71 Description. This work shall consist of furnishing, filling with stones, and placing on a constructed base, open mesh wire mattresses in accordance with the lines, grades, and dimensions shown on the plans or as established by the Engineer during construction. 611.72 Materials. The gabion baskets shall be constructed of hexagonal triple twist mesh with heavily galvanized steel wire. 611.72.1 Steel wire used in gabion construction shall be heavily galvanized with a zinc coating exceeding federal specification requirements (QQ-W-461g, Class 3). The mesh wire diameter for the galvanized gabions shall not be less than 0.1181 inch, approximately U.S. Gage Number 11. The mesh edge wire and selvedge wire shall not be less than 0.1535 inch, approximately U.S. Gage Number 9. The lacing steel wire for binding gabion units together shall not be less than 0.0866 inch, approximately U.S. Gage Number 13½ . 611.72.2 The mesh steel wire diameter for PVC coated gabions shall not be less than 0.1063 inch, approximately U.S. Gage No. 12. The mesh edge wire and selvedge wire shall not be less than 0.1338 inch, approximately U.S. Gage No. 10. The lacing wire shall not be less than 0.0866 inch, approximately U.S. Gage No. 13½ . The PVC coating shall not be less than 0.015 inch. Care shall be exercised during installation to avoid damage to the PVC coating. 611.72.3 Where the length of the gabion exceeds 4 feet the gabion shall be divided by diaphragms, of the same length mesh and gage as the body of the gabions, into cells of equal length and width. The gabion shall be furnished with the necessary diaphragms secured in proper position on the base in such a manner that no additional tying at this juncture will be necessary. 611.72.4 Concrete for the construction of the base pad, if required, shall consist of Class B concrete or concrete of a commercial mixture meeting the requirements of Section 501. Clean stone for base construction as required shall be hard and durable of the same size required in the gabion baskets. 611.72.5 Filter fabric shall be a woven polypropylene material meeting the following strength requirements: a) Minimum Burst Strength .................................................. 490 psi b) Minimum Trapezoidal Tear Strength ......................... 100# x 55# c) Minimum Puncture Strength ................................................ 130# 611.72.6 Gabion rock shall be 10 inch maximum size (95% to 100% passing a 10 inch screen), and a 4 inch minimum size.
1/1/2016
611-7
Embankment Protection
611.73 Mesh Dimensions. The maximum linear dimension of the mesh opening shall not exceed 4½ inches and the area of the mesh opening shall not exceed 8 square inches. Gabions shall be supplied, as specified, in various lengths and heights. The nominal lengths shall be 6 feet, 9 feet, or 12 feet as required. The horizontal width shall be 36 inches. Dimensions for heights, lengths, and widths are subject to a tolerance limit of plus or minus 3 percent of manufacturer's stated sizes. 611.74 Certificate of Compliance with Specifications. Each shipment of gabions to a job site shall be accompanied by a certification which states that the material conforms to the requirements of these specifications. A shipment shall consist of all material arriving at the job site at substantially the same time. The certification shall be on company letterhead and shall be signed by an officer of the company having legal authority to bind the company. 611.75 Construction Requirements. Prior to the placement of gabion baskets, the ground surface shall be smoothed and leveled to the line shown on the plans by the construction of a base pad of Portland cement concrete or compacted clean stone, or by a combination of these materials. The Engineer will select the method or methods to be used on each installation based on the character and soundness of the subsurface material exposed by the excavation. Generally, gabions to be place on uneven solid rock surfaces will require a Class B concrete pad not less than 2 inches nor more than 4 inches thick. Gabions to be constructed on surfaces other than solid rock will normally be placed on a 12-inch thick base constructed of clean, hard, durable stone of the same type and size required in the gabion baskets. The Engineer reserves the right to select the type of base construction considered most advantageous and desirable from the standpoint of structural adequacy and economy. The thickness of the base may be varied considerably, or the base may be stepped to take advantage of continuous formations of solid rock exposed by excavation. 611.75.1 The gabions are supplied folded flat, tied in pairs, and packed in bundles. The gabions are identified by color stripes and by labels indicating their code size and dimensions. The lacing wire is supplied in coils. All gabions on the channel bottom and lowest 3 feet in height on the walls shall be PVC coated. 611.75.2 For assembly, remove a single gabion from the bundle and proceed to unfold it on a hard, flat surface. Stretch the gabion and stamp out all kinks. Fold the front and back panels to a right angle by stepping on the base along the crease. Fold up the end panels and fasten them to the front and back panels using the heavy gage wire projecting from the upper corners of each panel. Assure all baskets are properly squared with the top of all panels even. Securely lace all vertical edges of ends and diaphragms. 611.75.3 The baskets shall be securely laced along all the perimeter of all contact surfaces with other baskets. Cut a length of lacing wire approximately one and one half times the distance to be laced but not exceeding 5 feet. Secure the wire terminal at the corner by looping and twisting, then proceed lacing with alternating single and double loops at approximately 5-inch intervals. Securely fasten the other lacing wire terminal. Baskets should be placed so the vertical joints are staggered.
1/1/2016
611-8
Embankment Protection
611.75.4 Set assembled gabion baskets in their proper location and lace the perimeters of all contact surfaces. The base of empty gabions placed on top of a completed row must also be tightly wired to the latter. Anchor the first gabion basket by completely filling it to no more than 2 inches above the top. The gabion rock shall be hand placed along and immediately next to exposed faces. When a 3-foot high gabion is used, it shall be filled in three equal lifts. Two connecting wires are to be placed between each lift in each cell of all exposed faces from front to back. The wires shall be looped around two meshes and tensioned. After anchoring the first gabion, apply tension to the other end of baskets with a come-along or other approved means in order to help achieve proper alignment. While the gabions are being stretched, inspect all corners for open "V's" which will result if corners were not properly secured. Replace any openings that occur. Keep gabions under tension while being filled. Leave last gabion temporarily empty to allow for each lacing of the subsequent assembly. Protect the vertical panels from being bent during the filling operation by temporarily placing and lacing reinforcing bars along the upper edges of the ends and diaphragms, or by other approved means. After the hand placement of exposed front faces with rock, the remainder of gabion rock fill may be placed mechanically throughout, provided care is taken to insure that it is tightly packed with a minimum of voids. Insure tension wires are placed each 1 foot in height. When the gabions are slightly overfilled to allow for settlement, the lids shall be folded down into position so that the lid and the gabion edges meet closely without gaps. Secure the lids at the corner with the wire projecting from the lid. Securely lace the lid shut starting with the front face and the ends. Adjacent lids may be wired to vertical panels in one operation. Lacing procedure should be as previously described, every 5 inches. Gabions shall be built with an offset or batter as shown on the project plans. 611.75.5 In general, the gabions may be cut to form curves or to allow pipe connections. When this is done, cut or bent edges of the mesh shall be fastened securely to another part of the gabion structure by lacing with wire. 611.75.6 The filter fabric shall be placed between the gabions or clean aggregate, if installed, and earth on all the unexposed sides. The material shall extend completely beneath the base row of gabions and up the sides of the bottom mat. All unexposed sections of counter forts shall be wrapped with filter material. The seams between adjoining rolls of filter material shall be made with a 12-inch overlap and the seams secured to the baskets every 18 inches to ensure tightness prior to backfilling. The filter fabric shall be cut even with the top of the wall. Fill or sod shall not extend over the top basket of the wall. 611.75.7 Areas beyond the pay lines established on the plans for the excavation item shall be backfilled with approved earth, or a mixture of clean sand and gravel if such is available from the creek bed.
1/1/2016
611-9
Embankment Protection
611.76 Method of Measurement. The excavation limits and wall details shown on the crosssections and the included sketch are based on the construction of the wall foundation to the elevations shown on the plans. However, as noted before, it is not intended to excavate sound, unweathered rock and replace it with gabions. It is therefore anticipated that the base of the new wall will be stepped or otherwise varied by the Engineer during construction depending on the location and character of the rock encountered in the excavation. A subsurface report when included in the plans is for the Contractor's information only. Unless an attempt has been made to separate or classify excavation quantities for this project, all excavation will be considered unclassified. Final excavation quantities for payment will be determined by the Engineer after the wall has been completed. Gabions shall be measured in their final positions to the nearest cubic yard. Quantities for the gabion aggregate and Class B concrete used in the construction of the wall base, as directed, will be determined by the Engineer. No measurement will be made for filter fabric or material used for backfilling areas around the completed wall. 611.77 Basis of Payment. Payment will be made at the contract unit bid price for each of the pay items included in the contract. Payment for Class B concrete will be made at a unit price of $150 per cubic yard regardless of the quantity used. No direct payment will be made for filter fabric or for backfill material.
1/1/2016
611-10
Embankment Protection
Section 612
Traffic Control Devices
612.1 Description. This work will consist of furnishing, constructing, and maintaining traffic control and safety devices at locations shown on the plans or as directed by the Engineer. Construction details shall be in accordance with the plans. 612.2 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Temporary Traffic Control Devices ............................................ 1063 612.3 Construction Requirements 612.3.1 Barricades (Moveable, Temporary, and Permanent). Lumber for barricades shall be well seasoned, straight, and free from serious defects which will materially impair the strength. Posts may be either square or round, except as designated on the plans, but if round, they shall be free from bark and shall present a good bearing surface for the rails or boards they support. Paint for barricades shall be good quality, commercially available products. Reflective sheeting shall be a commercially available product, with a reflective intensity of Type 1 Level A, enclosed lens sheeting as designated in Federal Specification FP-74 that consists of glass spheres embedded beneath a flexible, transparent plastic forming a smooth outer surface as exposed to use. The Contractor shall provide and maintain barricades in good condition throughout the duration of the contract. At a minimum, the number and location of traffic control and safety devices will meet the standard requirements of the most current Manual of Uniform Traffic Control Devices (MUTCD), where applicable. 612.3.2 Painting and Striping. The surfaces of all barricades shall be given a prime coat and a finish coat of white paint. The surfaces of horizontal boards for all types of barricades that face the traffic and extend across the roadbed shall be striped in accordance with the plans. The striping of all barricades shall be provided by the use of reflectorized white stripes separated by reflectorized orange stripes. Reflectorizing shall be accomplished by applying reflective sheeting to the barricade boards by means of an adhesive. 612.3.3 Any requirements of Section 107.7 in conflict with the following are hereby declared inapplicable. 612.4 Plans and Quantities. The plans will show the type and location of traffic control devices necessary to complete the work. The Contractor is herewith advised that St. Louis County will furnish and maintain all advance warning and detour signing. Any device that becomes damaged or rendered unserviceable shall be promptly repaired or replaced by the Contractor as directed by the Engineer. No direct payment will be made for repair or replacement of traffic control facilities as a result of compliance with this provision.
7/1/2012
612-1
Traffic Control Devices
612.5 All traffic control devices furnished and maintained by the Contractor shall remain the property of the Contractor. All other advance and detouring signs and devices will remain the property of St. Louis County. 612.6 Flasher Signs. Flasher signs shall be provided at locations shown on the plans or as designated by the Engineer. The sign shall be constructed of ¾ inch or ⅝ inch, 5-ply, high-density type overlaid Douglas Fir plywood. The sign shall be given a prime coat and a finish coat of white paint. The striping shall be provided by the use of white and reflectorized orange stripes. The arrow shall be painted black on a background of orange reflective sheeting. Unless otherwise specified in the contract, flasher signs shall become the property of the Contractor after their use is no longer required on the project. Flasher signs that are to become the property of the County shall be left in good condition with respect to repair and paint. 612.7 Basis of Payment. 612.7.1 The accepted quantity of temporary, moveable, permanent, and flasher sign barricades will be paid at the unit price bid for each item included in the contract.
7/1/2012
612-2
Traffic Control Devices
Section 612.30 Standard Traffic Control Devices 612.30.1 Description. This work will consist of furnishing, placing, and maintaining flags, channelizers, cones, and furnishing flagmen in accordance with the contract and as directed by the Engineer. This specification also covers the design and responsibility for signs normally required to be employed on construction projects only during construction operations and which are not to remain for any substantial length of time. These signs include such warning and regulatory measures necessary to warn the travelling public and to protect the Contractor's personnel and equipment during specific and limited phases of the work. These signs must comply with the current Manual on Uniform Traffic Control Devices (MUTCD) with respect to size, color, and mounting detail. No direct payment will be made for furnishing, placing, relocating, maintaining, or removing signs. Since these signs impose legal obligations or restrictions on traffic, prior approval for their use must be obtained from the Engineer and they will be placed at locations designated by the Engineer. 612.30.2 Flaggers. As directed by County personnel, the Contractor shall furnish flaggers to be used when the roadway is partially or wholly blocked by men or equipment. To increase the visibility of the flaggers, yellow or yellow-orange safety vests, caps, and gloves must be worn. Flaggers shall be located far enough from the work site so the vehicles have sufficient distance to slow down or stop before entering the work area. Under no circumstances will the Contractor's flaggers be allowed to direct traffic unless adequately protected by proper advanced warning signs. Flaggers shall be properly attired to perform their duties, shall be courteous, and shall use an approved "stop and slow" sign to control traffic. 612.30.2.1 Hand Signaling Devices. 612.30.2.1..Stop/Slow Paddles. The STOP/SLOW paddle shall have an octagonal shape on a rigid handle permanently attached 12-inch plastic handle and 60-inch detachable, plastic staff with safety-tip. Bottom of sign to top of staff is 6 feet. STOP/SLOW paddles shall be at least 18 inches wide with letters at least 6 inches high and should be fabricated from light semi rigid material. The background of the STOP face shall be red with white letters and border. The background of the SLOW face shall be orange with black letters and border. When used at night, the STOP/SLOW paddle shall be retroreflectorized. The STOP/SLOW paddle may be modified to improve conspicuity by incorporating white flashing lights. Two lights may be installed and centered vertically above and below the STOP legend, or centered horizontally on either side of the STOP legend. Instead of the above twilight arrangement, one light may be centered below the STOP legend. 612.30.2.1 Emergency Only. Flags, may be used in an emergency situation and only at low-speed and/or low-volume locations which can best be controlled by a single flagger. Flags shall be a minimum of 24 inches square, made of a good grade of red material, and securely fastened to a staff that is approximately 36 inches in length. The free edge of a flag should be weighted so the flag will hang vertically, even in heavy winds. When used at nighttime, flags shall be retroreflectorized red.
7/1/2012
612-3
Traffic Control Devices
612.30.3 The requirements of this specification shall not relieve the Contractor of his responsibilities for protecting both the public and the workers. 612.30.4 Flexible Non-Metallic Drum-Like Channelizers. 612.30.4.1 Description. This work shall consist of furnishing and placing reflectorized, flexible, non-metallic drum-like channelizers used for traffic control as specified in the contract or as directed by the Engineer. 612.30.4.2 Materials. Channelizers shall be manufactured from a plastic polymer, plastic copolymer, rubber elastomer, or any other non-metallic material which can be compounded to meet the requirements of this specification. Channelizers shall be pigmented and molded of a Highway Orange color throughout and stabilized against fading by ultra-violet or other light rays by the incorporation of adequate inhibitors. Channelizers shall be a minimum of 36 inches high and a minimum of 18 inches in diameter, if circular in shape. If other than circular, the minimum side-to-side dimension at the narrowest point shall be 18 inches. Reflective markings shall be horizontal, circumferential, alternating orange and white stripes 4 inches to 8 inches wide. If there are non-reflectorized stripes between the horizontal orange and white stripes, they shall be no more than 2 inches wide. The reflectorized stripes shall be Type 3 reflective sheeting meeting the requirements of Section 1063 unless otherwise noted on the plans. There shall be at least two orange and two white stripes on each channelizer laid out in accordance with Section 6C-6 of the Manual on Uniform Traffic Control Devices (MUTCD) as shown on the plans. The channelizer shall be a two-piece closed-top breakaway design and shall be capable of being securely fastened together in such a manner as to prevent accidental separation from air turbulence created by such things as passing trucks or normal winds, but be capable of separating if struck by a vehicle. The base shall contain a self-draining storage compartment for ballast. The ballast, consisting of loosely filled sand bags or loosely shoveled sand, shall be stored in the base in such a manner that it will not become a projectile upon impact. The base shall be low enough to allow a vehicle to pass over it without making contact with the undercarriage. Channelizers shall exhibit good workmanship and shall be free of objectionable marks or defects which affect appearance or serviceability. Channelizer seams shall be equal in strength to the rest of the channelizer. The top surface of the channelizer, including any recessed areas, shall be designed to drain and shall have a mounting bracket for attaching a Type III object marker. The marker shall be secured to the channelizer by use of a clear polycarbonate connector as shown on the plans. 612.30.4.3 Prequalification. Prior to starting work at any site requiring channelizers for controlling traffic, the Contractor shall submit or cause to be submitted to the Engineer certified documented evidence from the manufacturer which shows that two randomly selected channelizers representative of those to be used on the project withstood three direct impacts by a vehicle bumper at 55 miles per hour (mph) with the following results: a) Only negligible damage to the impacted vehicle and no injury to the occupants; b) No separation of the Type III object marker; c) No permanent deformation or damage to the channelizer that impairs its function or physical appearance, which renders it unusable; 7/1/2012
612-4
Traffic Control Devices
d) No significant loss of effectiveness of the reflective material; e) A non-hazardous separation of the channelizer from its snap-on base with ballast; f) The channelizer design did not allow the ballast or any part of the unit to be trapped under the vehicle. A new certification will be required upon any modification of the design of the channelizer or any change in the formulation of the plastics used in its manufacture. If directed by the Engineer, the Contractor shall demonstrate that the channelizer can meet the impact requirements specified above. If the Engineer determines that the channelizer constitutes a potential hazard to traffic because of rupture, excessive damage to the impacting vehicle, or other hazardous behavior, the channelizers represented by the test shall not be used for traffic control. 612.30.4.4 Basis of Acceptance. Materials furnished under this specification will be accepted for use upon receipt and approval of a certification indicating the channelizers being supplied are the same model and design as previously approved. The certification shall include the manufacturer and model number of the channelizer and the type, grade and manufacturer of the reflective sheeting. 612.30.4.5 Basis of Payment. Payment for flexible non-metallic drum-like channelizers and Type III object markers will be in accordance with Section 616. 612.30.5 Object Markers. Object markers are defined as panels, 8 inches to 12 inches in width and 24 inches in height striped and reflectorized in the same manner as barricades and mounted with the top a minimum of 36 inches above the roadway on a single lightweight post. These devices shall be used for traffic separation or shoulder barricading where space is at a minimum. 612.30.6 All open trenches within ten feet of the travel way or low shoulder adjacent to the travel way, shall be marked by the use of reflectorized object markers spaced at intervals of not more than 50 feet. Object markers shall be placed as soon as those conditions exist and shall remain in place until all trench has been filled to the level of the travel way and the adjacent shoulder has been leveled sufficiently to be used safely by traffic. During actual operations object markers may be removed through areas where work is actually in progress. They shall be reset as soon as operations have moved ahead if hazards requiring their use remain. Object markers shall be striped on both sides. No direct payment will be made for furnishing, placing, relocating, or maintenance of object markers. 612.31 Method of Measurement. No direct measurement will be made for the use of channelizers, cones, object markers, construction signs, or the furnishing of flaggers. 612.32 Basis of Payment. The furnishing, placing, and maintaining of reflectorized object markers, construction signs, channelizers, cones, and the furnishing of flaggers as required will be paid for at the contract lump sum bid price for Standard Traffic Control Devices.
7/1/2012
612-5
Traffic Control Devices
Section 612.40 Detour Lighting 612.40.1 Description. This work shall consist of furnishing and installing detour lighting equipment and materials as shown on the plans and as directed by the Engineer. 612.40.2 Materials. Wood poles shall be Class II conforming to details of Section 1050, Materials Details. Poles shall be 40 feet in length, set 3 feet below grade in order to provide a mounting height of 32 feet for luminaries. Luminaries shall be 400-watt high-pressure sodium vapor. Each luminary shall be fitted with a photoelectric device in order to provide "dusk to dawn" lighting capabilities. Photoelectric controls will operate on 240 volts, 60 cycles current. 612.40.2.1 The Contractor shall be responsible for contacting the utility companies and making arrangements with regard to power source and metering. Bracket arms shall be 6 feet in length and arranged for 2-inch slip fitter luminary mounting. Bracket arms shall be fitted to poles by an approved design. 612.40.2.2 Service poles shall consist of wood poles and crossarms, insulators, necessary pole line hardware, conduit, ground rods, guy wires and anchors, and all other accessories and appurtenances mounted on the pole except those furnished by the utility company, or set out separately in the contract. The assembly shall meet the safety requirements and approval of the utility company or municipality furnishing power for operation. 612.40.2.3 Electrical conduit shall be cross-linked Polyethylene, 194 F, type RHH-RHW, #10, 2 Conductors, 7 strand twisted, 600 volt, soft drawn copper, color-coded black and white. 612.40.2.4 When detour lighting is no longer required on the project, the Contractor shall carefully disassemble all components and store all poles, brackets, and luminaries on the right-of-way for County Forces to remove. 612.40.3 Method of Measurement and Basis of Payment. No direct measurement will be made for this work. Payment for detour lighting will be based on the unit price bid for each of the pay items included in the contract. No direct payment will be made for any incidental items necessary to complete the work unless specifically provided as a pay item in the contract.
7/1/2012
612-6
Traffic Control Devices
Section 612.50 Project Information Signs 612.51 Description. This work shall consist of the furnishing and installing of project information signs at the time physical construction work begins on the contract. 612.52 Construction Requirements. 612.52.1 Signs shall be constructed and erected in accordance with the details shown and materials specified on the plans. They shall be placed within the right-of-way at locations indicated in the contract or as directed by the Engineer. The required number of signs and the locations will be shown on the title sheet of the plans for each affected project. They shall face approaching traffic and be located so as not to obscure or detract from the effectiveness of other official highway signs and markers. Signs shall be kept clean and in good repair, and shall become the property of the Contractor after their use is no longer required on the project, unless otherwise specified. 612.52.2 For Federal Aid Projects, project signing will be prohibited. For other projects, the Director will furnish the Contractor all information pertinent to the erection of project information signs. 612.53 No direct payment will be made for project information signs.
7/1/2012
612-7
Traffic Control Devices
Section 612.60 Temporary Excavation Fencing 612.61 Description This item will consist of enclosing an open cut excavation or vertical drop to provide protection to pedestrians on the project with a polyethylene fence fabric on a temporary basis. The location of such temporary excavation fencing will be shown on the plans or designated by the Engineer. 612.62 Construction Requirements. 612.62.1 Polyethylene fencing of a good commercially available quality, 5 feet in height, fluorescent orange in color, capable of withstanding exposure to the sun and elements will be required to completely enclose open cut trenches or excavations, or vertical drop-offs produced during construction. Temporary posts may be of any kind which will adequately support the attached fence fabric free of distortion, sagging, gaping and open areas at the bottom of the fence. Temporary posts must be driven in place and the subsequent hole backfilled upon removal. Additional fence post installation may be required by the Engineer when deemed necessary. Fencing shall be so placed as to completely enclose all designated areas. 612.62.2 All open cut excavation areas within 10 feet of the back of curb or edge of pavement and over 3 feet in depth must be fenced in accordance with the provisions of this section. Areas where vertical cuts exist and are accessible to pedestrians with a depth greater than 3 feet must be fenced along the top of the cut. These requirements are in addition to other standard safety practices required by the contract and shall not in any manner be construed to relieve the Contractor of any liability incumbent on his part or as imposed by Sections 104 or 107 of these specifications. A minimum compliance with the requirements of these sections and the Manual on Uniform Traffic Control Devices (MUTCD) will always be required. 612.63 Method of Measurement. Temporary excavation fencing, complete in place, will be measured on a lump sum basis and will consist of fencing, posts, mounting hardware, backfilling postholes and associated items necessary to safely enclose open cut excavations or trenches or vertical drop-offs to the satisfaction of the Engineer. 612.64 Basis of Payment. Temporary excavation fencing will be paid at the contract unit bid price.
7/1/2012
612-8
Traffic Control Devices
Section 612.70 Advanced Warning Arrow Panel 612.71 Description. The advanced warning arrow panel shall be of a moveable design, generally trailer mounted, and shall be capable of operation from a fixed power source or from a self-contained power source. The arrow panel shall be located as shown on the plans or as designated by the Engineer. 612.72 The arrow panel shall be at a minimum 48 inches x 96 inches with a minimum of 15 replaceable panel lamps which produce a yellow light and are an integral part of a non-reflective black background. An indicator lamp will be incorporated in the black face of the arrow panel to indicate operation. Provision will be made to place the arrow panel, while in operation, at a minimum height of 7 feet above the pavement to the bottom of the arrow panel. The arrow panel should produce a minimum legibility distance of one mile. The arrow panel will be equipped with the capability of the following mode selections: 1) Left or right flashing or sequential arrows; 2) Left or right sequential chevrons; 3) Double flashing arrows; 4) Caution. The caution mode consists of four or more lamps arranged in a pattern which will not indicate direction. 612.73 Arrow panels will be of Type A or Type B designation. Type A arrow panels will be operated from a fixed power source supplied by a utility company. Arrangement for power supply will be the Contractor's responsibility as will acquisition of necessary permits and payment of connection fees. Type B arrow panels will be supplied with electrical power from a self-contained system of batteries and generator powered by a diesel engine. The engine will be silenced with baffles and mufflers so as not to produce a disturbance when in operation. A fuel storage tank having a capacity for not less than 48 hours of uninterrupted engine service must be provided. 612.74 The Contractor will be responsible for the maintenance of his equipment and must have a backup system available in case of failure of the primary system. At no time will mechanical failure of the arrow panel be an acceptable reason for discontinuing its use as a safety or traffic control device. If repairs or a backup system cannot be effected in a two-hour period, work may be suspended or other measures may be required by the Engineer. These other measures may include, but not be limited to, requirements for flaggers, guide cars, or arrow panels provided from companies offering such services. 612.75 Method of Measurement. The quantity of Type A or Type B arrow panel will be measured on a lump sum per each unit basis. No separate compensation for fuel, lubricants, repair parts or man-hours or cost involved in securing a backup system will be considered. 612.76 Basis of Payment. The accepted quantity of Type A or Type B arrow panel will be paid at the contract unit bid price.
7/1/2012
612-9
Traffic Control Devices
Section 612.80 Nighttime Worksite Lighting Requirements 612.81 Description. This work consists of furnishing, installing, operating, maintaining, moving, and removing nighttime lighting to illuminate construction work areas for night work. Night work is defined as work performed from 30 minutes before sunset to 30 minutes after sunrise. Before beginning night operations, demonstrate to the Engineer the method of meeting the specified illuminance levels and visibility requirements for workers and equipment for each planned operation. Do not begin night operations until the Engineer approves the method of meeting the specified illuminance levels and visibility requirements 612.82 Work Site Lighting. Because typical street and highway lighting is rarely adequate to provide sufficient levels of illumination for work tasks, temporary lighting should be provided where workers are active to supply sufficient illumination to reasonably safely perform the work tasks. Temporary lighting for night work should be designed such that glare does not interfere with driver visibility, or create visibility problems for truck drivers, equipment operators, flaggers, or other workers. 612.82.1 Provide an illuminated zone around all operating machinery. Provide an illuminated zone of at least 5 foot-candles of lighting luminance in the immediate vicinity of pavers, rollers, grinding equipment, material transfer vehicles, etc., and at least 1 footcandle at 25 feet from this equipment. Provide an illuminated zone of at least 5 foot-candles of lighting luminance in the immediate vicinity of coring equipment and at least 1 foot-candle at 10 feet from this equipment. Positions the light sources so they don’t interfere with or impede traffic in any direction and do not cause glare for motorists or point onto adjacent properties. Mercury vapor and fluorescent light sources are not approved for night operations illumination.
7/1/2012
612-10
Traffic Control Devices
TABLE: MINIMUM ILLUMINANCE LEVELS FOR NIGHT OPERATIONS Minimum Level, Foot Candles
Work Description
Minimum Lighting Area
Embankment Fill, compaction and maintenance; Excavation, regular, lateral and ditch; Landscaping (seeding and sodding); Mechanical sweeping and cleaning; Subgrade, stabilization and construction
5
General lighting throughout area of operation
Traffic Control setup and removal (excluding barrier curb)
5
Lighting on task
5
Lighting on task plus minimum of 50 feet ahead and 50 feet behind employee
Milling1 HMA paving operation1 HMA roller operation1 Concrete Paving and repair Base course grading and shaping Bridge Decks Surface Treatments (micro-surfacing, seal coating) Sidewalk construction Waterproofing and sealing Striping and pavement marking Pot hole filling Guard rail and fence repair Draining Structures and pipe installation
10
Lighting on task and around equipment plus minimum of 25 feet ahead and 25 feet behind equipment plus 10 feet to each side of equipment
Crack Sealing and filling Saw cutting and Sealing Joints Electrical work Traffic Signals Intelligent Transportation System work
20
Lighting on task
All work not listed in this table1
10
Lighting on task
Flagger stations
1
7/1/2012
Provide 5 foot-candles for the indicated lighting area outside the limits for 10 foot-candles to a minimum of 100 feet ahead and 100 feet behind equipment
612-11
Traffic Control Devices
612.82.2 The Contractor shall provide a photometer capable of measuring the level of luminance on each night project. Obtain the Engineer’s approval of the lighting at the beginning of the project and before starting the paving operation by measuring the luminance. Obtain the luminance level any time requested by the Engineer. Take luminance measurements at a height of 20 inches above the roadway. Test the illumination levels on the site each time a change in lighting configuration is made. 612.83 For moving operations, ensure that lighting and illuminance requirements are maintained where the work is in progress and that lighting keeps pace with the operation. Replace non-functioning lamps immediately. Provide sufficient fuel, spare lamps, generators, and qualified personnel to ensure that required illuminance levels are maintained continuously during night operations. If at any time minimum illuminance levels are not met, the Engineer will cease night operations until the required illuminance levels are attained. 612.83.1 Uniformly light the hopper, auger, and screed areas of pavers as well as the operator's controls on all machines. 612.83.2 Ensure that lighting equipment is in good operating condition, and in compliance with applicable NEC and NEMA codes. Use freestanding portable or trailer-mounted towers capable of being moved as needed to keep pace with construction operations. Check the luminaries aiming daily. Clean the luminaries regularly. 612.83.3 Prevent or minimize glare that may interfere with traffic or disturb local residents. Perform glare control to the Engineer's satisfaction. Glare control may require relocating, aiming, or adjusting lights or providing screens, shields, visors or louvers on lights. 612.84 Conventional vehicle headlights do not meet illuminance requirements. Ensure that moving lighting equipment used for night operations has lights directed ahead and behind the equipment. 612.85 No direct payment will be made for Nighttime Work Site Lighting.
7/1/2012
612-12
Traffic Control Devices
Section 613
Pavement Repair
613.1 Description. 613.1.1 Full depth pavement, joint and base repair shall consist of removing specified areas of existing variable thickness of Portland cement concrete and existing bituminous overlays and replacing with macro-synthetic fiber reinforced or non-reinforced Portland cement concrete as specified in the contract documents. 613.1.2 Pavement repair greater than 15 feet in length, as measured in the direction of traffic, shall be reinforced with macro-synthetic fiber material specified herein. No welded wire reinforcement or steel fibers shall be allowed. 613.1.3 Pavement repair thickness may be increased by up to 2 inches by the contractor at no additional cost to the County, to reduce the required minimum opening compressive strength as required by Section 502.11. 613.1.4 Very Early Strength repairs shall be opened to traffic in 4 to 6 hours. High Early Strength repairs shall be opened to traffic in 24 to 48 hours. Very Early or High Early Strength pavement, base or joint repair that does not meet the required opening time due to not meeting the minimum specified compressive strengths as specified in Section 613.3.25.2 will receive a pay adjustment. 613.1.5 Due to high volumes of traffic on most of the roadways where work is to be performed, bid items and quantities for fast setting concrete have been included to allow the Engineer and Contractor some flexibility in dealing with lane closures, traffic control and access to streets and driveways. The Engineer shall have final approval over the type of concrete to be used. Payment as approved by the Engineer shall be made under the appropriate bid items. 613.2 Materials. All material, proportioning, air entrainment, mixing, slump, and transporting for Concrete Pavement Repair shall be in accordance with Section 501 or as modified herein. Concrete pavement repair concrete coarse aggregates shall consist of Class B or D crushed limestone in accordance with Section 1005. All materials, unless specified otherwise in this specification, shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Aggregates for Concrete Bituminous Materials Silica Fume (Microsilica) Ground Granulated Blast Furnace Slag Fly Ash for Concrete Cement Reinforcing Steel for Concrete Epoxy Resin Material Concrete Admixtures Concrete Curing Material Material for Joints Calcium Chloride
3/15/2022
613-1
1005 1015 1016 1017 1018 1019 1036 1039 1054 1055 1057 1068
Pavement Repair
613.2.1 Calcium Chloride. The amount of calcium chloride by mass of cementitious materials used shall not exceed 1 percent during hot weather conditions and shall not exceed 2 percent during all other weather conditions. The amount of calcium chloride is to be added in pre-mixed solution form to the aggregates in the mixer drum or as a portion of the mixing water, reducing the total mixing water required by the amount of solution being used. Concentrated calcium chloride should not come into direct contact with dry cement as it may cause flash set. Concentrations other than listed in Section 501.8.1.5 will be required to have the dosage adjusted so as not to exceed the calcium chloride percentage specified per 100 pounds of cementitious materials. 613.3 Construction Requirements. 613.3.1 Pavement Removal Locations. Specific locations and areas of pavement repair removal shall be as specified by the Engineer. 613.3.2 Pavement Removal and Base Replacement. Specified areas of full depth pavement repair shall be removed in accordance with the applicable requirements of Section 202.30 except that the saw-cut shall be full-depth for pavement thickness of 7 inches or greater. A diamond saw shall be used for perimeter cuts. Saw cut such that traffic will not dislodge any pieces or segments. A rock saw may be used to make this cut with prior approval of the Engineer. Any damage caused to the pavement due to pre-sawing shall be repaired by the contractor at the contractor's expense. Asphalt backfill and maintenance of saw cut will be at no cost to the County. 613.3.2.1 Subgrade Removal and Compaction. Any aggregate base disturbed by the Contractor shall be recompacted. Unstable base aggregate shall be removed and replaced in accordance with Section 304, as directed by the Engineer. Subgrade compaction shall be performed in areas of unstable subgrade in accordance with Section 210, if directed by the Engineer. In areas of unstable subgrade, the unstable subgrade may be removed and replaced with Type 5 aggregate base material in accordance with Section 304 Compaction shall be in accordance with Section 304 and to the satisfaction of the Engineer. 613.3.2.2 Base Repair Forming. Forming for concrete pavement repair shall be in accordance with Section 502 of the Standard Specifications for Road and Bridge Construction. 613.3.2.3 Undercut Spalling. When concrete removal operations result in deterioration of the bottom slab of sound concrete surrounding the repair area the Contractor shall saw back into the adjacent slab until sound concrete is encountered. 613.3.2.4 Removal of Excess Water. The repair area shall be free from standing water. The Contractor shall pump water from the repair area or drain it through a trench cut into the shoulder. The base shall be recompacted in accordance with Section 304.3.5.2 and to the satisfaction of the Engineer.
3/15/2022
613-2
Pavement Repair
613.3.3 Transverse Joint Reinforcement. accordance with Section 505.2.4.
Transverse joints shall be provided in
613.3.3.1 Dowel Bar Installation. Dowel bar diameter shall be based on repair thickness. Horizontal displacement is defined as difference in the actual dowel bar location from its theoretical position as detailed in the standard details. The maximum allowable horizontal displacement is 2 inches. The dowel holes shall be drilled on 12-inch centers, located vertically at mid-depth ±½ inch of the slab drilled, drilled with an automatic gang-mounted dowel drilling rig, referenced off the slab surface. Due to the likelihood of misalignment, hand-held drills will only be permitted with approval of the Engineer. Standard pneumatic and hydraulic percussion drills are acceptable for drilling dowel bar holes. The drilling rig shall be able to maintain proper bar alignment, drilled to required diameter +⅛ inch, and to a depth approximately ½ the length of the dowel bar. Dowel bars shall have a typical spacing of 6 inches from any longitudinal joint or edge of pavement. The holes shall be blown clean and allowed to dry. 613.3.3.2 Dowel Bar Epoxy Anchoring. The holes shall be injected with an epoxy bonding agent meeting the requirements of Section 1039.3 of the current St. Louis County Standard Specifications for Road and Bridge Construction. If the epoxy bonding agent is either in bulk or cartridge form, it shall be thoroughly mixed in the proper ratio by an automatic mixing unit prior to injection into the dowel holes. The automatic mixing unit shall be an integral part of the injection device. The bonding agent shall be injected into the dowel hole by inserting the injection device to the back of the hole and slowly withdrawing the device while dispensing sufficient material to completely fill the void around the dowel when the dowel is inserted. 613.3.3.3 Dowel Bar Insertion. Prior to inserting the dowel into the hole, a thin plastic disk, manufactured to slip tightly over the dowel, shall be placed over the dowel at approximately midpoint to prevent the bonding agent from flowing from the hole during placement of the dowel and to create an effective face at the entrance of the dowel hole. The dowel shall be inserted into the hole with a twisting motion so the material in the back of the hole is forced up and around the dowel. The dowel shall be placed parallel to the surface and the centerline of the travel way and shall not vary more than ¼ inch in alignment. Dowels shall be firmly seated prior to placing concrete. 613.3.3.3.1 Dowel Bar Alignment Tolerance. Dowel bar(s) that vary more than ½ inch per 12 inches of bar in horizontal skew or vertical tilt alignment on more than three bars shall be cause for removal of the dowels, re-sawing the pavement repair boundaries beyond the embedded bar, removing the concrete and re-installing the dowel bars for the full length of the repair joint. No additional compensation will be made for removal and replacement of dowels, concrete pavement and other incidentals associated with their replacement. 613.3.4 Longitudinal Joint Reinforcement Installation. Tie bar size shall be based on repair thickness. The 30-inch-long steel epoxy coated No. 5 or No. 6 round deformed dowel bar, in accordance with Section 1057.4, shall have holes drilled on 30 inch centers that are located vertically at mid-depth ±½ inch of the slab drilled, ⅛ inch in diameter larger than the actual bar diameter required, to a depth approximately ½ the length of the tie-bar drilled with an automatic gang-mounted dowel drilling rig, referenced off the slab surface. Single, handheld drills are permitted for pavement widths less than 6 feet or as approved by the Engineer. Standard pneumatic and hydraulic percussion drills are acceptable for drilling tie-bar holes. 3/15/2022
613-3
Pavement Repair
Tie bars shall have a typical spacing of 15 inches from any transverse joint or edge of pavement. Horizontal displacement is defined as difference in the actual dowel bar location from its theoretical position as detailed in the standard details. The maximum allowable horizontal displacement is 2 inches. The holes shall be blown clean and allowed to dry. 613.3.4.1 Tie Bar Epoxy Anchoring. The holes shall be injected with an epoxy bonding agent meeting the requirements of Section 1039.3 of the current St. Louis County Standard Specifications for Road and Bridge Construction. A standard keyway section shall be provided for pavement repair depths 7 inches or greater wherever new pavement abuts a full depth pavement repair section. 613.3.4.2 Tie Bar Alignment Tolerance. Tie bar(s) that vary more than ½ inch per 12 inches of bar in horizontal skew or vertical tilt alignment on more than three bars shall be cause for removal of the bars, re-sawing the pavement repair boundaries beyond the embedded bar, removing the concrete and re-installing the tie bar(s) for the full length of the repair joint. No additional compensation will be made for removal and replacement of tie bar(s), concrete pavement and other incidentals associated with their replacement. 613.3.5 Macro-Synthetic Fiber Reinforcement. When pavement repairs require reinforcement, macro-synthetic fibers shall be used. Fibers shall meet the minimum requirements in accordance with Section 505.2.3. Fiber manufacturer, brand and weight per cubic yard shall be included in the concrete mix design and on concrete delivery ticket. The concrete producer-supplier is required to obtain and submit the following macro-synthetic fiber information for review: 1) Specific product brand name; 2) Independently performed test results (include minimum average residual strength at dosage rate specified); 3) Material Safety Data Sheet; 4) Technical Data Sheet; 5) Contact person's name, title, address, email address, and phone number; 6) A letter stating the subject material will not be changed without prior written notification to the county. 613.3.5.1 Macro-Synthetic Dosage. The minimum macro-synthetic fiber dosage rate for concrete reinforcement shall be at a rate of 5 pounds per cubic yard for pavement repair. 613.3.5.2 Macro-Synthetic Fiber Storage and Handling. Macro-synthetic fiber blend material shall be delivered, stored, handled, and mixed in accordance with Section 505.2.3.1.
3/15/2022
613-4
Pavement Repair
613.3.6 Repair Removal and Waste Disposal. The removed concrete and any excavated subgrade material shall be disposed of at a location furnished by the Contractor or at locations on the right-of-way approved by the Engineer. If the material is disposed of outside the rightof-way, an acceptable written agreement executed with the property owner on whose property the material is placed shall be submitted by the Contractor. 613.3.7 Crack Relief. Crack relief is required at all locations where the repair is intersected by a full-depth pavement crack. 613.3.7.1 If the crack is located further than 6 feet from an established joint, an additional dowel basket assembly shall be installed and the pavement appropriately jointed. 613.3.7.2 If the crack is located 6 feet or less from an established joint omit the tie bars from that section and establish crack relief by installing and securing to the slab face a ¼ inch thick by 3 inches wide (minimum) commercial quality polyethylene, flexible foam expansion material across the crack prior to concrete placement. Extend the isolation joint material from flush with the top of pavement repair to the base of the pavement with the full-depth crack. Maintain the isolation joint material in a vertical position throughout the entire thickness of the repair. 613.3.8 Early Opening to Traffic Concrete Mix Design. The Contractor shall provide a trial mix design with materials proportioned so that the slump, entrained air content, workability, minimum compressive strength and minimum opening times are achieved. 1) All mixes shall have Class A or B fine aggregate proportioned at a minimum amount of 35 percent of the total aggregate volume. . 2) All non-reinforced mixes shall have Class B or D coarse aggregate proportioned at a minimum of 55 percent of the total aggregate volume. 3) All fiber reinforced mixes shall have Class B or D coarse aggregate proportioned at no less than 45 percent or no more than 55 percent of the total aggregate volume. 4) The Contractor shall submit all mix design(s) for Engineer review and approval in accordance with Section 501. All mixes shall be highly workable and achieve their early opening strength without producing adverse effects such as shrinkage or thermal cracking. 613.3.8.1 Mix designs shall be prepared by personnel experienced in the use of ASTM C 94, ASTM C 192, ACI 211.5R-01, ACI 301, and ACI 318 Chapter 5.
3/15/2022
613-5
Pavement Repair
613.3.8.2 The Contractor shall submit to the Engineer the following for review and approval no less than 7 days in advance of pre-production trial batch: 1) Mix Design. Strength type, Pavement Repair Class, opening time, minimum opening compressive strength, sources, grade or type, and volumetric properties of the proposed concrete-mix materials (water, cement, coarse aggregate, fine aggregate, macro-fiber and admixture(s) (brands and dosages), and production water/cementitious ratio for 1 cubic yard of concrete at the specified target air entrainment. The mix should be developed that uses the minimum amount of cementitious materials to achieve performance requirements. 2) Special Requirements: a) Water Reducer. A water reducing admixture (ASTM C494 Type A or F) is required for all mix designs. b) Accelerating Admixture. A liquid accelerating admixture (ASTM C 494 Type C or ASTM D 98) is required for mix designs to achieve set and compressive strength for the following conditions: i) Hot Weather. For Very Early Strength mix designs placed during hot weather conditions as defined in Section 502.4.1.7, the addition of no more than 1 percent of calcium chloride per 100 weight of cementitious materials, in solution form in accordance with Section 1068,) is required. ii) All Other Conditions. For Very Early and High Early mix designs, when the forecasted temperatures do not meet hot weather requirements, addition of no more than 2 percent of calcium chloride per 100 pounds of cementitious materials, in solution form in accordance with Section 1068, is required. iii) In all cases, the use of the minimum amount of cement and accelerator to achieve the required opening compressive strength within the specified opening time is encouraged. 3) Curing Material Plan. The plan shall include moisture and thermal materials (in accordance with Section 613.3.23) used to cure, cover and weight the cover materials so when placed and weighted that they remain in contact with the pavement surfaces and edges, providing a secure enclosure during moisture and thermal curing period. 613.3.8.3 The Contractor is responsible for complying with opening times, specified slump, plastic air content and minimum compressive strengths specified. The concrete for pavement repair shall be composed of materials, proportioning, air-entraining, mixing, slump, and transported in accordance with Sections 501 and 502, as applicable to concrete pavement, or as specified in this specification. Changes in the source of materials or concrete-mix proportions shall not be made without written authorization of the Engineer. Supplementary cementitious materials may be used, but are not required. Dosage of admixtures shall be determined by the manufacturer in accordance with ambient conditions expected at the time of placement. Admixture dosage may be adjusted 3/15/2022
613-6
Pavement Repair
to achieve, slump, entrained air content, temperature and compressive strength requirements within the specified opening time. The admixture dosage shall not permit the segregation of aggregate at the time of concrete placement. Addition of Type C calcium chloride brine accelerating or Type A or F water reducing admixtures to increase slump and control set after the concrete is delivered, but not discharged, is allowed only once. Failure to achieve the minimum air entrainment, concrete temperature, slump at the time of placement and compressive strength within the early opening time specified shall be cause for application of penalties or rejection of the mix design and the concrete placed. 613.3.8.4 Water Reduction and Accelerator Requirements. It is required that optimum mix trials be made before the start of job site pours. This will allow the ready-mix concrete producer to determine the proper batching sequence and the required dosage of other admixtures needed to deliver the specified concrete mix. 613.3.8.5 Type C Calcium chloride brine accelerator is recommended to be added at the job the site. Reduce the quantity of mixing water by 7 pounds per gallon of calcium chloride brine used. 613.3.8.6 Early Opening Strength Trial Batch. No trial batch is required for High Early Opening strength concrete. For Very Early Opening strength concrete, before starting slab replacement work, the Contractor shall complete a minimum of one (1) trial batch for each mix design, specified herein. If the specified mix design fails to meet specification requirements, the Contractor shall submit alternate mix design(s) using adjusted batch weights of the materials and admixtures specified. The Contractor shall produce a minimum of 4 ±1 cubic yard pre-production trial batch at a non-critical location selected by the Contractor, and agreed upon by the Engineer. The trial batch shall be produced at approximately the same season and ambient temperature conditions as those anticipated during production. The Contractor shall provide the Engineer a 7-day minimum advance notification of trial batch production. The Contractor shall produce the trial batch in the presence of the Engineer. 613.3.8.7 Concrete Placement and Workability. The mix shall remain workable through all placement and finishing operations. The maximum time permitted from the end of mixing to the completion of concrete discharge shall be twenty (20) minutes. All concrete remaining in the drum after this time shall be rejected and removed from the work site. No cold joints are allowed. 613.3.8.8 Slab Performance. The slab(s) shall demonstrate that the contractor is capable of producing slab repair in conformance with these specifications. The Contractor will be required to produce additional trial batches, at their expense, if the slab performance fails to conform to these specifications. 613.3.9 Concrete Maturity Testing. The Contractor shall be required to provide maturity loggers and assist in the development, maintenance and verification of repair's strengthmaturity relationship in accordance with Standard Specifications for Road and Bridge Construction Section 507, "Strength of Concrete Using the Maturity Method", when specified or allowed. When maturity testing is required, no trial batch will commence without Contractor supplied maturity loggers. The maturity curve shall be submitted to the Contractor by the Engineer after completion of the approved trial batch and at least 4 days in advance of production pavement repair.
3/15/2022
613-7
Pavement Repair
613.3.10 High Early Strength (24 - 48 Hour Opening Time). For pavement repair to be made and opened to traffic between 24 and 48 hours after placement, the allowable Type I/II cement content shall not be less than 700 pounds or exceed 850 pounds per cubic yard. Water/cementitious ratio shall be maintained at ±0.03 from the target established on the mix design and shall be within the minimum-maximum range when the tolerance is applied. All concrete shall have the additional properties: Required High Early Strength (24-48 Hour Early Opening) Mix Properties at the Time of Placement Property
Minimum
Maximum
Water / Cement Ratio Range from Target
-0.03
+0.03
Mix Temperature at time of placement, °F
83
-
Slump at the time of placement, inch
4
6
Entrained Air, percent
4.0
7.0
613.3.10.2 No addition of water to the concrete shall be permitted after addition of the HRWR. 613.3.11 Very Early Strength (4 - 6 Hour Opening Time). For the repair to be made and opened to traffic in 4 to 6 hours after placement, the Type I/II or III Portland cement, water reducing admixture, water/cement ratio and slump requirements shall be Option I (Type I/II or Type IL cement) or Option 2 (Type III cement). Water/cementitious ratio shall be maintained at ±0.03 from the target established on the mix design and shall be within the minimummaximum range when the tolerance is applied. 613.3.11.1 Option I. The allowable Type I/II or IL cement content shall not be less than 830 pounds or exceed 950 pounds per cubic yard. 613.3.11.2 Option II. The allowable Type III cement content shall not be less than 650 pounds or exceed 800 pounds per cubic yard.
3/15/2022
613-8
Pavement Repair
613.3.11.3 No addition of water to the concrete shall be permitted after addition of the HRWR. All 4 to 6 hour very early opening concrete shall have the additional properties: Required Very Early Strength (4 - 6 Hour Opening) Mix Properties at the Time of Placement Property
Minimum
Maximum
Water / Cement Ratio Range from Target
-0.03
+0.03
Temperature at time of placement, °F
88
-
Slump at the time of placement, inch
4
6*
Entrained Air, percent
4.0
7.0
* Slump may be increased up to 8 inches in accordance with manufacturer's recommendations. Mixes with slump greater than 8 inches will be designed in accordance with Self Consolidating Concrete (SCC) requirements specified in Section 501.5.1.1 except slump-flow minimum shall be 20 inches. The SCC shall include additional ASTM C494 admixtures: a Type S workability retaining admixture, a Type A and F water reducers, and Type C accelerator.
613.3.12 Concrete Mixing and Placement Limitations. Concrete mixing and placement limitations shall be in accordance with Section 502.4.1. 613.3.13 Entrained Air. The quantity of air by volume entrained in early opening strength concrete shall be 5.5 ± 1.5 percent as determined in accordance with ASTM C 231. 613.3.14 Consolidation. Internal concrete vibrator(s) shall be supplied in accordance with Section 502.3.7. Concrete shall be consolidated in accordance with Section 502.4.7.3. Vibrators and equipment to operate vibrators shall be on-site and functional prior to arrival of concrete on site. No concrete shall be placed without operational vibrators. 613.3.15 Coordination of Repairs with Asphalt Work. Concrete Pavement repairs shall meet the requirements stated below based on the existing roadway conditions, project working restrictions, and sequence of operations: 613.3.15.1 Concrete Pavement without Previous Overlay. The repaired area shall be filled to the existing surface with Portland cement concrete. 613.3.15.2 Concrete Pavement with Previous Overlay to be Removed. The concrete repair area shall be filled to the surface of the existing overlay with Portland cement concrete, unless contract provisions allow the milling to occur prior to the pavement repair operation. No additional payment will be made for the concrete required to match the existing surface.
3/15/2022
613-9
Pavement Repair
613.3.15.3 Concrete Pavement with Previous Overlay Not to be Removed. If the existing asphalt overlay will be overlaid with additional lifts of asphalt, the concrete repair area shall be filled to the surface of the existing overlay with Portland cement concrete. If no additional lifts of asphalt will be added following the pavement repair operation the concrete repair area shall be filled with Portland cement concrete to the surface of the underlying concrete pavement. The remaining area shall then be filled with approved hotmix asphalt to the surface of the existing overlay. 613.3.15.4 Mill and Fill Operations. When the contract requires all milled areas to be resurfaced in the same work day, prior to opening the pavement to traffic, any pavement repairs identified after milling will be marked for future repair, and the area shall be resurfaced as planned for that work day. No additional lifts of hot-mix asphalt will be allowed until the marked pavement is repaired. The pavement repair shall be performed in accordance with Section 613.3.15.3. 613.3.16 Concrete Pavement Repair Smoothness. All repaired areas shall be finished to provide a smooth ride and to the satisfaction of the Engineer. Prior to surface texturing, repaired areas shall be checked with a straightedge in accordance with Section 502.4.7.7 if required by the Engineer. When straightedged, the surface of the repaired area shall not vary more than ¼ inch per 10 feet from a straight line between the surface of the existing pavement on each side of the repaired area, regardless if the repair is to be resurfaced or not. When the tolerance is not met, plastic concrete shall be added or removed from the repair until the surface tolerance is met. 613.3.17 Surface Texturing. No concrete shall be placed without proper texturing equipment on the job. The repair texture shall be similar to that on the surrounding pavement. For concrete not to be overlaid and placed on Arterial roads, concrete shall be finished with a wire comb in accordance with Section 502.3.8.3. For all other conditions, concrete shall be finished with a broom finish in accordance with Section 502.3.8.4. 613.3.18 Rain Protection. Rain protection shall be in accordance with Sections 502.3.11 and 502.10.1. No concrete shall be placed without adequate type and quantity of rain protection material on the job. 613.3.19 Moisture and Temperature Retention Curing. No concrete shall be placed without proper curing material on the job. Immediately after finishing and as soon as marring of the concrete will not occur, the entire surface of the newly placed concrete shall be cured with one or more of the following methods: 613.3.19.1 Moisture Retention Curing. Moisture retention curing material is required if temperature retention material is not certified to meet the water retention requirements in this section. Material shall be on repair site prior to concrete placement. Concrete shall be cured once the surface resists marring and within 30 minutes following texturing. The entire surface of the newly placed concrete shall be cured with one of the five following moisture retention materials:
3/15/2022
613-10
Pavement Repair
613.3.19.1.1 Polyethylene Sheeting. Polyethylene sheeting for moist curing Portland cement concrete shall have a minimum nominal thickness of 4 mils and be white opaque (Hot Weather), clear or black (Cold Weather). Polyethylene sheeting physical requirements shall be in accordance with ASTM C 171. Sheeting shall extend 12 inches beyond the edges of placement, be secured to the perimeter of the pavement repair with 15-pound minimum sand bags spaced 12 inches center-tocenter, beginning at the repair edge and proceeding inward in a grid pattern over the entire placement area to ensure an air-tight enclosure. 613.3.19.1.2 White-Burlap Polyethylene Sheeting. White-Burlap Polyethylene Sheeting for moist curing shall consist of burlap weighing not less than 9 ounces/yard2 extrusion coated on one side with white opaque polyethylene of a minimum nominal thickness of 4 mils and meeting the requirements of ASTM C 171. Sheeting shall be secured to the perimeter of the pavement repair to ensure an air-tight enclosure in the same manner as the polyethylene sheeting. Burlap shall be maintained in a moist condition through the curing period. 613.3.19.1.3 High Performance Curing Compound. Curing compound for moist curing concrete not to be overlaid with hot mix asphalt shall consist of a highperformance white liquid membrane-forming compound that conforms to the requirements of ASTM C 1315 for Type 2, Class A or B as follows: 1) Percent Solids. The curing compound shall have a minimum of 42 percent solids (total solids minus pigment) by total weight and the vehicle shall be 100 percent poly-alpha-methylstyrene (PAMS). 2) Water Retention. As per ASTM C 156 the loss of water shall not be more than 0.15 kg/m2 in 24 hours and no more than 0.40 kg/m2 in 72 hours. 3) Reflectance. As per ASTM E 1347, the three-day reflectance readings shall be greater than 65. 4) Drying Time. As per ASTM C 1315 Part 8.3, shall set to touch in no longer than one hour after application and will be tack-free in no longer than four hours after application. 5) Application Rate. The application rate of at least 1 gallon per no more than 200 square feet is required. 6) Flash Point. As per ASTM C 1315 Part 8.3, shall have a flash point greater than 100°F. 613.3.19.1.4 Tack Coat. When hot mix asphalt is to be applied immediately after compressive strength is achieved and before opening to traffic, apply SS-1h meeting the requirements of Section 1015 and applied in accordance with Section 407.
3/15/2022
613-11
Pavement Repair
613.3.19.1.5 Self-Dissipating Curing Compound. When hot mix asphalt is to be applied after a minimum of 5 days after compressive strength is achieved and after opening to traffic, apply a dissipating curing compound shall be applied with material being in accordance with ASTM C 309 Type I, Class B curing compound. The application rate of at least 1 gallon per 200 square feet is required. 613.3.19.2 Temperature Retention Curing. If temperature retention material is not certified to meet the water retention requirements for water vapor transmission rate (WVTR) of the sheet material of no more than 10g/m2 in a 24-hour period when tested in accordance with ASTM E 96, then moisture retention curing, or polyethylene sheeting will be required with temperature retention curing. In accordance with Section 1058, all polyethylene sheeting will be required to be a minimum of 4.0 mils thick. After moisture retention curing is applied and has set, closed cell curing blankets shall be used. Closedcell curing blankets (multi-use) shall be manufactured for hot and cold weather concrete curing use in accordance with Section 1055.4.1.4, Closed-Cell Curing Blankets (MultiUse), and shall be certified having a minimum R-value of 3. Cover materials shall be so placed and weighted that they remain in contact with the pavement surfaces and edges, providing an airtight enclosure in the same manner as in Section 613.3.21.1. Application of curing blankets shall be based on ambient temperature and desired opening time in accordance with the following tables: High Early Strength (24-48 Hour Opening to Traffic) Temperature Retention Requirements* Time to Opening Time (TOT), (hrs.)
Minimum Ambient Temperature (MAT) in Curing Period, (°F)
TOT ≤ 24
24 < TOT ≤ 36
36 < TOT ≤ 48
MAT < 50**
Yes
Yes
Yes
50 ≤ MAT < 65
Yes
No
No
MAT ≥ 65
No
No
No
* To reduce thermal cracking thermal curing shall be removed when the concrete temperature reaches 140°F. Maintain moisture cure method until opening time. ** Concrete exposed to temperatures below 45°F may require additional curing blankets.
Very Early Strength (4-6 Hour Opening to Traffic) Temperature Retention Requirements* Minimum Ambient Temperature (MAT) in Curing Period, (°F)
Time to Opening Time (TOT), (hrs.)
MAT ≤ 80**
Yes
MAT > 80
No
4 ≤ TOT ≤ 6
* To reduce thermal cracking thermal curing shall be removed when the concrete temperature reaches 140°F. Maintain moisture curing method until opening time. ** Concrete exposed to temperatures below 45°F may require additional curing blankets.
3/15/2022
613-12
Pavement Repair
613.3.20 Concrete Joint Sawing. Equipment shall be in accordance with Section 502.3.14 and the requirements specified herein. Concrete maturity may be used to determine the compressive strengths specified below. 613.3.20.1 Standard Concrete Saw. When a standard (water cooled diamond bladed) concrete saw is used to cut the transverse or longitudinal joint when the pavement reaches 950 psi compressive strength (before final set) the following applies: 1) For pavement < 7 inches thick, saw the joint to a minimum depth of one-fourth (T/4) the specified pavement thickness. 2) For pavements ≥ 7 inches thick, saw the joint to a minimum depth of one-third (T/3) the specified pavement thickness. 3) Saw joints ⅜ inch ±1⁄16 inch wide as measured at the time of sawing. 613.3.20.2 Early-Entry Saw. When using early-entry (dry cut, light weight) saws, only use saw blades and skid plates as recommended by the manufacturer. Perform the early entry sawing when the pavement reaches 150 psi compressive strength (after initial set and before final set) as follows: 1) Saw the joint 2¼ to 2½ inches deep. 2) Saw joints approximately ⅛ inch ±1⁄16 inch wide as measured at the time of sawing. 613.3.21 Concrete Joint Sealing. If the repaired area is not to be resurfaced, the joints and overcut from the sawing operations shall be filled with an approved joint material in accordance with Section 502.9. For concrete repairs to be resurfaced, no joint sealing will be required. 613.3.21.1 Sealing Crack Relief. Remove isolation joint material to a depth of 1 inch below the pavement surface. Immediately prior to sealing, the crack relief must be clean, dry, and free of all incompressible material. Seal the crack relief with hot-poured sealant as specified in Section 613.3.23. The top of the sealant (after cooling) must be flush to ⅛ inch below the surface of the pavement. 613.3.22 Compressive Strength Requirements. For standard or High Early Strength (24 to 48 hour opening) concrete, the opening compressive strength shall be attained based upon concrete cylinders, or at the Contractor's option, may be determined by maturity in accordance with Section 507. For Very Early Strength (4 to 6 hour opening) concrete, the opening compressive strength shall be attained based upon concrete maturity in accordance with Section 507. When the repair is opened to traffic, the concrete strength shall be in accordance with Section 502.11. 613.3.23 Damaged or Defective Concrete. Rain damage, spalling and cracking will be cause for rejection of the concrete. Concrete pavement, base or joint repair not in compliance with straightedge smoothness specifications shall be corrected by grinding or removal and replacement.
3/15/2022
613-13
Pavement Repair
613.3.23.1 Deductions for Failure to Meet Minimum Time to Opening of Early Strength Pavement, Base, or Joint Repair. The Engineer shall deduct payment for concrete repair that is not opened within the specified time due to failure to meet the specified minimum compressive strength as follows: 613.3.23.1.1 The opening compressive strength of concrete pavement will be determined through testing of cylinders and/or maturity meters at frequencies determined by the Engineer. The cylinders or maturity meters will represent the compressive strength for all pavement poured by consecutive trucks with the corresponding concrete order, regardless of the number of locations poured Time to opening - is measured from when the last repair concrete placement is begun until removal of the traffic control from the lane closure is completed. Time of opening shall be determined by the Engineer to a quarter hour basis. Deductions for failure to open early strength pavement, base, or joint repair at the required time shall be assessed based on the following tables: Very Early Strength Time to Opening
Deduction of Bid Price
≤6 hrs
None
>6 to 8 hrs
25%
>8 to 12 hrs
50%
>12 hrs
100% or Remove and Replace High Early Strength
Time to Opening
Deduction of Bid Price
≤48 hrs
None
>48 to 72 hrs
25%
>72 to 96 hrs
50%
>96 hrs
100% or Remove and Replace
613.3.23.2 Diamond Grinding. Pavement repair(s) that fail to meet the smoothness requirement shall be corrected by diamond grinding in accordance with the following. 613.3.23.2.1 Description. This work shall consist of grinding the surface of Portland cement concrete pavement repair as directed by the Engineer and as specified in these special provisions.
3/15/2022
613-14
Pavement Repair
613.3.23.2.2 Location. Grinding shall begin and end at lines perpendicular to the pavement center line and shall be centered within the lane width. When deficient concrete repair pavement is ground, the grinding shall take place in the longitudinal direction of the traveled way, shall cover the full lane width and smoothly transition into and out of the repair. 613.3.23.2.3 Texture. Grinding concrete pavement repair must result in a parallel corduroy texture with grooves from 0.08 to 0.12 inch wide and from 50 to 60 grooves per foot of width. Grooves must be from 0.06 to 0.08 inch from the top of the ridge to the bottom of the groove. 613.3.23.2.4 Profile Grinding. Grinding concrete pavement repair constructed as part of the project that is not in compliance with straightedge smoothness specifications must comply with the following: 1) Both sides of transverse joints and cracks must have the same depth of texture. The surface must be within 0.01 foot of the lower edge of a 10-foot-long straightedge when laid parallel with the centerline with its midpoint at the joint or crack. 2) If necessary, perform additional grinding to achieve the required surface smoothness. Straightedge requirements do not apply to areas abnormally depressed from subsidence or other localized causes. End straightedge testing 25 feet before and resume 25 feet after these areas. 3) Cross-slope must be uniform and have positive drainage across the traveled way and shoulder. The surface must be within 0.02 foot of the lower edge of a 10-foot-long straightedge when laid perpendicular to the centerline. 613.3.23.2.5 Pavement Grinding Residue. Remove grinding residue with a vacuum attached to the grinding machine. Prevent residue from flowing across the pavement or remaining on the pavement surface. Dispose of grinding residue at an appropriate disposal facility. Do not store concrete pavement grinding residue within the highway. If authorized, the Contractor may transport liquid grinding residue to an offsite location for drying. The offsite drying location must be identified and protected under the SWPPP or Water Pollution Control Program. 613.3.23.2.6 Pavement Repair Replacement. Instead of grinding, the Contractor may remove and replace deficient concrete repair pavement at their expense. The new concrete pavement must be no less in thickness as the removed pavement. Replace between longitudinal joints or pavement edges and between transverse joints. Do not remove portions of slabs.
3/15/2022
613-15
Pavement Repair
613.4 Method of Measurement. 613.4.1 Measurement for full depth pavement, joint and base repair shall be made to the nearest 0.1 square yard. 613.4.2 Measurement for aggregate base shall be made to the nearest 0.1 square yard. 613.4.3 No measurement will be made for drilling dowel or tie-bar holes, keyway construction, furnishing and installing dowels, tie-bars, epoxy or polyester bonding agent, saw cutting and removing existing concrete pavements, concrete maturity loggers, assistance with creation, verification and maintenance of concrete-maturity curve, curing, or for subgrade or aggregate base compaction. 613.5 Basis of Payment. The accepted quantities of full depth pavement, joint and base repair will be paid for at the contract unit price. The accepted quantities of aggregate base shall be paid for at the contract unit price. No direct payment will be made for: removals; drilling and installing dowels; saw cutting pavements; subgrade or aggregate base compaction; or other work incidental to the completed pavement repair. 613.5.1 No extra compensation will be paid for: removal and replacement of temporary repair; Contractor optional extra repair depth as described in section 613.1.3; or corrective finishing or repairs to damaged or defective concrete. 613.5.2 The "Deductions for Failure to Meet Minimum Time to Opening of Early Strength Pavement, Base, or Joint Repair" in Section 613.3.23.1 is used for the purpose of determining deductions. The Engineer shall deduct payment for concrete pavement repair when opening to traffic exceeds the time specified.
3/15/2022
613-16
Pavement Repair
Section 614
Drainage Fittings
Section 614.10 Grates and Bearing Plates 614.11 Description. This work shall consist of furnishing and installing grates and bearing plates of the size and design shown on the plans. 614.12 Materials. Grates and bearing plates shall be constructed of structural steel meeting the requirements of ASTM A 36 or AASHTO M 183, or carbon steel castings meeting the requirements of ASTM A 27, or gray iron castings meeting the requirements of ASTM A 48 as indicated on the plans. 614.13 Construction Requirements. Grates and bearing plates shall be fabricated as shown on the plans. Welds shall be of full section and sound throughout. Obvious dimensional defects and structural discontinuity of welds will be cause for rejection. All welding residue shall be removed by chipping, brushing, or other suitable means. If grates are to be galvanized, all tightly contacting surfaces shall be completely sealed by welding. Removal of welding beads will not be required except on bearing surfaces. Grates and bearing plates shall be hot dip galvanized. 614.13.1 If galvanized grates and bearing plates are furnished, they shall be galvanized in accordance with the requirements of AASHTO M 111. Bolts, nuts, and washers shall be galvanized in accordance with the requirements of AASHTO M 232, or they may be mechanically galvanized. If mechanically galvanized, the coating thickness, adherence, and quality requirements shall conform to AASHTO M 232, Class C. Damaged spelter coating shall be repaired in accordance with Section 712.14. 614.13.2 Settings of Castings, Frames, and Fittings. All castings, frames, and fittings shall be placed in the positions shown in the project plans or as directed, and shall be set true to line and to correct elevation upon a full bed of mortar. If frames or fittings are to be bolted or anchored in concrete or brick masonry, all anchors or bolts shall be set and held in place before the concrete or mortar is placed. The unit shall not be disturbed until the mortar or concrete has hardened to adequate strength. When frames or fittings are to be placed upon previously constructed masonry, the bearing surface of masonry shall be brought true to line and grade to present an even bearing surface clean and free of debris particles. The unit shall be set in a full mortar bed as shown in the Standard Drawings or the project plans. All units shall be firmly and securely seated. Frames and cover, frames and grates, or other similar pairs of items shall have true common bearing surfaces such that covers or grates will seat firmly without rocking or shifting. The grates or covers shall be placed after the frames or fittings have been installed, and after the concrete or mortar has been allowed to harden for at least twenty-four hours, will not be damaged. 614.14 Basis of Payment. No direct payment will be made for furnishing or installation and will be considered incidental to the structure.
5/1/2010
614-1
Drainage Fittings
Section 614.20 Automatic Floodgate 614.21 Description. This work shall consist of furnishing and installing automatic floodgates of standard design to fit the opening shown on the plans. Type 1 floodgates shall be installed on concrete structures. Type 2 floodgates shall be installed on corrugated metal pipe. Gates shall be of the off vertical type when specified on the plans. 614.22 Materials. 614.22.1 Automatic floodgates shall have a frame and flap constructed of cast iron meeting the requirements of ASTM A 48 or AASHTO M 105, minimum Class 30. 614.22.2 Each link shall be provided with commercial grade bronze bushings permanently lubricated and installed at the factory. For hydraulic heads greater than 10 feet, the bottom of the links shall be provided with an adjusting screw to align seating faces on the cover properly with respect to the seat. For hydraulic heads less than 10 feet, adjusting screws are not required; however, the seating faces on the cover shall properly align with respect to the seat. The links shall be designed to prevent the cover from rotating far enough to become wedged in the open position. 614.22.3 The seat shall be one-piece cast iron with a raised section around the perimeter of the waterway opening to provide the seating face, and shaped to provide two pivot bosses extended above the top of the waterway opening. 614.22.4 All anchor bolts, assembly bolts, screws, and nuts shall be of galvanized steel having ample section to withstand safely the forces created by operation of the gate under a hydraulic head. Quantity and size of anchor bolts shall be as recommended by the manufacturer, except there shall be a minimum of four bolts. Each anchor bolt shall be furnished with two nuts to facilitate installation and alignment of the flat back gates when attached to concrete. 614.22.5 The Contractor shall furnish in triplicate a manufacturer's certification that the floodgate being supplied conforms to the specified materials requirements and that the floodgate will operate properly under the specified hydraulic head. When the hydraulic head is not specified, the height of fill above the pipe will be considered the hydraulic head. 614.23 Construction Requirements. Automatic floodgates shall be carefully machined, watertight, and automatic in operation. They shall react to any difference in water level and shall be hinged to seat accurately. They shall be attached in accordance with the manufacturer's recommendations to corrugated metal pipes or concrete structures. 614.24 Basis of Payment. The accepted quantity of automatic floodgates, complete in place, will be paid for at the unit bid price for each of the pay items included in the contract.
5/1/2010
614-2
Drainage Fittings
Section 614.30 Gray Iron Castings for Manhole or Inlet Frame, Cover and Gratings 614.31 Description. This work shall consist of furnishing and installing manhole frames and covers, or any items of similar nature. They shall be of the size and type necessary to fit appurtenant details shown on the plans, shall be of a standard design, and shall meet the approval of the Engineer. 614.32 Materials. These items shall be constructed of Class 30 B cast iron meeting the requirements of ASTM A 48 and AASHTO M 105. Specific classes, when required, will be shown on the plans. All castings shall be clean and free of scale, adhesions or inclusions. 614.33 Construction Requirements. Bearing surfaces of both the frame and cover shall be finished to a non-rocking fit and bearing surfaces for standard manhole frames and covers shall be machined. 614.34 Basis of Pavement. No direct payment will be made for furnishing or installation and will be considered incidental to the structure.
5/1/2010
614-3
Drainage Fittings
(This Page Intentionally Left Blank)
5/1/2010
614-4
Drainage Fittings
Section 615
Office for Engineer
615.1 Description. This work shall consist of the furnishing and maintaining of an office for the Resident Engineer in accordance with the contract. Refer to Standard Drawing C615.00, Field Office for Resident Engineer. 615.2 Construction Requirements. 615.2.1 The Contractor shall provide the office as the first order of work. The office shall be located on the project right-of-way unless another suitable location is approved by the Engineer. The office for the Engineer shall be completely operational before any other work on the project can proceed. 615.2.2 Unless otherwise approved by the Engineer, the office shall consist of one trailer, with minimum outside dimensions of 10 feet x 40 feet, excluding hitch. The trailer shall have sanitary facilities, telephone, a separate enclosure for the Resident Engineer, a storage room, and other facilities required in the contract. This trailer shall be constructed as to provide finished panel walls, vinyl floor covering, adequate lighting fixtures, and a minimum of partitions or attachments which will reduce the effective working area. 615.2.3 The office shall be weatherproof, insulated, and with central air conditioning and electric or gas heating facilities capable of maintaining a temperature of 72°F. 615.2.4 Adequate light, both artificial and natural, along with sufficient windows to provide acceptable ventilation, shall be provided. All doors and windows shall be equipped with vandal proof grills and locking facilities. Electric, water, gas (if required), and sanitary hookups shall be provided. 615.2.5 The office shall be furnished with 1 desk/computer desk; 4 chairs; 1 drafting stool; 1 drafting table; 1 work table; 1 legal size file cabinet; 1 calculator (approved by the Engineer); 1 locker with lock; 1 electric water cooler; 2 telephone lines (1 for a cordless telephone and 1 for a fax machine); 1 cordless telephone; 1 fax machine; 1 DSL phone line for high speed computer Internet; 1 printer stand; and other items as shown on St. Louis County Standard Drawing C615.00, "Field Office for Resident Engineer". The telephone and fax machine shall have metropolitan numbers. Use of the telephone and fax machine shall be restricted to personnel of the County. For projects over one-hundred fifty thousand dollars that do not include an office for the Engineer, a Nextel mobile phone will be required for the Engineer. 615.2.6 The Contractor shall furnish four 10-pound dry chemical type fire extinguishers including refills and inspection as necessary, aggregate surfaced parking area of sufficient capacity for eight vehicles. If specified in the contract, the Contractor shall furnish and install a 6-foot chain-link fence. The Contractor shall be required to carry insurance to cover County owned equipment and supplies stored in office for Engineer.
1/1/2016
615-1
Office for Engineer
615.2.7 The office, equipment, and furnishings shall remain the property of the Contractor, and after being vacated by the resident Engineer all portions of the installation on the right-ofway shall be promptly removed. The right-of-way shall be restored to a satisfactory condition. The Office for Engineer will be turned over to Contractor for removal when the Engineer determines that it is no longer required. Removal of office or disconnection of utilities prior to notice from Engineer will result in Contractor having to restore office for Engineer on existing site or new site at his expense. 615.3 Method of Measurement. Payment for office for Engineer will commence when all utilities and equipment in the trailer are functional. Quantity will be paid to nearest ½ month. 615.4 Basis of Payment. The accepted office for Engineer complete with furnishings, maintenance, all utilities and heating facilities including operation and fuel, fence if required, ground rentals, labor, tools, supplies (includes first aid kit and supplies), and removal will be paid for at the contract unit bid price. On projects requiring a mobile phone, the cost shall be considered as included in other items of work.
1/1/2016
615-2
Office for Engineer
Section 616
Traffic Control Plan
616.1 Description. This work shall consist of furnishing and installing traffic control devices in accordance with the contract and as directed by the Engineer. 616.2 Materials. All construction sign and reflective material shall conform to Section 1063. 616.2.1 Flashing Electric Light. This unit shall be an 8-inch conventional traffic signal section meeting the requirements of Division 900. Each unit shall contain a yellow lens. The Contractor shall furnish lamps for the flashing electric lights. Each unit shall contain a minimum 8-inch tunnel visor and be equipped for single section mounting. The flasher unit may be the synchronous motor or NEMA solid-state type operated on 120 volts AC. Flashing electric lights which will become property of the County shall be controlled by NEMA solidstate flasher units and be connected to a permanent power supply. Two-circuit flasher units shall be used to provide alternate flashing of the lights when mounted on barricades or bridges. Indications shall be flashed at not less than 50 nor more than 60 flashes per minute, with an approximate 50 percent on-off ratio. The Contractor shall, at his expense, provide all necessary connections to an electrical power source for operation of flashing electric lights. 616.3 Construction Requirements. 616.3.1 The Contractor shall furnish, install, maintain, clean, and relocate all signs, drums, cones, barricades, object markers, flashing arrow panels, channelizing devices, lights, and other traffic control devices shown on the plans, or as directed by the Engineer. All signs and traffic control devices shall meet the requirements of the Manual on Uniform Traffic Control Devices (MUTCD) and shall be kept legible, in alignment, and in good repair. All signs, except the project terminal signs, shall be covered, set aside, turned, removed, or relocated as work progresses or is completed and their necessity ceases to exist. All traffic control devices shall be removed after completion of construction and shall remain the property of the Contractor unless specified otherwise. 616.3.2 The contract will indicate the minimum requirements for traffic control. The Contractor may, at his expense, add to the traffic control plan any standard signs or traffic control devices he considers necessary to adequately protect the public and the work. 616.3.2.1 Signs and sign quantities for blasting areas are not included in the contract traffic control plan. It shall be the Contractor's responsibility and expense to furnish, install, maintain, and remove blasting zone signing in accordance with the MUTCD. Placement of blasting area signing shall be subject to the Engineer's approval. 616.3.2.2 Some projects require establishment of stage construction, and the traffic control plans are developed accordingly. Work in any of the specified construction stages or other unrelated items of work may be accomplished concurrently with another specified stage provided that no interference with the prescribed handling of traffic procedures will occur. The Contractor shall submit traffic control plan revisions to the Engineer should he choose to deviate from the stages shown in the contract. All changes to the traffic control plan are subject to the Engineer's approval and shall be verified in writing prior to implementation. Sign and device quantities shall be adjusted accordingly.
1/1/2016
616-1
Traffic Control Plan
616.3.2.3 If the Engineer determines the need for additional signs or other traffic control devices not included in the traffic control plan, the Contractor will be notified in writing to provide the additional signs or devices. Reimbursement for authorized changes to the traffic control plan will be made in accordance with Section 104.3, unless covered by contract unit prices. 616.3.3 Flaggers will be required when equipment is crossing a road that is open to vehicular traffic. Hand signaling devices, flagger attire, flagging procedures, and flagger stations shall be in accordance with MUTCD. On resurfacing projects requiring handling two-way vehicular traffic over a single lane, each flagger involved in controlling traffic through and along the work area shall be equipped with a portable transceiver radio and a stop-slow hand-signaling device. 616.3.4 The length of time that the Contractor may maintain lane closures or one-way traffic operations shall be kept to a minimum and shall be subject to the Engineer's approval. The Contractor shall furnish the Engineer a traffic control plan indicating the proposed method to achieve temporary stoppage of all traffic lanes if construction operations require such. The plan shall indicate any advance warning or regulatory signs, if used, and their locations; flagmen, if used, and their locations; and all other traffic control devices and their locations which may be used to temporarily stop all traffic. A one-time payment for traffic control devices used to temporarily stop all traffic will be made at the unit price for those like items contained in the contract. No direct payment will be made for removing or reusing these particular signs as an indeterminate number of occasions for their use may occur. Traffic control devices used by the Contractor which do not have a specific pay item in the contract shall be supplied, installed, maintained, and removed by Contractor at his expense. 616.3.5 The Contractor will not be allowed to park vehicles or equipment nor store materials on pavements or shoulders being utilized by traffic except in cases of emergency. If the contract specifies time periods that the Contractor will not be permitted to perform work, no vehicles or equipment utilized in the construction of the project shall enter or leave the construction area via the pavements handling traffic nor be operated on the pavements handling traffic within the construction area. 616.3.6 The requirements of this specification shall not relieve the Contractor of his responsibility for protecting both the public and the work. Should the Contractor fail to clean, repair, replace, or otherwise maintain the traffic control devices when directed to do so by the Engineer, one or more of the following actions will be taken: a) The Engineer may employ another agency to correct deficiencies in signing or warning devices and deduct the cost from the Contractor's pay estimate. b) Suspension of all pay estimates until deficiencies are corrected. 616.4 Basis of Payment. Signs and other traffic control devices specified in the traffic control plan or authorized by the Engineer will be paid for at the unit price for each of the pay items included in the contract. No direct payment will be made for any incidental items necessary to complete the work unless specifically provided as a pay item in the contract. No direct payment will be made for cleaning, repair, or replacement of traffic control devices.
1/1/2016
616-2
Traffic Control Plan
Section 617
Concrete Median Barrier
617.1 Description. This work shall consist of constructing a concrete median barrier in conformity with the lines, dimensions, and typical sections indicated on the plans. The concrete median barrier may be either cast-in-place, extruded, or precast as shown on the plans. 617.2 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Reinforcing Steel for Concrete Structures ................................................... 1036 Concrete Curing Material ............................................................................ 1055 Mortar for Grout ............................................................................................1066.2.2 Item
Specification
Prestressing Strands ............................................................................. ASTM A 416 AASHTO M 203 Concrete median barriers shall be constructed of Class B or B1 concrete. Materials, proportioning, air entrainment, mixing, slump, and transporting shall be in accordance with Section 501. Concrete shall be placed and finished in accordance with the applicable provisions of Section 703. 617.3 Construction Requirements. 617.3.1 Concrete median barriers shall conform to Standard Drawings C617.00, C617.01, C617.02, and to the dimensions shown on the plans. Forms shall be of either metal or wood, of sufficient strength to resist springing. 617.3.2 Concrete barriers may be constructed by using an extrusion machine or other equipment specifically designed for constructing cast-in-place reinforced concrete barriers, provided that the finished barrier is true to line and grade and the exposed surfaces conform to the requirements of Section 617.3.6. 617.3.3 Concrete barriers may be a combination of prestressed concrete sections and reinforced cast-in-place concrete sections, except that this option shall not be used on curves exceeding 5 degrees. Prestressing tendons shall not be stressed until the concrete in the barrier section has attained a compressive strength of at least 3,000 pounds per square inch (psi). Prestressing tendons shall be encased in plastic ducts or sheaths which will eliminate bonding between the concrete and prestressing tendon. Prestressing strands shall be liberally coated with an approved corrosion inhibiting material. End plates for prestressed concrete barrier sections shall be fabricated of steel meeting the requirements of ASTM A 36 and in accordance with details shown on the plans. End plates shall be hot dipped galvanized after fabrication in accordance with ASTM A 123 or painted with the prime coat of System C in accordance with Section 712.12. Prestressing strands extending into cast-in-place concrete sections of the barrier shall be cleaned and tied in accordance with details shown on the plans.
1/1/2016
617-1
Concrete Median Barrier
617.3.4 Precast units shall not be removed from forms and casting beds less than 12 hours after casting and until a compressive strength of not less than 1400 pounds per square inch (psi) is attained. Compressive strength will be determined by tests made in accordance with ASTM C 39. Concrete shall be cured for not less than 7 days in accordance with Section 703.3.17, except membrane curing will not be permitted. 617.3.5 Cast-in-place units shall be cured in accordance with the applicable provisions of Section 703.3.17, except membrane curing will not be permitted. 617.3.6 The surface shall be of a smooth and even texture, true to line and grade. Median barrier will be straight edged along the top surface and shall not show a variance greater than ½ inch in 10 feet on all exposed faces. Failure to comply with this provision will require complete removal and replacement of the affected area. No area less than 10 feet in length will remain in place. 617.3.7 When cast-in-place or extruded construction is used, contraction joints shall be constructed as shown on the plans. Insertion of joint filler will not be required. 617.4 Method of Measurement. 617.4.1 For the purpose of measurement and payment, Type A Concrete Median Barrier will be considered that which is cast or formed with two traffic faces regardless of the width of the barrier. Type B Concrete Median Barrier will be considered that which is cast or formed with one traffic face. 617.4.2 Measurement of concrete median barrier will be made to the nearest ½ linear foot for each continuous length and totaled to the nearest linear foot for the sum of the lengths. The length will be measured separately for each type. Final measurement will not be made except for authorized changes during construction, or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. 617.5 Basis of Payment. The accepted quantities of concrete median barrier, complete in place, will be paid for at the unit bid price for each of the pay items included in the contract.
1/1/2016
617-2
Concrete Median Barrier
Section 618
Mud Jacking
618.1 Description. This work shall consist of repairing settlements under rigid type pavement by filling voids or cavities located beneath the pavement to reestablish the pavement elevation. 618.2 Materials. Portland cement shall conform to Section 1019. Water shall conform to Section 1070. 618.3 Mix Design. The Contractor will be required to submit a mix design for approval 14 days prior to intended date of use. 618.4 Construction. Equipment required for this work shall be inspected and approved by the Engineer. Holes shall be drilled through the existing pavement with spacing as designated by the Engineer. Holes shall be 1½ to 2½ inches in diameter. Where excess water is found in the subgrade, the water shall be removed by pumping the major amount of water out of the subgrade. The addition of cement to the slurry mixture should correct for small amounts of water remaining. The slurry mixture shall be pumped beneath the pavement and continued to be placed until the pavement is lifted to the desired elevation. 618.5 Basis of Payment. Payment shall be made at the unit cost bid for each of the items included in the contract.
1/1/2016
618-1
Mud Jacking
(This Page Intentionally Left Blank)
1/1/2016
618-2
Mud Jacking
Section 619
Mobilization
619.1 Description. This item shall consist of preparatory work and operations including, but not limited to, those necessary for the movement of personnel, equipment, supplies, and incidentals to the project site; for the establishment of all offices, buildings, and other facilities necessary for work on the project except as provided in the contract as separate pay items; and for all other work and operations which must be performed, or costs incurred, prior to beginning work on the various items on the project site. 619.2 Basis of Payment. 619.2.1 Payment for the actual cost of the contract bond and railroad liability insurance will be authorized upon presentation of invoices at least four days prior to the estimate date. Receipted invoices for payments previously allowed on the estimate shall be submitted to the Engineer within 27 days of the date of the estimate on which payment was made, or such payment will be deducted from future estimates. The amount paid, but not more than the price bid for mobilization, will be deducted from the contract lump sum price for mobilization and the remainder will be used as the basis for partial payments which will be allowed on the next estimate as follows: a) When 5 percent or more of the original contact amount is earned, 25 percent. b) When 10 percent or more of the original contract amount is earned, an additional 25 percent. c) When 25 percent or more of the original contract amount is earned an additional 25 percent. d) When 50 percent or more of the original contract amount is earned, the final percent. 619.2.2 Nothing herein shall be construed to limit or preclude partial payments otherwise provided by the contract.
1/1/2016
619-1
Mobilization
(This Page Intentionally Left Blank)
1/1/2016
619-2
Mobilization
Section 620
Inlaid Pavement Markers
620.1 Description. This work shall consist of furnishing materials for and installation of inlaid, prefabricated, thermoplastic markers into an asphalt surface. 620.2 Materials. 620.2.1 The marker shall be supplied with a precoated factory applied adhesive backed with protective release paper to make possible immediate application to asphalt pavement without the use of heat, solvent, or other type adhesive operations. The thermoplastic and adhesive shall be of a type that water will not be harmful to successful application. 620.2.2 The nominal thickness of the marker shall be 60 mils including the adhesive with nominal widths of 4 inches, 12 inches, and 24 inches. The edges shall not be tapered. The length, width, and shape will be specified on the plans. 620.2.3 Thermoplastic marker material applied at 120 mils thickness shall consist of a minimum, by weight, of 20 percent plastics, 30 percent pigments, and 48 percent graded glass spheres. Titanium dioxide shall be at least 20 percent by weight of the total pigment in white markers. Yellow markers shall have a minimum of 18 percent by weight of the total pigment as chrome yellow. Graded glass spheres shall be colorless, clean, and transparent. When tested by ASTM D 1214, at least 85 percent of the glass spheres shall be retained on a 140mesh U.S Standard sieve. Glass spheres shall be uniformly distributed throughout the entire cross section of the marker. 620.2.4 Flexibility of the thermoplastic material shall be such that it can be applied without cracking or breaking. 620.3 Construction Requirements. 620.3.1 Markers shall be installed in accordance with the plans, or as directed by the Engineer. The width of placement of the asphaltic concrete shall be adjusted so that inlaid markers will not fall on longitudinal joints. 620.3.2 Lines shall be of either white or yellow, continuous or intermittent, and of the widths and configurations required. 620.3.3 Arrows, words, and legends shall be white and may be formed from one piece, multiple pieces, or strips of the marker material. 620.3.4 Markers shall be imbedded in the asphalt surface by the final roller. 620.4 Acceptance. The Contractor shall furnish manufacturer's certification that the thermoplastic pavement marker material meets or exceeds the requirements of this specification.
1/1/2016
620-1
Inlaid Pavement Markers
620.5 Method of Measurement. 620.5.1 Measurement of lines will be made to the nearest 10 linear feet of marker material used. 620.5.2 Measurement of arrows and stop lines will be made per each. 620.6 Basis of Payment. Accepted thermoplastic pavement markers will be paid for at the unit bid price for each of the pay items included in the contract.
1/1/2016
620-2
Inlaid Pavement Markers
Section 621
Temporary Pavement Markings
621.1 Description. This work shall consist of furnishing, installing, maintaining, and removing temporary and permanent pavement marking as shown on the plans, as specified herein or as directed by the engineer. 621.2 Temporary Pavement Marking Following Obliteration of Existing Markings. When the contractor obliterates existing pavement markings by cold milling, grinding, resurfacing or for any other operation, the contractor shall, at the contractor’s expense, provide and maintain temporary pavement markings until permanent pavement markings are in place. The contractor shall place temporary or permanent pavement markings on all open lanes of traffic at the completion of each daily operation prior to leaving the work zone unattended. At no time shall more than one mile of roadway be unmarked. Pavement marking shall be replaced in the same configuration as the previously existing pavement marking unless otherwise shown on the plans or directed by the engineer. Materials. 621.2.1 Temporary Paint. Paint shall be used on pavements that are to be obliterated or overlaid at the completion of either the current phase of construction or the completion of the project. The temporary paint will have an application of glass beads. 621.2.2 Temporary Construction Grade Tape. This type of temporary tape shall be used on short term striping applications such as between lifts of asphalt, on a final lift prior to final striping, or as otherwise approved by the Engineer. The tape shall consist of a white or yellow retroreflective film on a conformable metallic backing "foil back" precoated with a pressure sensitive adhesive. The tape shall contain beads that are not easily removed when the material surface is scratched with a thumbnail. It shall have a minimum thickness of 15 mils. If used on final pavement, this tape must be removed by the Contractor immediately after final striping has been completed. 621.2.3 Temporary Pavement Marking for Traffic Pattern Changes. The contractor shall place temporary pavement markings for bypasses, lane shifts, narrow lanes and other traffic pattern changes as shown on the plans. Temporary paint shall not be used in lieu of tape without approval from the engineer. The contractor shall install and maintain temporary pavement marking until the permanent marking material has been placed as specified in the contract. 621.2.4 Temporary Removable Detour Grade Tape. This type of temporary tape shall be used on projects for handling traffic during detour operations on new and existing pavements that are to remain in place, on temporary pavement used for more than one (1) detour, or in any other circumstance where temporary striping must be readily removed, or as directed by the Engineer. This tape shall be capable of performing for the duration of the detour and be able to be removed intact or in large pieces. 621.2.4.1 The tape shall not contain metallic foil and shall consist of a mixture of highquality polymeric materials and pigments with glass beads throughout the pigmented portion of the film and a reflective layer of beads bonded to the top surface. 621.2.4.2 The tape shall have a minimum thickness of 40 mils. 9/1/2023
621-1
Temporary Pavement Markings
621.2.4.3 The white and yellow tapes shall have the following initial minimum reflectance values at 0.2 degree and 0.5-degree observation angles, and 86.0-degree entrance angle as measured in accordance with the testing procedures of Federal Test Method Standard 370. The photometric quantity to be measured shall be specific luminance (SL) and shall be expressed as millicandelas per square foot per foot-candle [(mcd / ft2) / fc].
White Observation Angle 2
SL [mcd / ft ) / fc]
Yellow
0.2°
0.5°
0.2°
0.5°
1770
1270
1310
820
The metric equivalent shall be expressed as millicandelas per square meter per lux. The test distance shall be 50 feet and the sample size shall be a 2.0-foot x 2.5-foot rectangle. The angular aperture of both the photoreceptor and the light projector shall be 6 minutes of arc. The reference center shall be the geometric center of the sample and the reference axis shall be taken perpendicular to the test sample. 621.2.4.4 The surface of the markings provides an initial minimum skid resistance value of 50 BPN when tested according to ASTM E 303-74. 621.2.4.5 The marking film shall be removable from asphalt and Portland cement concrete intact or in large pieces, either manually or with a roll up device, at temperatures above 40°F without use of heat, solvents, grinding, or blasting. The manufacturer shall be able to show that the marking film has met this requirement after the following minimum traffic exposure based on transverse test decks with rolling traffic: 1) Time in place ............................................................................. 632 days 2) ADT per lane ....................................... 9000 (23% Trucks, 3.5axles/unit) 3) Minimum axle hits...................................................................13,000,000 621.3 Construction Requirements. 621.3.1 All temporary striping/markings shall conform to the latest edition of the Manual on Uniform Traffic Control Devices (MUTCD) and any revisions thereof. Temporary pavement striping / markings shall be as shown on the plans or as directed by the Engineer. The s u r f a c e must be free of rotomill debris, loose or caked dirt, gravel, oily residues, road salt residues, or other foreign materials, which may inhibit proper adhesion. The air and surface must be above 50 degrees and rising. All pavement striping / markings applied within the project limits shall be maintained by the Contractor. The Contractor shall notify the Division of Operations office 48 hours prior to the placement of Temporary Pavement Striping / Markings.
9/1/2023
621-2
Temporary Pavement Markings
621.4 Removal. Removal of temporary pavement striping and other pavement marking within the project limits will be shown on the plans. Tape shall be removed by hand methods. Paint s h a l l be removed from Portland cement concrete pavement by a high-pressure water blast method or a low-pressure water and sand blast method. Paint shall be removed from bituminous pavement by push grinding method. Paint shall be removed without damaging the surface or texture and without leaving an image which might mislead traffic. High-pressure water blast methods shall not exceed 10,000 psi. Any thermo-plastic markings shall be removed by methods mentioned above prior to the beginning of any surface treatment. 621.5 Approval. 621.5.1 The temporary paint will have an application of glass beads that shall be approved by the Engineer and must have certification. 621.5.2 Prior to use of construction grade tape or removable detour grade tape, the Contractor shall submit material and application specifications and samples of the tape for testing and evaluation. Satisfactory performance of the material must be obtained in the field with evaluation and acceptance at the discretion of the Engineer. 621.6 Method of Measurement. The temporary pavement striping (paint or tape) will be measured to the nearest 10 linear feet of actual material applied. The temporary pavement markings (paint or tape) will be measured to the nearest 1.0 square foot of actual stop line, crosswalk, turn arrows, or other such markings applied. 621.7 Basis of Payment. 621.7.1 Payment for accepted quantities of pavement marking for traffic pattern changes (paint or detour grade tape), including removal, if necessary, will be made at the contract unit price. Payment will be made for initial installation only and not for repair or replacement. 621.7.2 No payment will be made for any temporary pavement markings, regardless of type, when used as temporary pavement marking due to obliteration of existing markings as defined in section 621.2.
9/1/2023
621-3
Temporary Pavement Markings
(This Page Intentionally Left Blank)
9/1/2023
621-4
Temporary Pavement Markings
Section 623
Concrete Bonding and Epoxy Mortar
Section 623.10 Concrete Bonding Compound 623.11 Description. This work shall consist of surface preparation, and application of concrete bonding compound to be used to bond plastic concrete or mortar to hardened concrete as shown on the plans. 623.12 Materials. All mortar shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Type II Epoxy Resin Materials .............................................. 1039.10 623.13 Construction Requirements. 623.13.1 Surface Preparation. The surface of the hardened concrete to which the plastic concrete or mortar is to be bonded shall be thoroughly cleaned by sand blasting, wire brushes, hammers, or other methods so that all loose and unsound concrete is removed and only sound concrete remains. The areas to be bonded shall be surface dry and all dust and loose particles removed by air jets prior to application of the bonding agent. 623.13.2 Application. The bonding agent shall not be applied when either the air or surface temperature is 60°F or below. 623.13.2.1 The two components shall be thoroughly mixed in the ratio and in accordance with the instructions shown on the containers. The two components may be warmed with indirect heat to a temperature of 90°F to 100°F to reduce the viscosity. Under no circumstances shall any solvent be added to the compound. 623.13.2.2 The mixed bonding agent shall be applied with a moderately stiff bristle brush, and thoroughly worked into the hardened concrete surface. The thickness of application shall be an average of 20 to 25 mils. If the concrete absorbs the bonding agent, another coat shall be applied. 623.14 Basis of Payment. No direct payment will be made for the furnishing of material, surface preparation, or application.
1/1/2016
623-1
Concrete Bonding and Epoxy Mortar
Section 623.20 Epoxy Mortar 623.21 Description. This work shall consist of surface preparation and the furnishing and application of epoxy mortar as shown on the plans. 623.22 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Type III Epoxy Resin Materials ......................................................... 1039.20 623.22.1 Sand for mortar shall be an approved silica aggregate such as quartzite sand (Ottawa sand or equivalent). The sand shall be clean, dust free, dry (2 percent maximum moisture), bagged, and shall conform to the following requirements: a) Chemical Analysis (Average Quarry Run) Silicon Dioxide (percent min.) ...................................................... 98.80% Aluminum Oxide + Titanium Dioxide (percent maximum) ............. 0.85% Iron or Ferric Oxide (percent max.) ............................................... 0.10% Sodium Oxide (percent max.) ........................................................ 0.10% Potassium Oxide (percent max.) ................................................... 0.20% b) Physical Properties Specific Gravity......................................................................2.60 to 2.70 Loss on ignition at 1,832°F ....................................................0.08 to 0.16 Melting Point, degrees F....................................................3,049 to 3,400 Weight per cubic foot (loose), lb. .................................................75 to 95 Mohs Hardness Scale ..........................................................7 (minimum) Voids (loose), percent........................................................... 30% to 50% c) Gradation Sieve Size
Percent Passing
No. 16 ............................................................................................. 100% No. 30 ................................................................................. 97% to 100% No. 50 ..................................................................................... 5% to 35% No. 100 ..................................................................................... 0% to 2% No. 200 .................................................................................. 0% to 0.4% The Contractor shall furnish a certification in triplicate to the Engineer certifying that the sand supplied conforms to all requirements specified. The certification shall include or have attached typical test results for all specified properties.
1/1/2016
623-2
Concrete Bonding and Epoxy Mortar
623.23 Construction Requirements. 623.23.1 Surface Preparation. The surfaces to which the epoxy mortar is to be applied shall be free of oil, solvents, grease, dust, bitumen, dampness, loose particles, and foreign matter. A large size commercial vacuum cleaner, or an air jet or both shall be used to remove dust and other particles just prior to placing the mortar. If an air jet is used, care shall be taken to avoid deposit of oil by the air pump. 623.23.2 Application. The epoxy mortar shall be prepared and placed when the weather is dry and the air temperature is above 70°F but not higher than 93°F. The Engineer may permit placement when the mix temperature and the surface temperature are above 60°F and the air temperature is steady or rising. 623.23.2.1 The mortar shall be 3¼ parts sand to 1 part low viscosity epoxy, by volume. 623.23.2.2 The Contractor shall estimate the time required to complete an area to be patched or leveled and the volume of material needed, and he shall mix only the number of containers of material that can be placed in 20 to 40 minutes depending on the temperature. 623.23.2.3 The two components of the low viscosity epoxy shall be thoroughly mixed in the ratio and in accordance with the instructions shown on the containers. Mixing shall be done with a special paddle designed for the purpose and driven by a low speed electric drill (500 to 600 rpm) or other approved mixing device. The mixing shall continue for 2 to 3 minutes or as required to obtain uniformity. 623.23.2.4 When the low viscosity epoxy material has been thoroughly mixed, sand shall be added gradually while mixing continues, and after the proper quantity of sand has been added, mixing shall continue for 1 to 2 minutes until the mixture is uniform. 623.23.2.5 The areas to be patched or leveled shall be thoroughly primed with an application of neat low viscosity epoxy. After the area is primed, the mortar shall be placed and struck off to grade. The surface shall have a rough finish equivalent to that of a Portland cement concrete deck. 623.23.2.6 The patched or leveled area shall be protected during the curing period to prevent damage. The length of time required for curing will vary with temperature. The Contractor shall acquaint himself with information from the epoxy resin manufacturer relative to the normal curing periods which can be expected at various ambient temperatures. Under no circumstances shall curing be hastened by direct flame application, but approved types of radiant heating systems may be used. 623.24 Safety Precautions. Epoxy resin compounds are toxic and the solvents are flammable. The Contractor shall take due precaution to protect workmen from the hazards of handling these materials. 623.25 Basis of Payment. No direct payment will be made for the furnishing of material, surface preparation, or application.
1/1/2016
623-3
Concrete Bonding and Epoxy Mortar
(This Page Intentionally Left Blank)
1/1/2016
623-4
Concrete Bonding and Epoxy Mortar
Section 624
Geotextile Construction
624.1 Description. This work shall consist of installing geotextile for use in subsurface drainage, in erosion control, as a permeable separator or as otherwise specified. 624.2 Material. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Geotextile ...............................................................................1011 624.3 Construction Requirements. Geotextile shall be placed in accordance with AASHTO M 288 for the appropriate application. 624.4 Method of Measurement. Geotextile used for lining drain trenches, wrapping drain pipe or for control of piping through structural joints and facing panels will not be separately measured. Geotextile used for other purposes will be measured to the nearest square yard of surface area covered without regard to any overlap. 624.5 Basis of Payment. Geotextile used for lining drain trenches, wrapping drain pipe or for control of piping through structural joints and facing panels will be considered as incidental and will be included in the contract unit price for the drain or structure. The accepted quantity of geotextile used for other purposes will be paid for at the contract unit price for each of the pay items included in the contract. No direct payment will be made for securing pins or other incidental items.
1/1/2016
624-1
Geotextile Construction
(This Page Intentionally Left Blank)
1/1/2016
624-2
Geotextile Construction
Section 625
Flowable Fill (Controlled Low-Strength Materials)
Section 625.10 Excavatable Flowable Fill 625.11 Description. This work shall consist of furnishing, transporting and placing excavatable "Controlled Low-Strength Material (CLSM)" as flowable backfill to fill trenches for pipe, structures, culverts, utility cuts, and other cavity filling uses under pavement or at other locations as designated in the contract documents or as directed by the Engineer. 625.12 Material. 625.12.1 All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Aggregate for Concrete
1005
Class C Fly Ash
1018
Type I/II Portland Cement
1019
Admixtures
1054
Water
1070
625.12.1.1 If for any reason cement or fly ash become partially set or contains lumps of caked cement or fly ash, it shall be rejected. Cement salvaged from discarded or used bags shall not be used. 625.12.2 Fine aggregate shall be in accordance with Section 1005.2, except for the percent passing the No. 200 sieve. Aggregate shall be fine enough to stay in suspension in the mortar to the extent required for proper flow and shall be in accordance with the following gradation: Sieve Size
Percent Passing
¾ inch
100
No. 200
0-10
625.12.3 Admixture. The air-entraining admixture may be in powder or liquid form. Prior to approval, a CLSM air-entraining admixture will be evaluated in the laboratory by the Engineer. The admixture shall be able to meet the air content requirements specified. 625.12.4 Batching and Delivery. CLSM shall be batched and delivered in accordance with Sec 501 and 502. Non-agitating and agitator equipment will not be permitted. Delivery ticket information shall be in accordance with Section 501. The supplier shall load the truck mixer at standard charging speed in the following sequence:
1/1/2016
625-1
Flowable Fill (CLSM)
a) Add 70 to 80 percent of the required water; b) Add 50 percent of the aggregate; c) Add all cementitious materials required; d) Add balance of aggregate; e) Add balance of water. 625.12.4.1 Water and Admixture Addition. The addition of water and admixtures on the jobsite is permitted. The amount of water and admixture added shall be recorded on the delivery ticket. The CLSM mixture shall be mixed for a minimum of 30 revolutions after the addition of the water of admixture. All testing of CLSM shall be made after final water and admixture adjustment. 625.12.4.2 Pigment. If required by the Engineer, a coloring pigment shall be thoroughly mixed in the CLSM following the utility coloring code specified below and meeting the requirements of ASTM C 979. Coloring pigments shall be stored, mixed, and dosed in accordance with the manufacturer's recommendations. Utility Coloring Code Color
Code Number1
Dosage, lbs./sack2
Electrical Power Lines and Cables
Red
100
3
Gas, oil, or steam
Yellow
569
5
Fiber optics, communications, alarms
Orange
5084
5
Potable water
Blue
418
5
Sewer lines
Green
5376
3
Non-potable water
Purple
1395
4
Utility Type
1
Code number and dosage may vary in accordance with manufacturer's guidelines. The specific color and dosage will vary with the type and color of cement and fly ash as well as the color of the aggregates. 2 Color dosage is determined in the dry form since it is dosed as pounds of color additive per 94 lb. of cementitious materials.
625.12.5 Mixture Proportions. The contractor shall submit to the engineer a certified mix design with the proportions, names and sources of material, admixtures, dry cubic yard batch weights and physical property test results. Target mix design flow shall be a minimum of 8 inches. Material shall yield slightly over 1 cubic yard. The contractor may use the mix design as designated below. Set time shall be indicated on the mix design. The material supplier may adjust fine aggregate, water and entrained air to achieve the necessary physical and performance requirements for the application of excavatable flowable fill (CLSM).
1/1/2016
625-2
Flowable Fill (CLSM)
625.12.5.1 Set Time. CLSM may also be specified as Rapid Set (RS) or Normal Set (NS). A minimum compressive strength of 35 psi is required at 16 hours for Type RS or at 48 hours for Type NS when cured under standard laboratory conditions. Report the laboratory compressive strength at these times as part of the mix design submittal. 625.12.5.2 Mix Design Submittal. The mix design materials and proportions listed shall be used unless the Contractor's submitted CLSM mix design is approved. The CLSM mix design submitted for review shall include the following information: a) Application; b) Source of materials; c) Gradation of fine aggregate; d) Absolute volumes, specific gravities, unit weights, and any other values used in the CLSM mix design process; e) Type and proposed doses of air entraining or accelerating admixtures; f) Target flow and entrained air content; g) Set Time; h) Laboratory test data indicating unconfined compressive strengths at specified set time, 7 and 28 days; i)
Wet density;
j)
Ambient air temperature and CLSM temperature at time of testing. Flowable Fill (CLSM) Ingredients Design Amounts Per Cubic Yard Material
1/1/2016
Amount
Type I/II Portland Cement, pounds
75
Type C Fly Ash, pounds
250
Class A Fine Aggregate, pounds
2480
Water, pounds (gallons)
292 (35)
Entrained Air, percent
20
625-3
Flowable Fill (CLSM)
Controlled Low-Strength Mixture (Excavatable) Physical Properties Test Method
Property
Controlled Low-Strength Mixture (Excavatable) Minimum
Maximum
Wet Unit Weight, pcf
ASTM D 6023
90
120
Air Content, percent1
ASTM D 6023
15
25
Hardening (Set) Time2, penetration number
ASTM C 403
650
1500
Subsidence & Settlement, inch per foot of depth
As Determined
0
0.250
Hydraulic Conductivity Coefficient3 (k), cm/sec
ASTM D 5084
1.0 x 10-8
-
1
Report to the nearest 0.1 percent. Normal: 3 to 5 hours; Accelerated: 1 hour or less. 3 This test may be waived if air void system is equivalent or greater than that of a uniform fine sand. 2
Controlled Low-Strength Mixture (Excavatable) 28-day Unconfined Compressive Strength
Application
Test Method
Pipe Backfill, bedding and encasement Utility bedding
ASTM D 4832
Voids
1/1/2016
625-4
Excavatable Controlled Low-Strength Mixture (psi) Minimum
Maximum
30
100
50
100
15
150
Flowable Fill (CLSM)
625.12.5.3 Consistency. Consistency of the fresh mixture shall be such that the mixture be placed without segregation. The correct consistency of the mixture will produce an 8-inch diameter circular type spread without segregation. Adjustment of air and water proportions shall be made to achieve proper solid suspension and Flowable characteristics, however, the theoretical yield shall be maintained at one cubic yard for the given batch weights. The production flow rates required for different applications are listed in the following table: Flow Requirements for Controlled Low-Strength Mixture (Excavatable) Application
Test Method
Pipe backfill, bedding and encasement Utility bedding Voids
ASTM D 6103
Bridge Approach 1
Flow Spread (inches)1 Minimum
Maximum
8
10
7
9
8
9
7
10
Report to nearest 0.25 inch.
625.12.5.4 Mix Design Verification. If the Contractor submits a mix design which intends to be applied at a temperature less than performed in the laboratory and has not been previously verified by the Department, a trial batch shall be performed. The trial batch shall be scheduled a minimum of 30 calendar days prior to anticipated use and shall be performed in the presence of the Engineer. A minimum of 1 cubic yard trial batch shall be produced and placed offsite. The trial batch shall be produced with the equipment and methods intended for construction. The trial batch will be evaluated for temperature, flow, air content, set time, and 7 and 28 day unconfined compressive strength by the Engineer. The Engineer reserves the right to require a 180 day unconfined compressive strength test. Verification of the mix design will include the trial batch test results, field observations (i.e. flowability and solid suspension), and other criteria as determined by the Engineer. The Contractor will be notified in writing of verification approval status. Verification of a mix design by the Engineer shall in no manner be construed as acceptance of any CLSM produced. 625.12.5.5 CLSM Compatibility. CLSM shall be free of any material deemed toxic or hazardous. Material Safety Data Sheets shall be provided for all components of the mixture and shall be submitted with the mix design. CLSM shall be compatible with backfill materials, electrochemically and otherwise, if used when surrounding metal conduit or strapping. 625.12.5.6 Electrical Resistivity. Materials for CLSM mixtures shall be evaluated as non-corrosive by appropriate ASTM standards including ASTM A 674. If the CLSM mixture has an electrical resistivity value of less than 5,000 coulombs, then to ensure compatibility with any proposed or encountered metal conduit or strapping, a polyethylene encasement shall be required conforming to ASTM A 674.
1/1/2016
625-5
Flowable Fill (CLSM)
625.13 Construction Requirements. 625.13.1 Placing. Chutes, conveyors, buckets or progressive cavity pump lines are allowed depending on the application and accessibility and shall not cause a change in density. Agitation is required during transportation and waiting time. Each placement of CLSM shall be as continuous an operation as possible. If CLSM is placed in more than one layer, the base layer shall be free of surface water and foreign material before placement of the next layer. 625.13.2 Consistency. Flowable backfill will be tested by filling an open-ended 3-inch diameter, 6-inch high cylinder to the top with the mixture and immediately pulling the cylinder straight up. The correct consistency of the mixture shall produce the specified diameter circular-type spread with no segregation. Adjustments of the proportions of fine aggregate or water may be made to achieve proper solid suspension and optimum flowability with the approval from the engineer, except the theoretical yield shall be maintained at one cubic yard for the given batch weights. 625.13.3 The open ends of the area to be backfilled shall be temporarily plugged or bulk headed to control required placement quantities and resist hydraulic pressure expected from the CLSM and the void area filled. 625.13.4 General. Care shall be taken to prevent the movement of any structure from the designed location or intrusion of flowable backfill into undesirable locations. If such movement or intrusion occurs, the engineer may require the affected structure to be excavated and replaced to the proper grade at the contractor's expense. Do not place CLSM in direct contact with in-service cast iron pipes. 625.13.5 Standing Water. CLSM may be placed in confined spaces containing standing water. CLSM shall be placed to displace the water to the surface and shall not entrap or entrain standing water. 625.13.6 Placement Temperature Limitations. Flowable fill (CLSM) shall not be placed in contact with frozen soil or other material. Mixing and placing shall begin only if the ambient temperature is 35°F and rising. At the time of placement, the material temperature shall be a minimum of 40°F. Mixing and placing shall stop when: •
The anticipated air or ground temperature will be 35°F or less in the 24hour period following proposed placement;
•
The ambient temperature is 40°F and falling; or
•
The material temperature is less than 40°F.
625.13.7 Application. When placing CLSM for pipe backfill, discharge the material onto the top and at the center of the pipe. Do not place CLSM in contact with aluminum pipe, including connections, fixtures, etc., unless the aluminum has been thoroughly coated with Zinc in accordance with Section 1022 or an equivalent. Do not place CLSM in direct contact with cast iron or ductile iron pipes, fittings or appurtenances. Internal vibration consolidation is not required.
1/1/2016
625-6
Flowable Fill (CLSM)
625.13.7.1 Pipe or Conduit Bedding. CLSM shall be placed in lifts to prevent floating pipe or conduit in accordance with pipe manufacturer's guidelines. The contractor shall have the pipe or conduit manufacturer's flowable fill installation instructions submitted for Engineer approval prior to use. Each lift shall be allowed to harden before continued placement. For plastic pipe the lifts of CLSM shall be placed so that lateral support can be developed along the side of the pipe before the next lift of CLSM is placed. The contractor shall prevent flotation through the use of sand bags placed over the pipe, straps around the pipe anchored into the soil or use a fast setting CLSM at strategic locations over the pipe. The contractor shall be advised with the use of anchors, straps and sand bags, as arching between the anchor points can occur. Pipe or conduit vertical and horizontal alignment shall be unaltered by placement of bedding. 625.13.7.2 Trench Backfill. CLSM shall be placed continuously. Pipe or conduit vertical and horizontal alignment shall be unaltered by placement of backfill. 625.13.7.3 Anchoring Systems. Effective anchoring systems include the use of wiring or rebar. The spacing of tie-downs should not be greater than 5 feet along the length of the pipe so that upward bending can be mitigated between the restraints. In addition, anchors should also be provided on each side of every joint to prevent joint misalignment. Pipe joints shall be centered between two restraints and the restraint shall not be placed within 2-feet of the joint. Additionally, restraining systems should not create point loads on the pipe. 625.13.7.4 Lift Thicknesses. In addition to the anchoring system, it is recommended the flowable fill be placed in incremental lifts as directed by the manufacturer, contract documents, or by the Engineer. Provided flotation restraints have been properly designed and installed, for a 12 inch to 30-inch diameter pipe, the first lift should be brought up ¼ of the pipe diameter. After this lift cures, the rest of the fill can then be placed in one continuous lift. For 36 inch to 60-inch diameter pipe, the fill should be placed in three lifts. The first lift should be ¼ the pipe diameter and the second lift should be ⅓ of the pipe diameter so that the two lifts combined extend beyond the pipe springline. After these layers are allowed to cure, the final layer can be placed in one continuous lift. CLSM shall be brought up evenly on both sides to prevent unbalanced forces from acting on the pipe. The mix design set time shall be used as the minimum waiting period provided between lifts. This time is dependent on the mix design as well as the ambient temperature and moisture. The manufacturer should be contacted to determine the site-specific waiting period recommended between lifts for placement conditions. 625.13.7.5 Opening to Traffic, Paving or Lift Application. No CLSM backfill shall be covered with another lift or accepted until a minimum unconfined compressive strength of 30 psi has been attained, as demonstrated by failure to deform or crush underfoot when a pressure of approximately 30 psi is applied. The flowable fill shall not be subject to load nor disturbed by construction activities until a minimum has compressive strength of 30 psi for Portland cement concrete pavement or 50 psi for bituminous concrete pavement been attained or as approved. If the backfill does not harden to support the required load, the backfill shall be removed and replaced with an acceptable material at the contractor’s expense. Any of the following methods are considered acceptable for determining the bearing strength to allow surfacing to be placed:
1/1/2016
625-7
Flowable Fill (CLSM)
a) Tested in accordance with ASTM C 403, a minimum penetration number of 650 is required. b) Tested in accordance with ASTM D 6024, the maximum drop ball indentation diameter required is 3 inches. c) Tested in accordance with ASTM D 6951, and using a Dynamic Cone Penetrometer (DCP) in accordance with County Test Method QA-24 (Use of Dynamic Cone Penetrometer (DCP) in shallow pavement applications), a minimum CBR value of 5 (DCP Index ≤ 1.5 in. / blow) is required. 625.13.8 Curing and Protection. 625.13.8.1 Thermal. CLSM shall be protected from freezing for a minimum of 72 hours. 625.13.8.2 Moisture. Moist curing methods to retain moisture specified for concrete are not required for CLSM. 625.13.8.3 Protection. CLSM shall not be subjected to loads and shall remain undisturbed until a compressive strength of 15 psi is obtained. The Contractor shall be responsible for providing evidence to the Engineer that the material has reached the desired strength. 625.13.8.4 Quick Condition Protection. Excavations filled by CLSM shall be covered and secured to protect pedestrians and vehicles until hardening occurs. 625.13.8.5 Floating Tanks, Pipe and Cables. Underground utilities and tanks shall be secured against floating during CLSM placement. 625.13.8.6 CLSM Minimum Soil Cover Requirements. CLSM shall be kept encapsulated with soil, as it is highly erodible and disintegrates when left exposed to the environment. For short-term conditions (< 3 months), a minimum soil cover of 6 inches is required. For longer than 3 months, a minimum soil cover of 12 inches is required. 625.13.9 Quality Control. For sampling, determination of consistency, unit weight and casting of unconfined compression specimens, the minimum acceptable technician certification requirement is ACI Level Concrete Field Testing Technician Grade I or approved equal. 625.13.9.1 Sampling. Sampling of CLSM delivered to the jobsite for unconfined compressive strength, flow consistency, unit weight and air content shall be performed at the point of discharge in accordance with ASTM D 5971. 625.13.9.2 Consistency. The test for flow, as tested by ASTM 6103, shall consist of filling a 3-inch diameter by 6-inch high open-ended plastic cylinder placed on a smooth level surface to the top with the CLSM. The cylinder shall be smooth, rigid and open at both ends and have a maximum variation from the normal inside diameter and length shall be ⅛ inch. The cylinder shall be pulled straight up within 5 seconds. The spread of the CLSM shall be measured. For good flow in placement, the diameter of the CLSM spread shall be greater than or equal to the mid-range of the flow specified for the application. Minor flow adjustments may be made by making adjustment in the water 1/1/2016
625-8
Flowable Fill (CLSM)
content in the CLSM. A minimum of one flow test shall be performed for each set of cylinders cast. 625.13.9.3 Unit Weight. CLSM unit weight shall be determined in accordance with ASTM D 6023, reporting the unit weight to the nearest 1 lb/ft3. A minimum of one unit weight test shall be performed per day of production. 625.13.9.4 Unconfined Compression Strength Testing. Six 4" x 8" cylinders will be required for any placement of 100 cubic yards or more at a frequency of the first load and then for each 100 cubic yards thereafter. Three cylinders will be broken at 7 days and 28 days in accordance with ASTM D 4832. If the placement is less than 100 cubic yards, five cylinders will be taken on the first load and then every 50 cubic yards of production. Two cylinders will be broken at 7 days and three cylinders at 28 days. 625.13.9.5 The contractor shall be responsible for the curing and protection of the cylinders until such time that they are ready to be picked up by the testing laboratory. The contractor shall coordinate this activity with the Engineer. The cylinders will be held by a testing laboratory until the required breaking date. For unconfined compression testing, the minimum acceptable technician certification requirement is ACI Level I, Concrete Technician or approved equal. 625.14 Method of Measurement. If flowable backfill is specified, measurement will be made by the computed volume to the nearest 0.10 cubic yard, as determined from the dimensional area of the open area and totaled to the nearest cubic yard. A deduction will be made for pipes (based on nominal diameters) and other features when the combined cross-sectional area exceeds 1 square foot. No additional quantity shall be measured for payment to make up losses due to foundation settlement, compaction, exceeding pay limit dimensions, erosion or any other cause. Cross sectioning, for the purpose of determining quantities for payment, will be employed only where payment lines are not shown on the contract documents or Standard Drawings, and cannot be reasonably established by the Engineer. When Flowable fill is not shown as a pay item, include the cost of the work in the bid price for the appropriate item. Final measurement will not be made except for authorized changes during construction or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added or deducted from the contract quantity. 625.15 Basis of Payment. The unit price bid shall include the costs of furnishing all labor, material, and equipment necessary to satisfactorily complete the work, including work needed to counteract buoyancy. If flowable backfill is specified, the accepted quantity will be paid for at the contract unit price. No additional payment will be made if flowable backfill is used as an alternate to compacted backfill. The accepted quantity will be paid for at the contract unit price for the item specified.
1/1/2016
625-9
Flowable Fill (CLSM)
Section 625.20 Non-Excavatable Flowable Fill 625.21 Description. This work shall consist of furnishing non-excavatable CLSM as specified on the plans or otherwise allowed for compacted backfill to fill bridge approaches, the space remaining around any type pile after it is driven, or as designated in the project specifications. The space remaining around any type pile after it is driven shall be completely filled with a nonexcavatable CLSM having a 28-day unconfined compressive strength of more than 200 psi. 625.22 Material. Materials shall be in accordance with Sections 625.12.1 and 625.12.4.2. 625.22.1 Mixture Proportions. The contractor shall submit to the engineer a certified mix design with the proportions, names and sources of material, admixtures, dry cubic yard batch weights and physical property test results. Target mix design flow shall be a minimum of 8 inches. Material shall yield slightly over 1 cubic yard. Set time shall be indicated on the mix design. 625.22.1.1 The mix design materials and proportion range listed shall be used unless the Contractor's submitted non-excavatable CLSM mix design is approved. The CLSM mix design submitted for review shall include the following information: a) Application; b) Source of materials and design amount(s); c) Gradation of fine aggregate; d) Absolute volumes, specific gravities, unit weights, and any other values used in the CLSM mix design process; e) Type and proposed doses of air entraining or accelerating admixtures; f) Target flow and entrained air content; g) Set Time; h) Laboratory test data indicating unconfined compressive strengths at set time, 7 and 28 days;
1/1/2016
i)
Wet unit weight;
j)
Ambient air temperature and CLSM temperature at time of testing.
625-10
Flowable Fill (CLSM)
Non-Excavatable Flowable Fill (CLSM) Ingredients Design Amounts Per Cubic Yard Amount
Material
Minimum
Maximum
Type I/II Portland Cement, pounds
75
150
Type C Fly Ash, pounds
250
600
Class A Fine Aggregate, pounds
2000
-
Water, pounds (gallons)
See Note 1
Entrained Air, percent 1
10
30
Adjust for flow.
Controlled Low-Strength Mixture (Non-Excavatable) Physical Properties Non-Excavatable Controlled Low-Strength Mixture (psi) Property Test Method Minimum
Maximum
Wet Unit Weight, pcf
ASTM D 6023
100
125
Air Content, percent 1
ASTM D 6023
10
30
Hardening (Set) Time 2, penetration number
ASTM C 403
650
1500
Subsidence & Settlement, inch per foot of depth
As Determined
0
0.250
Hydraulic Conductivity Coefficient 3 (k), cm/sec
ASTM D 5084
1.0 x 10-8
-
1
Report to the nearest 0.1 percent. Normal: 3 to 5 hours; Accelerated: 1 hour or less. 3 This test may be waived if air void system is equivalent or greater than that of a uniform fine sand. 2
Controlled Low-Strength Mixture (Non-Excavatable) 28-day Unconfined Compressive Strength Application
Test Method
Bridge Approach; Bearing Pile Pre-Boring hole void fill
ASTM D 4832
1/1/2016
625-11
Excavatable Controlled Low-Strength Mixture (psi) Minimum
Maximum
200
1200
Flowable Fill (CLSM)
625.22.2 Mix Design Verification. Mix design verification shall be in accordance with Section 625.12.5.1. 625.22.3 CLSM Compatibility. CLSM Compatibility shall be in accordance with Section 625.12.5.2. 625.22.4 Electrical Resistivity. Electrical resistivity shall be in accordance with Section 625.12.5.3. 625.23 Construction Requirements. Construction requirements non-excavatable CLSM shall be in accordance with Section 625.13. 625.23.1 Structural Backfill. CLSM shall be placed in lifts to prevent overstressing the structure. Maximum lift thickness shall be specified in the contract documents or by the Engineer. If possible, both sides of the structure shall be filled simultaneously to avoid displacement. If it is not possible to fill both sides simultaneously, fill shall be alternated side to side in shallow lifts. Each filling stage shall be as continuous as possible to prevent cold joints. 625.24 Method of Measurement. No additional quantity shall be measured for payment to make up losses due to foundation settlement, compaction, exceeding pay limit dimensions, erosion or any other cause. Cross sectioning, for the purpose of determining quantities for payment, will be employed only where payment lines are not shown on the contract documents or Standard Drawings, and cannot be reasonably established by the Engineer. When nonexcavatable flowable fill is not shown as a pay item, include the cost of the work in the bid price for the appropriate item. Final measurement will not be made except for authorized changes during construction or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added or deducted from the contract quantity. 625.25 Basis of Payment. The unit price bid shall include the costs of furnishing all labor, material, and equipment necessary to satisfactorily complete the work, including work needed to counteract buoyancy. If non-excavatable flowable backfill is specified, the accepted quantity will be paid for at the contract unit price. No additional payment will be made if non-excavatable flowable backfill is used as an alternate to compacted backfill or to fill bearing pile pre-bored voids. The accepted quantity will be paid for at the contract unit price for the item specified.
1/1/2016
625-12
Flowable Fill (CLSM)
Section 626
Temporary Steel Plate Trench Bridging
626.1 Description. This specification covers the temporary bridging of the roadway or sidewalk to accommodate excavation work by permit or contract. Steel plates are occasionally used in areas where an excavation is made in the roadway for repairs or utility work, providing temporary protection to motorists and pedestrians and continued movement of traffic. When backfilling operations cannot be completed by the end of the authorized work shift, steel plates (meeting the requirements below) may be used to temporarily cover the excavation. All plate(s) shall be visibly identified with permittee's / contractor's name and 24-hour notification telephone number. All plates must be installed such that there will not be any rocking, noise, hammering or shaking of adjacent property. Installation and maintenance shall be overseen by the permittee's / contractor's competent person. 626.1.1 Definition of Competent Person. The designated competent person should have and be able to demonstrate the following: 626.1.1.1 Training, experience, and knowledge of: soil analysis; use of protective systems; and requirements of 29 CFR Part 1926 Subpart P. 626.1.1.2 Ability to detect: conditions that could result in cave-ins; failures in protective systems; hazardous atmospheres; and other hazards including those associated with confined spaces. 626.1.1.3 Authority to take prompt corrective measures to eliminate existing and predictable hazards and to stop work when required. 626.2 Materials and Manufacture. 626.2.1 Plate Material. The steel shall be semi-killed or killed. The steel for plate(s) shall be manufactured in accordance with one of the following: 626.2.1.1 ASTM A 36 Grade 36 (Yield Strength of 36,000 psi). 626.2.1.2 ASTM A 572 Grade 50 (Yield Strength of 50,000 psi). 626.2.2 Plate Dimensions. The plate(s) must extend beyond the edge of the trench wall to adequately support the traffic loads on it. Plate(s) shall be large enough to allow minimum of 2 foot of bearing on each side of the excavation. Plates shall be placed perpendicular or parallel to the direction of travel. In all situations, the longitudinal edges of the steel plates shall not be in the wheel path. 626.2.2.1 Thickness. For trench widths less than or equal to 4.0 feet as determined in the direction of travel, steel plates shall have a minimum thickness of 1 inch. 626.2.2.2 Structural Design. For trenches and excavations with spans greater than four (4.0) feet as measured in the direction of travel, a structural design, to include plate dimensions, thickness, ASTM A 36 or ASTM A 572 steel grade, and minimum shoring or bracing requirements, shall be prepared by a structural professional engineer registered by the Missouri Division of Professional Registration and approved by the Engineer.
1/1/2016
626-1
Temporary Steel Plate Trench Bridging
Consideration shall also be made for traffic volume and composition, duration and size of excavation and weather conditions. A minimum factor of safety of 4.0 is required. In accordance with the Design Criteria for the Preparation of Improvement Plans Manual, Section 50.22, "Bridge Structure Design", the design loading for plates spanning a trench width exceeding 4.0 feet shall be the more severe of: 626.2.2.2.1 Vehicular Traffic Areas. a) St. Louis County T45 Loading; b) St. Louis County HS25 Loading; c) Other loading conditions as specified by permit or in the contract documents. 626.2.2.2.2 Non-Vehicular Traffic Areas. a) OSHA, AASHTO, ADA standards, and as directed by 626.4.11. 626.2.2.3 Plate Deformations. All plating used shall be without deformations (warping, cracking, etc.) and shall be subject to straightedge testing. Plate removal will be required if plate is permanently deformed. Steel trench plate deformation may occur during loading, but if a steel plate is deformed without loading to at least 0.5 inch per 10 feet in length the plate shall be removed and replaced. 626.2.2.4 Welding. To hold multiple plates tightly together, plates may require a 6-inch long tack weld for stability. When the steel is to be welded, a welding procedure suitable for the grade of steel and intended use is to be utilized. See ASTM A6, Appendix X3 for information on weldability. 626.2.3 Plate Skid Resistance. The utility or contractor shall maintain a non-skid surface on the plate. Plate(s) without the required skid-resistant surfacing will require removal. Surfacing requirements are not required in areas not exposed to traffic or pedestrian movements. Epoxy-coated plates are not approved for use. The utility or contractor shall be responsible for periodically monitoring skid resistance, reporting results to the Engineer, and removing deficient plates from service. 626.2.3.1 The manufacturer may elect to imprint waffle-shaped patterns or right-angle undulations to achieve skid resistance on the steel plate wearing surface. The maximum vertical deviation within the pattern shall be no more than 0.25 inch. 626.2.3.2 Vehicular Traffic Areas. For products proposed for use in vehicular traffic areas, test data verifying the material meets the requirements of this Section including verification that the product, installed in accordance with the manufacturer's specifications and procedures, has been tested in accordance with ASTM E 303 using the British Pendulum Tester and have an initial British Pendulum Number (BPN) of no more than 60 and no less than 50. Plates will be rejected for use when the BPN value is 40 or less when tested in accordance with ASTM E 303. 626.2.3.3 Non-Vehicular Traffic Areas. For products proposed for use in nonvehicular traffic areas, test data verifying the material meets the requirements of this Section including verification that the product, installed in accordance with the manufacturer's specifications and procedures, has been tested in accordance with ASTM E 303 using the British Pendulum Tester and have an initial British Pendulum 1/1/2016
626-2
Temporary Steel Plate Trench Bridging
Number (BPN) of no more than 50 no less than 40. Plates will be rejected for use when the BPN value is 30 or less when tested in accordance with ASTM E 303. 626.2.4 Plate Reflectivity Marking. Temporary steel plates installed on roadways open to vehicular traffic should be marked with a durable and highly reflective white pavement marking tape no less than 4 inches in width meeting the requirements of Section 621.2.3, Temporary Removable Detour Grade Tape. The 3-inch distance from the plate's edge to the tape may be varied depending on the conditions. The marking pattern used should, at a minimum, include all four corners of the plate. Replacement of the markings shall be based on a visual assessment performed periodically at night by a moving inspection vehicle. Any leg of the marking that has lost fifty percent or more of its conspicuity (retro reflectivity, or when damaged, torn or missing) shall be replaced. 626.2.4.1 Plates with All Sides Less than 6 Feet in Length. Reflective tape minimum corner length, in each direction shall be 1.0 feet. 626.2.4.2 Plates with Any Side Greater Than or Equal to 6 Feet in Length. Reflective tape minimum corner length, in each direction shall be 2.5 feet. 626.2.4.3 Reflective Markings Skid Resistance. The surface of the markings provides an initial and retained minimum skid resistance value of 50 and 45 BPN, respectively, when tested according to ASTM E 303. Tape replacement will be required when skid resistance falls below a BPN of 45. 626.3 Equipment. The contractor or utility shall supply appropriate equipment to deliver, place and install steel plates in accordance with manufacturer's recommendations. 626.4 Construction Requirements. The contractor or utility shall be responsible to ensure that the steel plate(s), shoring, and trench plate securing systems meet minimum specifications and are properly installed and maintained. The contractor or utility shall be responsible for any claims that may be associated with the use of steel plating. Whenever steel plating is installed on County roadways, work will be provided in accordance with the following. 626.4.1 Notification. 626.4.1.1 Non-Emergency. Notify County Inspector at least 48 hours in advance of placing steel plates in roadway. 626.4.1.2 Emergency. All emergency work situations (i.e., water main break, ruptured gas main, sanitary sewer break) shall be reported immediately by telephone to the St. Louis County Department of Transportation. Emergency work occurring within normal working hours (7:30 a.m. to 4:00 p.m., Monday through Friday) shall be reported to the Department of Transportation's Permit Inspection Section at (314) 615-1150. Emergency work occurring at other hours or on Saturdays, Sundays and holidays shall be reported to the St. Louis County Police Information Center at (314) 889-2341. The Department of Transportation will dispatch its personnel as required by the emergency situation. 626.4.2 Vertical Clearance. Contractor or utility shall maintain a vertical clearance for overhead installations of not less than 15 feet, 6 inches from the road surface.
1/1/2016
626-3
Temporary Steel Plate Trench Bridging
626.4.3 Vertical Grade Limitations. Contractor or utility shall install and maintain plates with the following pavement vertical grade limits: 626.4.3.1 Vehicle Areas. Apply plating on streets with vertical downhill or uphill grades of 5 percent or less. 626.4.3.2 Non-Vehicle Areas. Apply plating on non-vehicle (pedestrian) areas with vertical downhill or uphill grades of 8 percent or less. 626.4.4 Advanced Warning. Traffic control devices shall be in place before trench excavation is made and during plating period. Materials shall be in accordance with Section 1063. All temporary traffic control devices shall be manufactured and installed in accordance with Section 612, "Traffic Control Devices", as shown on the plans, as specified in accordance with current MUTCD requirements, and be NCHRP 350 compliant. 626.4.4.1 Roadways with Posted Speeds Greater than 45 MPH. DIP (WO8-2) or BUMP (WO8-1) signs shall be installed depending on the profile of the roadway. STEEL PLATE AHEAD (WO8-24), DIP, or BUMP signs shall be installed depending on the profile of the roadway or use of steel plating on the roadway. SPEED LIMIT (R2-1, GO20-5aP) signs may be used to reduce speed through the excavation area. 626.4.4.2 Roadways with Posted Speeds Equal to or Less than 45 MPH. STEEL PLATE AHEAD, DIP, or BUMP signs shall be installed depending on the profile of the roadway or use of steel plating on the roadway. 626.4.5 Open Trench Length Allowed. The maximum length of open trench allowed to be covered with steel plates shall be a total of fifty (50) lineal feet or as approved in the permit, the contract documents or in writing by the Engineer. 626.4.6 Shoring and Bracing. Trenches and excavations shall be adequately shored and braced to withstand roadway traffic loads in accordance with Section 726.3.11.9, "Bracing and Shoring". 626.4.7 Stability. Each plate must be fully supported around the perimeter to prevent wobbling or rocking with non-asphaltic shims and installed to operate with minimum noise. 626.4.8 Securing. The plates shall be secured to prevent any movement. Trench plates shall not be overlapped or stacked on top of another plate. Steel plate bridging shall be secured against displacement by using adjustable cleats, shims or other devices. Securing devices shall not extend above the wearing surface of the plate. When steel plates are removed, the dowel holes in the pavement shall be backfilled with graded fines of an asphalt concrete mix (asphalt pavement) or a pre-approved pre-mix non-shrink rapid set concrete material (concrete pavement). Steel plate bridging and shoring shall be installed using either Method 1 or 2 below: 626.4.8.1 Method 1 - Roadways with Posted Speeds Greater than 45 MPH. The pavement shall be cold-planed to a depth equal to the thickness of the plate and to a width and length equal to the dimensions of the plate(s). The approach and ending plates shall be attached to the roadway by a minimum of two Grade 60 No. 4 or equivalent dowels pre-drilled into the corners of the plate and drilled 3 inches into the pavement; subsequent plates shall be butted to each other. The gap between the edge 1/1/2016
626-4
Temporary Steel Plate Trench Bridging
of the plate(s) and the adjacent pavement shall be filled with Type "D" Bituminous or Commercial asphalt pavement in accordance with Section 405. 626.4.8.2 Method 2 - Roadways with Posted Speeds Equal to or Less than 45 MPH. Approach plate(s) and ending plate (if longitudinal placement) shall be attached to the roadway by a minimum of two Grade 60 No. 4 or equivalent dowels pre-drilled into the corners of the plate and drilled 2 inches into the pavement; subsequent plates are butted to each other. 626.4.9 Ramping. Plates shall be secured and ramped on all sides with a trench plate securing device, to ensure a smooth transition from the road surface to the top of the plate surface and back to the road surface. Ramping slope shall not exceed 12:1 (H:V or 8.5 percent) and can be accomplished by mechanical fastening or wedging asphalt. Ramping with approved bituminous asphalt shall be made, to the nearest 6 inches, with a minimum taper length of 12 inches to cover all edges of the steel plate. If a mechanical fastening trench plate securing system is used it shall be installed per manufactures direction and continuously maintained around all outside edges of the trench plate(s) until removal of the plate(s). Minimum Ramp Taper Lengths Vertical Distance (V) (inch)
Ramp Horizontal Distance (H) (min.) (inches)
V≤1
12
1< V ≤ 1 ½
18
1½<V≤2
24
626.4.9.1 Option 1 - Wedging Asphalt. Ramps shall be constructed using Type "C" Bituminous or fine-graded Commercial asphalt pavement in accordance with Section 405. 626.4.9.2 Option 2 - Mechanical Fastening. One pre-approved method of securing steel trench plates involves a perimeter restraint consisting of polypropylene (PP). The PP securing system shall be substantially similar, or equal to, the Plate Lock Trench Plate Securing System which is pre-approved for use. Other systems shall be submitted to the Engineer for review a minimum of 48 hours prior to use. 626.4.10 In-Place Time Limit. Unless specifically noted in the provisions of the contract or permit, plate bridging shall not exceed 7 consecutive working days. 626.4.11 Non-Vehicle Areas. When required to keep sidewalks or non-vehicle areas open, bridging may be secured by plywood with a skid-resistant surface. Design loading shall have a minimum factor of safety of 4.0. Plywood used in pedestrian areas shall be a minimum of ¾ inch thick, provide a non-skid surface, be a minimum of 5 feet in width, have an OSHA-approved handrail, extend a minimum of 2 feet past the surface edge of trench, and have approach ramps not to exceed 8.5 percent for a vertical height not to exceed 30 inches. Pedestrian bridging shall meet current ADA Accessibility Guidelines for Buildings and Facilities (ADAAG) requirements.
1/1/2016
626-5
Temporary Steel Plate Trench Bridging
626.4.12 Maintenance. The permit holder or contractor's competent person shall maintain records that the plate(s) have been checked a minimum of two times a day by the permit holder or contractor. Records shall include the location, time and date inspected and the inspector’s name, title, company information (name, address, telephone number), and any action taken. Records shall be submitted to the Engineer within 48 hours after removal of temporary bridging. 626.4.12.1 County Emergency Repair. If County forces must correct emergency condition due to excavation and plate placement or movement, the contractor or utility will be charged for cost of corrective measures required. The Contractor or utility shall be responsible for having the defective work, materials or equipment corrected, repaired or replaced within three (3) hours after notification by the Engineer. Unless otherwise approved by the Engineer, if defective materials or equipment cannot be repaired or replaced within this time, the Contractor shall make arrangements for their temporary replacement with similar materials or equipment. In any event, if directed by the Engineer, immediate repairs and / or adjustments are determined to be necessary to provide for the safe and efficient movement of traffic, and the Contractor or utility is not capable of making such repairs and/or adjustments to the satisfaction of the Engineer; the Engineer will order County personnel or other qualified Engineers or technicians to make immediate repairs and / or adjustments. The Contractor or utility will be charged the entire cost of the work performed by County or other qualified personnel (if paid by the County). The Contractor or utility will be charged for all labor (including benefits and indirect overhead), materials, and equipment furnished by the County in making immediate repairs and/or adjustments. There will be a three (3) hour minimum call-up time for overtime. The work performed by County or other qualified personnel will in no way waive continued maintenance of the temporary trench bridging by the utility or Contractor. 626.4.12.2 Seasonal Requirements. When approved for use, between November 15 and April 15 steel plate corner limits shall be marked with a 2 inch square stake painted International Orange and extending at least 4 feet above the ground, placed adjacent to the plated edge of the roadway. 626.5 Method of Measurement. Final measurement will not be made for temporary steel plate trench bridging. 626.6 Basis of Payment. No direct payment will be made for furnishing, placing, maintaining, and removal of plate(s) and any incidental items necessary to complete the work unless specifically provided as a pay item in the contract.
1/1/2016
626-6
Temporary Steel Plate Trench Bridging
Section 627
Diamond Grinding of Portland Cement Concrete or Bituminous Pavement
627.1 Description. This work shall consist of grinding concrete pavement to provide good riding characteristics, a surface texture and proper drainage. The finished surface shall be as shown on the plans or as directed by the engineer. This standard specifies the procedures for operations of continuous diamond grinding Portland cement concrete or bituminous pavement surfaces to provide desired surface characteristics such as ride, friction, and drainage. The standard also provides guidelines for levels of acceptance for the desired surface characteristics. The contractor shall be responsible to ensure that all local safety, health, and environmental standards are met. Nighttime grinding lighting requirements shall be in accordance with Section 612.80. 627.2 Equipment. Grinding shall be performed using diamond blades mounted on a selfpropelled machine designed for grinding and texturing pavement. The equipment shall weigh a minimum 35,000 pounds, including the grinding head with diamond blades mounted in series, and be of a size that will grind a strip at least 3 feet wide in a single pass. The effective wheelbase of the machine shall be no less than 12 feet. The equipment shall have a positive means of vacuuming the grinding residue from the pavement surface, leaving the surface in a clean, near-dry condition. Grinding equipment that causes raveling, aggregate fractures, or disturbance to the transverse or longitudinal joints shall not be permitted. Diamond blades shall be of the proper type based on the coarse aggregate to be ground. The equipment shall be maintained to ensure it is in proper working order, with attention paid to the "roundness" of the match and depth control wheels. Any wheel found to be out of round shall be replaced immediately. 627.3 Construction Requirements. The construction operation shall be scheduled and proceed in a manner that produces a neat, uniform finished surface. 627.3.1 Depth Tolerance. Mainline grinding adjacent to any unground turn lane, gutter section, shoulder, auxiliary lane, or ramp lane shall feather smoothly from the edge of the ground mainline into the unground surface leaving no more than a ⅛ inch to ¼ inch ridge at this transition as measured by a 3-foot straightedge. Unique project conditions may require the ground area to extend into the gutter section feathering up to 12 inches within the curb face to provide proper drainage. 627.3.1.1 Full and partial-depth concrete repairs, slab stabilization and dowel bar retrofit shall be completed prior to any grinding. Joint sealing shall be completed subsequent to the diamond grinding operations. Grinding of bridge decks will not be permitted unless specified in the contract.
9/1/2023
627-1
Diamond Grinding of Portland Cement Concrete or Bituminous Pavement
627.3.2 Side Tolerance. Grinding shall be accomplished in a manner that eliminates joint or 1 crack faults so there is no more than a 16-inch differential between the adjacent sides of the joints and cracks. Grinding shall also substantially remove pavement conditions such as warp and curl to provide an acceptable ride. 627.3.3 Utility Appurtances. The grinding shall feather into existing structures such as manholes and water shutoffs in a manner that eliminates abrupt ridges or drops and provides a uniform texture and acceptable ride. If project conditions exist that prohibit acceptable feathering operations, the engineer may require that the structure be raised or lowered. The added work of raising and lowering these structures that is not included as a predetermined bid item shall be paid for at an agreed upon price or as defined in the Force Account section of the Standard Specifications. Structure adjustments that occur within the limits of a full-depth repair shall be reset to an elevation ¼ inch below the new pavement surface to facilitate the diamond grinding operation. 627.3.4 Cross Slope Tolerance. Lateral drainage shall be achieved by maintaining a constant cross slope between grinding extremities in each lane. The finished cross slope shall mirror the pre-grind cross slope and shall have no depressions or misalignment of slope greater than ¼ inch in 10 feet when measured with a 10-foot straightedge placed perpendicular to the centerline. Steps will be taken to ensure that wheel path rutting is substantially removed, and that the grinding operation is simply not texturing the wheel path depressions. Areas of deviation shall be reground. Straightedge requirements will not apply across longitudinal joints, areas where existing structures limit grinding operations or outside the specified ground area. 627.3.5 Removal Limits. The maximum removal required in any area shall not exceed ½ inch on CRS routes and ⅝ inch on ARS routes. Areas where required removal exceeds this limit shall be excluded from smoothness requirements found elsewhere in this specification. 627.3.6 Grinding Limits. Grinding shall begin and end at lines normal to the pavement centerline at the project limits. Passes of the grinding head shall not overlap more than 1 inch. This requirement shall be waived in irregularly shaped roadway sections that do not allow for full passes of the grinding equipment. No unground surface area between passes will be permitted. 627.3.7 Concrete Pavements Final Texturing. When diamond grinding is used as the final texturing for new Portland cement concrete pavement, concrete paving shall be in accordance with Section 502, except as follows. All joints shall be protected to prevent grinding residue from entering. Joints to be diamond ground shall be cleaned and sealed in accordance with Section 502 after diamond grinding is completed. 627.3.8 Surface Correction (Bump Grinding). Surface correction for pavement smoothness may be required which includes bumps or dips. The correction shall be completed before the determination of pavement thickness. Bump, dip, and smoothness correction work shall be for the full lane width of the paved surface. All correction work shall be subject to the approval by the Engineer. After all required correction work is completed; the area will be re-straightedged for final profile tolerance acceptance.
9/1/2023
627-2
Diamond Grinding of Portland Cement Concrete or Bituminous Pavement
627.3.8.1 Portland Cement Concrete Pavement. PCC pavement surface correction (bump grinding) shall be accomplished by grinding the pavement using a grinder (diamond or carbide), by PCC resurfacing, or by replacement. Grinding and texturing equipment shall meet the requirements of Section 627.2 or 627.3.8.1.1; except the cutting head shall have a minimum width of 8 inches and the weight restriction is waived. Surface correction shall be performed parallel to lane lines or edge lines as directed by the Engineer and each pass shall be parallel to the previous passes. The ground surface shall be of uniform texture. Adjacent passes shall not overlap more than 1 inch and they shall not have a vertical difference of more than ⅛ inch as measured from bottom of groove to bottom of groove. Smoothness correction shall begin and end at lines normal to the pavement lane lines or edge lines within any one corrected area. The grinding shall proceed from the center line or lane line toward the pavement edge to maintain the specified pavement cross slope within ± 0.5 percent. The remaining requirements of this specification shall be followed. 627.3.8.1.1 Carbide Bump Grinding. Use grinders of the walk-behind type that have cutting heads of carbide tipped shackles, stars, or blades and have a locking depth control to produce a uniform pavement surface texture. Provide a pavement surface texture consisting of parallel grooves between 3⁄32 inch and ¼ inch wide width a "land area" between grooves 1⁄16 inch and 3⁄16 inch. Operate the grinder by making multiple passes, if necessary, with a maximum depth of any single pass of ⅛ inch. Grind longitudinally or transversely across the pavement surface. 627.3.8.2 Hot Mix Asphalt Pavements. For asphalt pavements, the surface correction shall be accomplished by diamond grinding, by overlaying the area, by replacing the area, or by inlaying the area. Grinding bumps shall only be permitted for 1½ inch or greater single lift overlays. Grinding depth shall be limited to ¼ inch. The final surface texture of corrected pavement shall be comparable to the adjacent sections that do not require correcting. If the surface is corrected by diamond or carbide grinding, the work and equipment shall be the same as specified for concrete pavement except that the ground surface shall be covered with an asphalt-based sealer approved in advance by the Engineer. If the surface is corrected by overlay, replacement or inlay, the surface correction shall begin and end with a transverse saw cut normal to the pavement lane lines or edge lines within any one area. Profile of surface must be smooth with no bumps or dips at beginning or end of correction. Overlay correction must be for the entire pavement width. Pavement cross slope must be maintained through the corrected areas. The remaining requirements of this specification shall be followed.
9/1/2023
627-3
Diamond Grinding of Portland Cement Concrete or Bituminous Pavement
627.3.9 Final Surface Finish. The grinding process shall produce a pavement surface that is true in grade and uniform in appearance with a longitudinal line-type texture. The line type texture shall contain corrugations parallel to the centerline and present a narrow ridge corduroy type appearance. The land area, height and groove dimensions shall be within the tolerances specified herein. Operating Tolerances for Final Surface Finish Hard Coarse Aggregate (Glacial)
Soft Coarse Aggregate (Limestone)
Minimum
Maximum
Minimum
Maximum
Groove (in.)
0.10
0.15
0.09
0.14
Land Area * (in.)
0.08
0.16
0.10
0.16
Height ** (in.)
0.03125
0.09375
0.03125
0.09375
Dimension
Note: * Target = 0.08 for hard aggregate & 0.10 for soft aggregate. ** Target = 0.06 inch.
Blades supplied shall result in 50 to 55 grooves per foot as measured perpendicular to the centerline. It shall be the contractor's responsibility to select the type of diamond blades to be used to provide the proper surface finish for the coarse aggregate type present on the project. The engineer may require removal of unbroken fins at the contractor’s expense. The project conditions may dictate that the contractor has to make multiple passes with the equipment to meet the specifications. It is the contractor's responsibility to determine the proper sequence of operations to meet the specification. If multiple passes of the grinding equipment are required, the area will only be considered for payment once. A minimum of 90 percent of the area of any 100-foot section of pavement surface shall be textured. 627.3.10 Pavement under-sealing or pavement repair, if required, shall be completed prior to any grinding. 627.3.11 Obliterated edge lines next to a shoulder will not be required to be replaced by the contractor unless specified in the contract. Any centerline or lane line markings removed by the contractor's operations shall be replaced with temporary pavement marking material in accordance with Section 621, unless permanent pavement marking material is specified in the contract. Prior to installation of permanent pavement marking material, all joints and cracks shall be cleaned and sealed if specified in the contract. 627.3.12 The pavement shall be cleaned prior to opening to traffic as directed by the engineer. 627.3.13 Slurry Handling and Removal. The contractor shall remove and dispose of all residues from the grinding in a manner and at a location to satisfy environmental regulations. The contractor shall have the engineer's approval for the method of spreading and disposal of the residue prior to beginning any grinding operations.
9/1/2023
627-4
Diamond Grinding of Portland Cement Concrete or Bituminous Pavement
The diamond grinding machine shall be equipped with a well-maintained vacuum system that is capable of removing all standing slurry, leaving the roadway in a damp condition after the grinder passes. Residue shall not be permitted to encroach into open lanes or enter into closed drainage systems. All catch basins shall be covered with filter fabric as shown in the plans. 1) No discharge of water / lime slurry will be allowed to enter "waters of the state". a) "Waters of the state", all rivers, streams, lakes, and other bodies of surface and subsurface water lying within the boundaries of the state which are not entirely confined and located completely upon lands owned, leased, or otherwise controlled by a single person or entity. b) The Slurry should not be discharged to drainage ways, un-vegetated areas or anywhere storm water runoff is likely to occur. 2) Slurry discharges should be stopped at least 25 feet from any waters of the state where roadway ditch grades are less than 12 percent or at least 50 feet where ditch grades are greater than 12 percent and less than 25 percent. A minimum of 12 feet of healthy vegetation must be present to filter slurry residue. 3) When specified in the contract documents, sites where there is sparse or no vegetation to control the movement of the slurry, alternatives that may be used include: a) Pump the slurry into tankers and hauled to an area where it can be spread as a lime supplement. This method will require additional tankers and land close to the project site. b) Incorporate the slurry into the soil on the right of way next to the road where it will not impact waters of the state, highway, or shoulders. The basic handling procedures for urban sections with enclosed drainage systems are outlined below: 627.3.13.1 Slurry Collection for Disposal or Pond Decanting. In urban and other areas with closed drainage systems, the slurry shall be collected. Residue shall not be permitted to encroach into open lanes or enter into closed drainage systems. 627.3.13.2 Slurry Collection and Pond Decanting. The slurry shall be collected in watertight haul units and transported to settlement ponds constructed by the contractor. These ponds may be constructed outside of the right-of-way. All locations, haul units, and settlement ponds shall be approved by the Engineer. These ponds shall be constructed to allow for the settlement of the solids and decanting of the water for reuse in the grinding operation. At the completion of the grinding operation, the remaining water will be allowed to evaporate or may be used in a commercially useful manner (e.g., dust control). After drying, the remaining solids may be used for fill material or other commercially useful applications. The pond area shall be reclaimed to its original condition and vegetated to protect against erosion.
9/1/2023
627-5
Diamond Grinding of Portland Cement Concrete or Bituminous Pavement
627.3.13.3 If the site does not contain sufficient grading or right-of-way to incorporate slurry solids, the contractor shall dispose of the waste material at an off-site location approved in advance by the Engineer. 627.4 Smoothness Requirements. Each segment of the finished ground surface shall have the smoothness checked using a 10-foot straightedge in each lane wheel path to the tolerance of ±⅛ inch. Depressed pavement areas due to subsidence or other localized causes will be exempted from texture and smoothness requirements. 627.4.1 New Concrete Paving. No diamond grinding shall be done until the pavement has attained a compressive strength sufficient to be opened to all types of traffic, and no sooner than twenty-one days after being placed. All diamond grinding shall be completed on any section prior to opening that section to other than construction traffic, unless approved by the engineer. 627.4.2 The final pavement surface from the grinding process shall be in accordance with Section 627.3.5. All grooves and adjacent passes shall be parallel to each other and the roadway, with no variation. Adjacent passes shall completely lap with no unground surface between; however, they shall not overlap more than 2 inches. Maintain cross-slope of adjacent passes. Adjacent passes shall be within ⅛ inch of the same height as measured with a 3-foot straightedge. No less than 98 percent of the specified surface shall be textured by grinding. There shall be no ridge between lanes. Any remaining ridges on the outside edge next to the shoulder greater than ⅛ inch high shall be feathered out to the satisfaction of the engineer in a separate operation. 627.4.3 Any deficiencies in the final surface due to improper contractor operations or equipment shall be corrected by the contractor, at the contractor's expense. 627.5 Traffic Control. The contractor shall provide all traffic control devices necessary for maximum protection of the traveling public and construction work area with only a minimum of interference. Unless otherwise specified, the contractor shall prepare and submit in advance, a written traffic control plan in accordance with Part VI of the Manual of Uniform Traffic Control Devices (MUTCD), current edition, for review and approval by the engineer. 627.6 Method of Measurement. Diamond grinding of existing Portland cement concrete and bituminous pavement construction will be measured by the square yard. The measurement will be the final textured surface area regardless of the number of passes required to achieve acceptable results.
9/1/2023
627-6
Diamond Grinding of Portland Cement Concrete or Bituminous Pavement
Grinding of pavement will be measured by the square yard. The measurement will be the final textured surface area regardless of the number of passes required to achieve the specified results. Minor areas of unground pavement within the designated areas to be ground will be included in the measurement up to 10 percent of the surface area. When conditions require a feather pass into the shoulder, auxiliary or ramp lanes, payment will be by the square yard based on a width of 2 feet times the length of the required feather pass. The minimum length of a feather pass will be 100 feet. Gutter sections requiring a feather pass will be paid by the square yard based on a width of 1-foot times the length of the required feather pass. The minimum length of a feather pass will be paid as 100 feet. 627.7 Basis of Payment. The accepted quantity of ground pavement surface will be paid for at the contract price per square yard for DIAMOND GRINDING (CONCRETE PAVEMENT) or DIAMOND GRINDING (BITUMINOUS PAVEMENT). Payment shall be full compensation for all labor, equipment, material, and incidentals to complete this work, including hauling and disposal of grinding residue, and cleaning the pavement prior to opening to traffic. Covering of catch basins will be paid per each unit. Structure adjustments will be by agreed price or by Force Account. Surface correction shall be considered incidental to the pavement being ground with no additional payment. Traffic control will be paid for under this pay items for the project. Traffic control will include all devices and requirements as stated in the traffic control Section 612 of the Standard Specifications for Road and Bridge Construction.
9/1/2023
627-7
Diamond Grinding of Portland Cement Concrete or Bituminous Pavement
Section 628
Keyhole Coring and Repair
628.1 General. This specification covers the requirements for keyhole coring, vacuum excavation, backfilling, and reinstatement of the keyhole core in asphalt or concrete pavements to allow for underground utility repairs and underground exploratory potholing. 628.2 Definitions. Keyhole Coring
-
The operation of coring a circular hole through the roadway pavement, shoulder, drive approach, median or sidewalk using diamond core drilling equipment.
628.3 Materials. 628.3.1 Supply of Materials. Unless otherwise specified, the Contractor / Utility shall supply all materials necessary for the execution and completion of the work. 628.3.2 Bonding Material. Bonding material when mixed with the appropriate quantity of water should flow easily up and around the reinserted core and, with no voids, completely fill the annular space around the core to achieve a waterproof, mechanical joint between the keyhole pavement core and the original slab of pavement from which it was originally extracted. The bonding agent shall be a packaged, single component cementitious, rapid hardening, high strength, waterproof bonding agent that is non-metallic; non-staining; non-toxic; available in two colors: aged asphalt and natural concrete; and conforming to the physical properties shown in Table 1. 1) The bonding material shall be impervious to water penetration at the joint after application. 2) The bonding material shall securely bond the undamaged keyhole core to the pavement and shall completely fill the annular space at the joint. 3) The bonding material shall, within 30 minutes at an ambient temperature of 70 degrees Fahrenheit, allow the core to support an equivalent traffic load condition of at least three (3) times the AASHTO H-25 standard. 4) Follow manufacture mixing, limitations, installation, and curing instructions.
1/1/2016
628-1
Keyhole Coring and Repair
Table 1 Bonding Material Properties Property
Test Method
Requirements
Bond Strength (Slant Shear), psi (70°F), 30 minute cure: 60 minute cure:
ASTM C 882
200 min. 600 min.
Compressive Strength, psi (70°F), 60 minute cure: 28-day cure:
ASTM C 109
1500 min. 8550 min.
Chloride Permeability @ 73°F, Coulombs
AASHTO T 277
229 max.
Length Change (Shrinkage), % Shrinkage in 28 days
ASTM C 157
0.07 max.
628.3.3 Backfill Material. The type and gradation of the granular backfill shall be MSD 3 in accordance with Section 726.6.3. The material shall consist of ¾ inch minus crushed limestone and screenings. 628.4 Construction. All work performed by the Utility using keyhole methods shall be carried out in such a manner that the pavement or sidewalk surfaces worked upon are restored and matched as close as possible to the original condition of the surface. 628.4.1 Vertical Alignment. The vertical alignment of the keyhole coring shall be perpendicular to the horizon, and the cutting shall extend to the full depth of the existing pavement section. 628.4.2 Keyhole Dimensions. Unless otherwise approved by the Engineer, keyhole cores shall not be less than 18 inches nor greater than 24 inches in diameter. Adjacent cores shall not be closer than 3 feet from each other (edge to edge), shall not contain a joint or any pavement cracks greater than ⅛ inch wide, and shall not be performed in pavements where the section is less than 4 inches thick. 628.4.3 Keyhole Equipment. Coring shall be performed with a keyhole-coring saw resulting in an 18 to 24 inch diameter core with a drilled pilot hole at the center of the core surface to facilitate extraction of the core. 628.4.4 Core Orientation. The Contractor / Utility shall place a temporary mark (paint or chalk) on the keyhole core prior to cutting to insure that the removed section is replaced in the same orientation as originally found in the sidewalk, median or pavement.
1/1/2016
628-2
Keyhole Coring and Repair
628.4.5 Core Storage. Pavement keyhole cores removed shall either be removed from the work site or stored in a safe and secure on-site location. The cores shall be made readily available for restoring the sidewalk, median or pavement after backfilling is complete and approved. 628.5 Soil Extraction. Soils within potholes shall be removed by air / vacuum extraction methods to expose utilities. The zone of soil removal shall remain essentially within a vertical plane extending below the edges of the removed pavement. 628.5.1 Operator Competency. Vacuum excavation equipment shall only be operated by a "Competent Person" as defined by OSHA. The operator must have the knowledge, training and experience to perform the work, be familiar with OSHA and the regulations that apply to the work and have knowledge of all potential and actual danger to health and safety in the workplace. It is a best practice that workers have training recognized by industry, defined safe work practices, manufacturer's recommended procedures specific to the equipment they are operating, and training specific to any known facilities in the area of excavation. 628.5.2 If damage to underground facilities and / or coatings on these facilities occurs while using vacuum excavation technology or any other method of excavation, the excavator shall contact the facility owner / operator. 628.5.3 The Utility / Contractor shall remove all materials excavated from the site. 628.6 Keyhole Backfill and Compact. 628.6.1 The Standard Compaction Test, used to determine material optimum dry density and moisture content, will be conducted on the MSD 3 backfill material in accordance with AASHTO T 99, Method C, replacing any material retained on the ¾ inch sieve, as provided therein. All granular materials shall be placed in loose lifts not to exceed 12 inches. 628.6.2 A Dynamic Cone Penetrating Device shall be used to determine compacting effort. Each lift of granular material shall be compacted by mechanical tamping to not less than the 95 percent of the standard maximum dry density and the moisture of the material shall be within ± 2 percent of optimum. The final inch of backfill may be replaced with pea gravel in accordance with the bonding material manufacturer guidelines. The Contractor / Utility shall use one of the following options to test and report compaction results to the Engineer. The MSD 3 aggregate backfill under both roadway and shoulders shall be compacted to achieve an average dynamic cone penetration index value through the keyhole backfill thickness less than or equal to: Option A - 0.5 inches per blow, as determined by a standard 17.6 lb. Dynamic Cone Penetrometer (DCP) device meeting the requirements of ASTM D 6951. Option B -The minimum number of drops required to drive the cone a distance of 3.25 inches, as determined using the 5 lb. Dynamic Cone Penetrometer (DCP) device meeting the requirements of ASTM D 7380. The Contractor / Utility shall be required to determine a correlation, in accordance with Appendix X1 of ASTM D 7380, to determine the drop value that achieves the minimum compaction effort of 95 percent of the standard maximum dry density.
1/1/2016
628-3
Keyhole Coring and Repair
628.6.3 The Contractor / Utility is responsible for backfill and compaction determination and reporting. A new lift shall not be placed until compaction requirements are met. Remove backfill and replace material that does not meet the compaction requirements after repeated compaction work. 628.7 Pavement Restoration. 628.7.1 The surface cut by keyhole coring restored to its original condition with the reinstated core flush with and in the original orientation as the existing surface, matching existing pavement surface appearance. 628.7.2 Bonding material meeting the requirements of Section 628.3, "Materials", shall be used for pavement core reinstatement. Excess bonding material shall be removed from the restored surface. A patched appearance shall be avoided in surface restoration wherever possible. 628.7.3 Plating. Unless otherwise approved by the Engineer, the Contractor / Utility shall reinstate the bonded keyhole core within 24 hours of cutting the pavement. Openings allowed to be left open to traffic / pedestrians shall be covered with an approved steel road plate with a non-skid surface capable of supporting traffic loads, and in accordance with Section 626. An asphalt mix shall be used to jam the plate into the pavement along all edges. 628.7.4 Optional Plating. In the event that a keyhole cored pavement cannot be reinstated and will be left unattended, the opening shall be covered with an approved form of an appropriately-sized, circular steel road plate with a non-skid surface, fitted with a collar that, when inserted into the keyhole, will prevent the hole cover from tipping, tilting, bouncing or spinning out of the hole in all types of the traffic conditions. 628.7.5 Quality Control, Surface Tolerances. The reinstated core shall be flush and level with the adjacent pavement. Gaps attributable to the positioning of the core shall be less than 1/16 inch between the bottom of a minimum 3 foot long straightedge and the surface of the pavement in any direction on the surface of the keyhole core, except across the crown or drainage gutters. 628.7.6 Opening to Traffic. The keyhole technology means and methods shall permit normal vehicular traffic to resume over the restored keyhole location within 30 to 45 minutes of the completed repair.
1/1/2016
628-4
Keyhole Coring and Repair
628.8 Deficiencies. 628.8.1 Where the keyhole core is found to be fractured or defective upon removal, or becomes damaged after removal and prior to reinstatement, the core shall not be used to restore the pavement. The pavement at damaged keyhole core locations shall be cut and a permanent patch shall be installed in accordance with Section 613, "Pavement Repair". 628.8.2 A keyhole core shall be considered unacceptable when one of the following conditions exist: 1) The keyhole core contains any vertical cracks wider than ⅛ inch extending full depth through the core; or 2) Any deteriorated piece of the keyhole core is larger than ten percent of the overall area of the core; or 3) Two or more successive layers of pavement in the keyhole core become horizontally delaminated and cannot be re-bonded to each other with the bonding material; or 4) In flexible pavements, where the sidewalk, median, or pavement layer is less than 4 inch thick, aged asphalt color bonding material may be used in filling of the keyhole to a depth equal to the thickness of the pavement layer, in lieu of reinstating the excavated core if the core is cracked, damaged, or deformed such that it is not practical to reinstate it. In this circumstance, the bonding material should satisfy the structural requirements of the original structure and match the color of the pavement. 628.8.3 All keyhole cores that are damaged or do not meet the surface tolerances shall be removed, and the Contractor / Utility shall cut and install a permanent patch in accordance with Section 613, "Pavement Repair". 628.9 Method of Measurement. Unless otherwise specified, the quantity of Keyhole Core Repair will not be measured for payment, but shall be considered incidental to other items of work. 628.10 Basis of Payment. No direct payment for sawing, removal, storage and replacement of keyhole core, vacuum extraction of material and disposal of waste material, furnishing, placing and compaction of backfill and bedding material, material certification, testing, and reporting, and furnishing of plates and other traffic control measures will be made for Keyhole Core Repair unless required in the Special Provisions.
1/1/2016
628-5
Keyhole Coring and Repair
(This Page Intentionally Left Blank)
1/1/2016
628-6
Keyhole Coring and Repair
Division 700
STRUCTURES
9/1/2023
700-1
Structures
(This Page Intentionally Left Blank)
9/1/2023
700-2
Structures
Standard Specifications for Road and Bridge Construction Division 700 - Structures Section
Description
Revision Date
701..... Drilled Shafts ....................................................................................................... 5/1/2010 702..... Bearing Pile ..................................................................................................... 12/12/2012 703..... Concrete Masonry Construction .......................................................................... 9/1/2023 704..... Concrete Masonry Repair .................................................................................... 5/1/2010 705..... Prestressed Concrete Members for Bridges ........................................................ 5/1/2010 706..... Reinforcing Steel for Concrete Structures............................................................ 5/1/2010 707..... Conduit System on Structure ............................................................................... 5/1/2010 708..... Blank ................................................................................................................................. 709..... Blank ................................................................................................................................. 710..... Epoxy Coated Reinforcing Steel .......................................................................... 5/1/2010 711..... Protective Coatings for Exposed Concrete Surfaces ........................................... 5/1/2010 712..... Structural Steel Construction ............................................................................... 5/1/2010 713..... Bridge Guard Rail ................................................................................................ 5/1/2010 714..... Blank ................................................................................................................................. 715..... Vertical Drain at End Bents.................................................................................. 5/1/2010 716..... Neoprene Bearings.............................................................................................. 5/1/2010 717..... Neoprene and Silicone Joint Systems ................................................................. 5/1/2010 718..... Blank ................................................................................................................................. 719..... Blank ................................................................................................................................. 720..... Mechanically Stabilized Earth Wall Systems........................................................ 5/1/2010 721..... Blank ................................................................................................................................. 722..... Blank ................................................................................................................................. 723..... Blank ................................................................................................................................. 724..... Pipe Culverts (New Section) ................................................................................ 7/1/2016 725..... Metal Pipe and Pipe-Arch Culverts ...................................................................... 5/1/2010
9/1/2023
700-3
Division 700 - Index
Section
Description
Revision Date
726..... Rigid Pipe Culverts, Storm Drains and Sewers .................................................... 9/1/2023 727..... Structural Plate Pipe and Structural Plate Pipe-Arch Culverts ............................. 5/1/2010 728..... Corrugated Polyvinyl Chloride (PVC) Culvert Pipe .............................................. 5/1/2010 729..... Blank ................................................................................................................................. 730..... Thermoplastic Culvert Pipe.................................................................................. 7/1/2016 731..... Precast Reinforced Concrete Manholes and Drop Inlets ..................................... 5/1/2010 732..... Flared End Sections ............................................................................................ 5/1/2010 733..... Precast Concrete Box Culverts ............................................................................ 9/1/2023 734..... Installation of Pipe by Horizontal Boring Methods ................................................ 5/1/2010 735..... (Removed) ........................................................................................................................ 736..... Bridge Deck Sealer.............................................................................................. 9/1/2012
9/1/2023
700-4
Division 700 - Index
Section 701
Drilled Shafts
701.1 Description. This work shall consist of constructing cast-in-place reinforced concrete drilled shafts and rock sockets, as required, to serve as a structural foundation. This work shall provide reinforced concrete shafts cast in cylindrically excavated holes extending sufficiently into soil or sound rock to adequately support the structure and all externally applied loads for which the shaft was designed. The drilled shaft foundation, including the rock socket, where required, shall be constructed in accordance with these specifications, as shown on the plans and in accordance with other specifications included in the contract documents. When directed by the engineer, corrections made by the contractor will be noncompensable and any effect on time of performance non-excusable. 701.2 Preconstruction Submittals. At least 30 days prior to drilled shaft construction, the contractor shall submit to the engineer for review an installation plan for the construction of drilled shafts. The installation plan shall be of sufficient detail to outline the contractor’s intended overall construction sequence and methods of excavation for the drilled shafts, including use of slurry, placement of reinforcing steel, details of concrete delivery to the site, an emergency construction joint method, placement of concrete in a continuous pour, including operational procedures for tremie or pump, and methods to prevent and handle delays in concrete batching and delivery to the site. The installation plan shall include details of casings to be used, if applicable, including calculations showing the ability of the casing to withstand anticipated hydraulic and earth pressures, and to withstand stresses due to installation without undue deformation. These details shall include methods for casing handling, splicing, straightening and out-of-round correction. Calculations included in the installation plan shall be signed and sealed by a registered professional engineer licensed to practice in the State of Missouri. 701.3 Materials. All material shall be in accordance with this specification, Division 1000, Material Details, and specifically as follows: Item
Section
Reinforcing Steel for Concrete .................................................. 1036 Concrete Admixtures ................................................................. 1054 Concrete Curing Material........................................................... 1055 Mortars and Grout ..................................................................... 1066 Water ......................................................................................... 1070 701.3.1 Concrete. Drilled shafts shall be constructed of Class B-2 concrete, and all material, proportioning, mixing and transporting of concrete shall be in accordance with Section 501, except as specified herein. An air entrainment admixture shall be used. A high range water reducing admixture may be used to increase the slump to a maximum of 8 inches. If used, the water-reducing admixture shall be added only after the concrete has reached the job site to reduce the potential for flash setting. The concrete mix for drilled shafts shall be dense, homogeneous, fluid and resistant to segregation, and shall consolidate under self-weight. The concrete mix shall have a set time that ensures that fluidity is maintained throughout the shaft concrete placement and removal of temporary casing, if used. A concrete retarder in accordance with AASHTO M 194, Type B, may be incorporated into the mix to retard set approximately two hours. Concrete for drilled shafts shall have a 28-day minimum
5/1/2010
701-1
Drilled Shafts
compressive strength of 4000 psi. Portland cement shall be Type I or Type II. The maximum water per cement ratio of a concrete mix to be placed under water shall be 0.45. 701.3.2 Casing. Welded or seamless steel permanent casings shall be in accordance with ASTM A 252, Grade 2, unless otherwise specified. The contractor shall furnish two copies of certification from the fabricator detailing the designated specification with which the furnished casings comply. 701.3.2.1 Shop Drawings. Shop drawings for permanent steel casings shall be prepared in accordance with Section 1080 and shall be submitted to the engineer prior to installation of the casings. 701.3.2.2 Condition of Casings. Casings shall be smooth, clean and watertight. For out of round tolerance of steel casings before and after installation, the departure of any point on the periphery of the casing from a true circle shall not exceed one inch, measured radially. 701.3.2.3 Extent of Casing Length. Permanent casings, if required, shall be continuous wherever possible or practical. The permanent casing shall terminate at the specified elevation, and the concrete shall be trimmed to within tolerances specified in Section 701.4.16 prior to acceptance of the completed drilled shaft. Permanent casings shall be extended into rock, as needed, to provide a positive seal and to stabilize the shaft excavation against collapse, excessive deformation, or flow of water. Casings meeting all specified requirements shall be installed from the work platform to the elevations shown on the plans. Where drilled shafts are located in open water areas, casings shall be extended from at least 18 inches above the water elevation and unless otherwise specified in the contract documents, to the specified bottom of casing elevation to protect the shaft concrete from water action during placement and curing of concrete. 701.3.2.4 Use of Teeth or Cutting Edge. The casing may be fabricated with teeth or a cutting edge to facilitate insertion into the rock. 701.3.2.5 Splices. Splicing of permanent casings is not desirable and will only be permitted when approved by the engineer. If splices are required, the welding process shall be in accordance with the requirements specified herein. The contractor shall be fully responsible for the adequacy of welds during driving. 701.3.2.6 Welding. Shop welding of casings shall be performed by a fully automated welding process to develop the full capacity of the shell. All welding shall be in accordance with Section 1080, except that shop welding of casings will not require radiographic inspection. Inspection will be of a visual nature. If evidence indicating poor welding is found, the engineer may require radiographing. Field-welded splices of sections of the steel casings shall be made by shielded metal-arc welding procedures performed by a MoDOT certified field welder using properly dried low-hydrogen E7018 electrodes that have been protected from the elements to maintain the dry condition. The welds shall be full penetration, watertight and of x-ray quality in accordance with Section 1080.
5/1/2010
701-2
Drilled Shafts
701.3.3 Slurry. Drilling slurry will be defined as mineral slurry, polymer slurry, natural slurry formed during the drilling process, water or other fluids used to maintain stability of the drilled shaft excavation to aid in the drilling process or to maintain the quality of the rock socket. In addition, the terms mineral slurry and polymer slurry, as used herein, will be defined as the final mixed composite of all additives, including manufactured mineral or polymer slurry additives required to produce the acceptable drilling slurry. 701.3.3.1 Slurry Usage. Drilling slurry shall be used if detailed in the approved installation plan, if in accordance with the contract documents or if approved in writing by the engineer. Drilling slurry may be used at the contractor’s option if the slurry is not in accordance with the contract documents; however, any slurry shall be approved by the engineer prior to use. Drilling slurry, when used, will be noncompensable and effect on time of performance due to the use of the slurry will be non-excusable. 701.3.3.2 General Properties. The material used to make the slurry shall not be detrimental to the concrete or surrounding ground strata. Mineral slurries shall have both a mineral grain size that remains in suspension and sufficient viscosity and gel characteristics to transport excavated material to a suitable screening system. Polymer slurries shall have sufficient viscosity and gel characteristics to transport excavated material to suitable screening systems or settling tanks. The percentage and specific gravity of the material used to make the slurry shall be sufficient to maintain the stability of the excavation and to allow proper concrete placement. If approved by the engineer, the contractor may use water and on-site soils as a drilling slurry. In that case, the range of acceptable values for density, viscosity and pH, as shown in the following table for bentonite slurry, shall be met, except that maximum density (unit weight) shall not exceed 70 pounds/cubic foot. When water is used as the drilling fluid to construct rock sockets in limestone, dolomite, sandstone or other formations that are not erodible, the requirements for slurry testing will not apply. 701.3.3.3 Preparation. Prior to introduction into the shaft excavation, the manufactured mineral or polymer slurry admixture shall be pre-mixed thoroughly with clean, fresh water and for adequate time in accordance with the slurry admixture manufacturer’s recommendations allotted for hydration. Water used for mixing shall be in accordance with Section 1070. Slurry tanks of adequate capacity will be required for slurry mixing, circulation, storage and treatment. No excavated slurry pits will be allowed in lieu of slurry tanks without written approval from the engineer. Adequate desanding equipment will be required as necessary to control slurry properties during the drilled shaft excavation in accordance with the values provided in the table below. Desanding will not be required for signposts or lighting mast foundations unless specified in the contract documents. 701.3.3.4 Control Tests. Control tests using a suitable apparatus shall be performed by the contractor on the slurry to determine density, viscosity, sand content and pH of freshly mixed slurry, recycled slurry and slurry in the excavation. Tests of slurry samples from within one foot of the bottom and at mid-height of the shaft shall be conducted in each shaft excavation during the excavation process to establish a consistent working pattern. A minimum of four sets of tests shall be conducted during the first eight hours of slurry use on the project. When the results show consistent behavior, the testing frequency may be decreased to one set every four hours of slurry use, or as otherwise approved by the engineer. Reports of all tests, signed by an authorized representative of the contractor, shall be furnished to the engineer on completion of each drilled shaft. An acceptance range of values for the physical properties will be as shown in the table below. 5/1/2010
701-3
Drilled Shafts
701.3.3.5 Sampling. When slurry samples are found to be unacceptable, the contractor shall bring the slurry in the shaft excavation to within specification requirements. Concrete shall not be poured until resampling and testing results produce acceptable values. Prior to placing shaft concrete, the contractor shall take slurry samples from within one foot of the bottom and at mid-height of the shaft. Any heavily contaminated slurry that has accumulated at the bottom of the shaft shall be removed. Disposal of all slurry shall be done in areas approved by the engineer. The contractor shall perform final shaft bottom cleaning after suspended solids have settled from the slurry mix. Range of Acceptable Values for Mineral and Polymer Slurries in Fresh Water Without Additives Property
Bentonite
Density (Unit Weight)
Emulsified Polymer
Dry Polymer
Units
Test Method
lb/ft3
Density Balance
sec/qt
Marsh Funnel
pH Paper or pH Meter
At Introduction
3.5 - 66.8 (1017-1070)
< 63 (1009)
< 63 (1009)
Prior to Concreting
63.5 - 70.5 (1017-1129)
< 63 (1009)
< 63 (1009)
At Introduction
32 – 60 (34 – 63)
33 – 43b (35 – 45)b
50 – 80b (53 – 85)b
Prior to Concreting
32 – 60 (34 – 63)
33 – 43b (35 – 45)b
50 – 80b (53 – 85)b
At Introduction
8 – 10
8 – 11
7 – 11
--
Prior to Concreting Sand Content
8 – 10
8 – 11
7 – 11
--
At Introduction
<4
<1
<1
Prior to Concreting Maximum Contact Timea
< 10
<1
<1
Percent by Volume
4
72
72
Marsh Funnel Viscosity
pH
a
Without agitation and sidewall cleaning.
5/1/2010
b
API Sand Content Kit
Hours
Higher viscosities may be required to maintain excavation stability in loose or gravelly sand deposits.
701-4
Drilled Shafts
701.4 Construction. 701.4.1 Protection of Existing Structures. All precautions shall be taken to prevent damage to existing structures and utilities. These measures shall include, but are not limited to, monitoring and controlling the vibrations from the driving of casing or drilling of the shaft, and selecting construction methods and procedures that shall prevent excessive caving of the shaft excavation. 701.4.2 Technique Shafts. When required by the contract documents, the contractor shall demonstrate the adequacy of methods and equipment used during construction of the first drilled shaft, which shall be an out of position technique shaft, constructed with reinforcement as identified for production shafts on the plans. This technique shaft shall be drilled in the position as directed by the engineer and drilled to the maximum depth for any production shaft shown on the plans. If at any time the contractor is unable to demonstrate, to the satisfaction of the engineer, the adequacy of methods or equipment and alterations required, an additional technique shaft(s) may be required. Technique shafts shall be cut off 3 feet below ground line, buried or otherwise disposed of as specified in the contract documents or as directed by the engineer. Once approval has been given to construct production shafts, no changes will be permitted in the methods of equipment used to construct the shaft without approval from the engineer. When a technique shaft is not required, construction of the first production shaft will be used to determine if the methods and equipment used by the contractor are acceptable. Failure at any time to demonstrate to the engineer the adequacy of methods or equipment will be cause for the engineer to require appropriate alterations in equipment or method by the contractor to eliminate unsatisfactory results. 701.4.3 Construction Sequence. Excavation to footing elevation shall be completed before shaft construction begins, unless otherwise authorized by the engineer. Any disturbance to the footing area caused by shaft installation shall be repaired by the contractor prior to pouring the footing. When drilled shafts are to be installed in conjunction with embankment placement, the contractor shall construct drilled shafts after placement of fills. Drilled shafts constructed prior to the completion of fills shall not be capped until the fills have been placed as near to final grade as possible, leaving only the necessary work room for construction of the caps. 701.4.4 General Equipment and Methods. The contractor shall perform excavations through whatever material is encountered to the dimensions and elevations shown on the plans. The contractor’s methods and equipment shall be suitable for the intended purpose and for whatever material is encountered. 701.4.4.1 General Equipment. The contractor shall provide equipment capable of constructing shafts to a depth equal to the deepest shaft tip elevation shown on the plans plus 15 feet, or as otherwise specified in the contract documents. When a rock socket is identified on the plans at a shaft location, the definition of "shaft tip elevation", for the purposes of this subsection, shall be taken to refer to the bottom of the rock socket.
5/1/2010
701-5
Drilled Shafts
701.4.4.2 General Methods. Excavations required for shafts and rock sockets shall be completed in a continuous operation. The contractor shall be responsible for ensuring the stability of the shaft excavation and the surrounding soil. When obstructions, either expected or unexpected, are encountered, the contractor shall notify the engineer promptly. Either the dry method, wet method, temporary casing method, permanent casing method if specified, or combinations, as necessary, shall be used to produce sound, durable concrete drilled shafts free of defects. The permanent casing method shall be used only when required by the contract documents. Blasting excavation methods will not be permitted. When a rock socket is required, the engineer will be the sole judge as to what constitutes the top of sound rock. The engineer may order in writing additional depths of rock socket below the top of sound rock as considered necessary to improve the foundation. If the top surface of the sound rock is found to be inclined across the width of the shaft, the contractor shall immediately notify the engineer. The contractor shall use an airlift, or other method approved by the engineer, to clean the bottom of the shaft excavation. 701.4.4.2.1 Dry Construction Method. The dry construction method shall be used only at sites where the groundwater table and site conditions, generally stiff to hard clays or rock above the water table, are suitable to permit construction of the shaft in a relatively dry excavation and where the sides and bottom of the shaft remain stable without any caving, sloughing or swelling and allow visual inspection prior to concrete placement. The dry method shall consist of drilling the shaft excavation, removing accumulated seepage water and loose material from the excavation and placing the shaft concrete in a relatively dry excavation. The dry construction method shall be used only when shaft excavations, as demonstrated in a technique shaft or first production shaft, have 12 inches per hour or less of seepage. 701.4.4.2.2 Wet Construction Method. The wet construction method shall be used at sites where a dry excavation cannot be maintained for placement of the shaft concrete. This method shall consist of drilling the shaft excavation below the water table, keeping the shaft filled with water, natural slurry formed during the drilling process, mineral slurry or polymer slurry to contain seepage and groundwater movement, and to maintain stability of the hole perimeter until excavation to the final depth and placement of the reinforcing cage and concrete has been completed. This procedure will require placing the shaft concrete with either a tremie or concrete pump beginning at the shaft bottom, and displacing the water or slurry as concrete is placed. Temporary partial depth casings near the ground surface shall be provided to aid shaft alignment and position and to prevent sloughing of the top of the shaft excavation. Where drilled shafts are located in open water areas, shafts shall be constructed by the wet method using casings extending from above the water elevation to the plan casing tip elevation to protect the shaft concrete from water action during placement and curing. The casing shall be installed in a manner that produces a positive seal at the bottom of the casing.
5/1/2010
701-6
Drilled Shafts
701.4.4.2.3 Temporary Casing Construction Method. The temporary casing construction method shall be used at all sites where the stability of the excavated hole or the effects of groundwater cannot be controlled by other means. In this method, the hole shall be advanced through caving material by the wet method in accordance with Section 701.4.4.2.2. When a formation is reached that is nearly impervious, a casing shall be placed in the hole and sealed. Drilling may proceed by the dry method to the projected depth. The placement of concrete shall proceed by the dry or wet method, except that the casing shall be withdrawn after the concrete is placed. In the event seepage conditions prevent use of the dry method, excavation shall be completed by the wet method. Before and during casing withdrawal, a 5-foot minimum head of fresh concrete above the bottom of the casing shall be maintained at such a level that fluid trapped behind the casing is displaced upward out of the shaft excavation without mixing with or displacing the shaft concrete. Casing extraction shall be at a slow, uniform rate with the pull in line with the axis of the shaft. Temporary casings shall be removed while the concrete is still workable and the slump of the concrete is between 4 and 8 inches. Vibratory hammers shall not be used for casing installation or removal within 50 feet of other shafts that have been completed less than 24 hours earlier. The reinforcing cage shall not be damaged or displaced when withdrawing the temporary casing. 701.4.4.2.4 Permanent Casing Construction Method. The permanent casing construction method shall be used only when required by the contract documents or authorized by the engineer. The casing shall be continuous between top and bottom elevations shown on the plans. Vibratory hammers shall not be used for casing installation within 50 feet of shafts that have been completed less than 24 hours earlier. 701.4.5 Slurry. 701.4.5.1 Time Limitations. When bentonite slurry is used, the contractor shall adjust construction operations such that the maximum time that slurry is in contact with the bottom 5 feet of the shaft, the time from the end of drilling to the beginning of concrete placement, does not exceed four hours without agitation. If the four-hour limit is exceeded, the bottom 5 feet of the shaft shall be over reamed prior to performing other operations in the shaft. For rock sockets constructed in shale using polymer slurry, concrete placement shall begin within 72 hours of starting the rock socket excavation to avoid degradation of the shaft sidewall. Before concrete placement begins, foundation inspection, when required, cleaning operations and reinforcing steel placement shall be completed and approved by the engineer. These operations will be included in the 72hour time limit. If concrete placement is not begun within the time limit, the contractor shall take corrective measures to the satisfaction of the engineer. 701.4.5.2 Level of Slurry. During construction, the level of slurry shall be maintained at a height sufficient to prevent caving of the excavation. If the engineer determines that the slurry construction method is failing to produce the desired final results, the contractor shall discontinue operations and propose an alternate method for approval from the engineer. Correction for a failed slurry construction method will be noncompensable and any effect on time of performance non-excusable.
5/1/2010
701-7
Drilled Shafts
701.4.5.3 Slurry Manufacturer’s Representative. When manufactured mineral or polymer slurry additives are to be incorporated into the drilling slurry mix, the contractor shall provide the technical assistance of a representative of the mineral or polymer slurry additive manufacturer at the site prior to introduction of the slurry into the first shaft where slurry use will be required, and during drilling and completion of a minimum of one shaft to adjust the slurry mix to the specific site conditions. 701.4.5.4 Drilling Fluids for Rock Socket Excavation. For rock sockets excavated in limestone, dolomite, sandstone or other formations that are not erodible and cannot be constructed in the dry, only water shall be used as the drilling fluid, except that when other slurry types are used in drilling through overburden, that slurry shall be removed and replaced with fresh clean water prior to rock socket excavation. For rock sockets excavated in geomaterial that may be eroded by drilling water, such as shales, a polymer slurry will be required prior to beginning rock socket drilling through completion of concreting the rock socket. 701.4.6 Cleaning of Shaft or Casing Sidewalls. Cleaning of the shaft or casing sidewalls shall occur by a method approved by the engineer as necessary to remove the depth of softening or to remove excessive slurry cake buildup. 701.4.7 General Excavation Considerations. The plans will indicate the top of shaft elevations and the estimated bottom of shaft elevations between which the drilled shaft shall be constructed. Drilled shafts may be extended deeper when the engineer determines that the foundation material encountered while drilling the shaft excavation is unsuitable or is not the same as anticipated in the design of the drilled shaft. Drilled shafts may be shortened when the engineer determines the material encountered is better than that anticipated, or based on the results of load tests. 701.4.7.1 Time Restrictions. The integrity of the drilled shaft excavation shall be maintained by the placing of reinforcement and concrete in a timely manner following completion of the excavation. No two adjacent shafts shall be excavated at the same time, and shafts shall not be constructed within 24 hours of the completion of an adjacent shaft if the center-to-center spacing is less than 3 shaft diameters. 701.4.7.2 Disposal of Excavated Material. Excavated material removed from the shaft and any drilling fluids used shall be disposed of in accordance with the contract documents, as directed by the engineer, and in compliance with federal and state laws. 701.4.7.3 Worker Entry Into Shaft Excavation. The contractor shall not allow workers to enter the shaft excavation for any reason, unless both a suitable casing has been installed and adequate safety equipment and procedures have been provided to workers entering the excavation. 701.4.8 Unexpected Obstructions. Subsurface obstructions at drilled shaft locations shall be removed by the contractor. The contractor shall employ special procedures or tools when the hole cannot be advanced using conventional equipment. Blasting will not be permitted. Except as provided in this section, all cost and time effects, direct, indirect and cumulative of subsurface obstruction of whatever nature, will be conclusively deemed fully compensated under the pay items in accordance with the contract. Encountering unexpected obstructions will be considered inherent risks in the nature of this work, both as to type and extent as is variability in material encountered in the work as to effort required to drill through or excavate 5/1/2010
701-8
Drilled Shafts
the material. In the event the contractor encounters at the site of a drilled shaft location a subsurface or latent physical condition that differs materially from that indicated in the contract documents, the contractor shall strictly follow the procedure provided for a differing site condition set forth in Section 104. Any adjustment to the contract amount or time will only be those expressly permitted by the contract documents and only to the extent expressly provided in the contract documents. No contract adjustment will be determined, as to entitlement or amount on any basis other than under the contract as a differing site condition. Specifically, but not by way of limitation, the contractor agrees that the contractor will not be entitled to any contract adjustment arising from encountering an unexpected obstruction on the basis that, with respect to the obstruction, the Commission made: (1) a positive representation; (2) of a material fact; (3) which was false or incorrect; (4) as to which positive representation of material fact the contractor lacked knowledge that the representation was false or incorrect; (5) upon which positive representation of material fact the contractor asserts that the contractor relied; and (6) was damaged as a direct result of the positive representation of material fact. 701.4.9 Lost Tools. Drilling tools lost in the excavation will not be considered obstructions and shall be promptly removed by the contractor. All work required to remove lost tools or to perform associated corrective work, including but not limited to repair of hole degradation due to removal operations, will be noncompensable and any effect on time of performance nonexcusable. 701.4.10 Excavation Inspection. 701.4.10.1 Inspection Equipment. The contractor shall maintain at the job at all times, all equipment suitable for use in the shaft inspection. 701.4.10.2 Removal of Excess Sediment and Water. Final shaft depth shall be measured with approved methods after final cleaning by airlift, or other method approved by the engineer. Unless otherwise stated in the contract documents, a minimum of 50 percent of the base of each shaft shall have less than ½ inch of sediment at the time of concrete placement. The maximum depth of sediment or any debris at any place on the base of the shaft shall not exceed 1½ inches. For dry excavations, the maximum depth of water shall not exceed 3 inches prior to concrete pour. Shaft cleanliness will be verified by the engineer for wet or dry shafts. 701.4.10.3 Television Camera Inspection. The primary means of inspecting a shaft excavation, steel casing and the rock socket shall be by television camera lowered into the shaft. The contractor shall furnish all equipment necessary to conduct the camera inspection. The contractor shall operate the camera and supporting equipment under the direction of the engineer in such a manner as to obtain optimum results from the equipment. The television camera and lighting equipment shall be capable of operating in dry or submerged conditions encountered during the inspection. The excavated shaft shall have the engineer’s approval prior to proceeding with construction. 701.4.10.3.1 Equipment. Methods and equipment for controlling the camera will be subject to approval from the engineer and achievement of a satisfactory video record.
5/1/2010
701-9
Drilled Shafts
701.4.10.3.2 Drawings. The contractor shall submit layout drawings to the engineer showing the relative position of all components of the television inspection system, including type and size of barge or other work area. The information submitted shall include a written description of the operating procedure in a step-by-step sequence and shall state the source of power. 701.4.10.3.3 Shaft Inspection. Inspection of a shaft by television camera shall be performed as directed by the engineer. The excavated shaft, including the rock socket when applicable, shall be thoroughly cleaned of all loose fragments, sediment and turbidity prior to inspection. The camera shall be operated such that optimum clarity of detail can be obtained and all surface areas of the shaft, including the rock socket and the rock socket’s base, can be observed. All scanning of the rock surfaces shall be recorded on videotape. After completion of the inspection of a rock socket, the engineer will direct whether or not drilling of the shaft shall be continued to a greater depth. All tapes shall be stored in proper containers with dust tight closures and shall be properly labeled as to shaft number along with project and contractor identification. Tapes shall be furnished to and shall become the property of the engineer upon completion of the work. 701.4.11 Foundation Inspection. NX size cores will be required for drilled shafts with rock sockets, where NX refers to the nominal diameter of rock core, and the NX core barrel has a 2⅛ inch inside diameter. The contractor may be directed to extend the rock socket to a lower elevation, resulting from the engineer’s evaluation of the foundation inspection cores. 701.4.11.1 Inspection for End Bearing Design. For drilled shafts that develop loadcarrying capacity in end bearing at the base of the rock socket, the contractor shall drill one NX size core for each rock socket to a depth of 10 feet below the bottom of the rock socket upon completion of the rock socket to the elevation shown on the plans, or as directed by the engineer. This requirement will also apply for rock socket designs that utilize a combination of end bearing and side friction. These rock cores will be used to determine the quality of founding material directly below the rock socket. When a casing method is used, foundation inspection holes may be drilled prior to rock socket excavation, if approved by the engineer. Foundation inspection holes may be drilled prior to shaft excavation if the contractor can establish, to the satisfaction of the engineer, that the method used shall place the NX size core directly below the tip of the rock socket. 701.4.11.2 Inspection for Side Friction Design. For drilled shafts that develop load carrying capacity through side friction only within the rock socket, the contractor shall drill one NX size core for each rock socket at a location directed by the engineer, to a depth of 10 feet below the bottom of the rock socket as shown on the plans or as directed by the engineer. These rock cores will be used to determine the quality of material of the rock socket sidewalls. Foundation inspection holes for rock sockets designed to provide side friction shall be drilled prior to rock socket excavation. 701.4.11.3 Log of Excavated Material. The contractor shall maintain a log of excavated material for each foundation inspection hole, and such logs shall be delivered to the engineer within 24 hours of completion of the boring. The log shall include the following: a) The amount of NX cored per run and the amount recovered. All core loss shall be noted and explained. Clay layers shall be noted and located on the log by depth.
5/1/2010
701-10
Drilled Shafts
b) The Rock Quality Designation (RQD) for the NX core. The bedding thickness and degree of weathering shall also be noted. c) For drilled shaft rock sockets that develop load-carrying capacity through side friction, one unconfined compression test per 5 feet of NX core, unless otherwise specified by the contract documents or directed by the engineer, shall be run on samples of NX core from the rock socket. The results of these tests shall be delivered to the engineer. Any effect on time of performance resulting from delays in delivery of the above test results to the engineer will be non-excusable. 701.4.11.4 Storage and Labeling of Rock Cores. Rock cores shall be stored in structurally sound core boxes and shall be protected from the elements. The core boxes shall be properly labeled to indicate location, depth, beginning elevation, contractor and date, and shall be delivered to the engineer. 701.4.12 Reinforcing Steel Cage Fabrication and Placement. The reinforcing steel cage, consisting of the longitudinal bars, ties, spirals, cage stiffener bars, spacers, centering devices, and other necessary appurtenances, shall be completely assembled as a unit, and shall be placed immediately after the shaft excavation is inspected and accepted, and just prior to shaft concrete placement. Temporary internal cage stiffeners shall be removed as the cage is placed in the shaft such that interference with the placement of concrete does not occur. 701.4.12.1 Reinforcing Ties, Splices and Clearances. All reinforcing steel in the shaft shall be double-wire tied and supported such that the steel remains within the allowable tolerances specified herein during placement of concrete or casing removal. With approval from the engineer, mechanical bar splices meeting the requirements specified in the contract documents may be used. Mechanical bar splices shall be staggered such that no more than 50 percent of the splices are within a 2-lap splice distance. Welding of reinforcing steel will not be permitted. The reinforcing steel cage shall have sufficient rigidity to prevent racking or permanent deformations during delivery or installation. Concrete Cover Shaft Diameter
Uncased
Casing Remains
Casing Withdrawn
2'-0" or less
3"
3"
4"
3'-0"
3"
3"
4"
4'-0"
4"
4"
4"
5'-0" or larger
6"
6"
6"
701.4.12.2 Spacers. Rolling spacers for reinforcing steel shall be used to minimize disturbance of the shaft sidewalls and to facilitate removal of the casing during concrete placement. Concrete spacers or other approved non-corrosive spacing devices shall be used at sufficient intervals, near the bottom and along the shaft at intervals not exceeding 5 feet, to ensure concentric location of the cage within the shaft excavation. When the vertical steel is greater than one inch in diameter, the maximum spacing may be increased to 10 feet. As a minimum, a set of spacers shall be provided within 2 feet of both the top and bottom of the shaft. In addition, one set of spacers shall be provided at both 2 feet above and below each change in shaft diameter. Non-corrosive spacers shall be provided at a minimum of one spacer per 30 inches of circumference of cage with a minimum of 5/1/2010
701-11
Drilled Shafts
three at each level to maintain the required reinforcement clearances. The spacers shall be of adequate dimension to maintain the specified clearance between the outside of the reinforcing cage and the side of the excavated hole or casing. 701.4.12.3 Bottom Supports. Approved non-corrosive bottom supports shall be provided for the reinforcing cage to ensure that the reinforcing is the correct distance above the bottom of shaft. The bottom supports shall not be used to support the weight of the cage. In the event that the shaft has been excavated below the anticipated tip elevation, the reinforcing cage shall be extended at the lower tip end by lap lengths for No. 11 bars or smaller or by use of mechanical connectors. Splices of adjacent bars will not need to be staggered in this situation and all of the reinforcing bars may be spliced at a given location. Reinforcement will not be required for the bottom 12 inches. 701.4.12.4 Durability of Spacers. Concrete spacers and bottom supports shall be constructed of concrete equal in quality and durability to the concrete specified for the shaft. Spacers fabricated from reinforcing steel shall be epoxy coated. 701.4.12.5 Protection of Reinforcing Cage. The reinforcing cage bottom supports shall be positioned such that the reinforcing steel is not allowed to come into contact with the soil or rock and to ensure that the bottom of the cage is maintained at the proper distance above the base as identified in the contract documents or directed by the engineer. 701.4.12.6 Check of Tolerances for Placement of Reinforcing Cage. The elevation of the top of the reinforcing cage shall be checked before and after the concrete is placed. The reinforcing cage shall be maintained within the specified tolerances, and the contractor shall make corrections to those tolerances, as required, to the satisfaction of the engineer. No additional shafts shall be constructed until the contractor has modified the reinforcing cage support to obtain the required tolerances. 701.4.13 Concrete Placement. 701.4.13.1 General Considerations. Accumulations of water in casings and excess sediment at the base shall be removed as described herein before the concrete is placed. No concrete shall be placed until all casings, if used, within a 15-foot radius have been installed. Within the 15-foot radius, all driving or vibratory installation methods shall be discontinued until the concrete in the last shaft has set at least five days. Concrete placement shall begin as soon as possible after completion of the excavation, inspection and setting of the reinforcing cage, and shall proceed in a continuous operation from the bottom of the shaft to the plan construction joint or above as specified herein. An unplanned stoppage of work may require an emergency construction joint during the shaft construction. 701.4.13.1.1 Placement of Concrete in the Shaft. Concrete shall be placed for each shaft with the flow of concrete directed down the center of the shaft. Concrete shall be placed by free fall or through a tremie or concrete pump. The free fall placement method will only be permitted in dry holes when approved by the engineer. The maximum height of free fall placement shall be 80 feet. Concrete placed by free fall shall fall directly to the base without contacting either the reinforcing cage or hole sidewall. Drop chutes may be used to direct concrete to the base during free fall placement.
5/1/2010
701-12
Drilled Shafts
701.4.13.1.2 Extent of Concrete Placement. Concrete placement shall continue after the shaft is filled until good quality concrete, as determined by the engineer, is evident at the plan construction joint at the top of the shaft and until a minimum of 18 inches of concrete, measured vertically, has been expelled. Immediately after concrete placement has been completed, all contaminated concrete and deleterious material accumulated above the top of shaft shall be removed to within one foot of plan top of shaft. Any concrete remaining above the top of shaft shall be carefully removed to the plan construction joint after curing and excess casing removal. 701.4.13.1.3 Time Limitations. The elapsed time from the beginning of concrete placement in the shaft to the completion of the placement shall not exceed two hours. All admixtures shall be adjusted for the conditions encountered on the job so the concrete remains in a workable plastic state throughout the two-hour placement limit. Prior to concrete placement, the contractor shall provide test results of both a trial mix and a slump loss test conducted by an approved testing laboratory using approved methods to demonstrate that the concrete meets the two-hour requirement. The contractor may request a longer placement time if a concrete mix is provided that will maintain a slump of 4 inches or greater over the longer placement time in the entire shaft as demonstrated by trial mix and slump loss tests. The trial mix and slump loss tests shall be conducted using concrete and ambient temperatures approved for site conditions. 701.4.13.1.4 Adequacy of Concrete Placement Method. Failure to demonstrate the adequacy of concrete placement methods or equipment during construction of any technique or production shafts will be cause for the engineer to require appropriate alterations in equipment or methods by the contractor to eliminate unsatisfactory results. Drilled shafts that are completed, but do not meet the concrete placement requirements, will be unacceptable. The contractor shall correct all unacceptable completed shafts to the satisfaction of the engineer at the contractor’s expense. 701.4.13.2 Concrete Placement by Tremie. Tremies used to place concrete shall consist of a tube of sufficient length to discharge concrete at the shaft base elevation. The tremie shall have sufficient weight to rest on the shaft bottom before the start of concrete placement and to prevent curling of the tremie line during placement of the concrete. The tremie shall not contain aluminum parts that may come in contact with the concrete. A tremie shall consist of a watertight tube having an inside diameter of no less than 10 inches and fitted with a hopper at the top. The inside and outside surfaces of the tremie shall be clean and smooth to permit both flow of concrete and unimpeded withdrawal during concrete placement. The tremie wall thickness shall be adequate to prevent crimping or sharp bends that restrict concrete placement. Tremies used for depositing concrete in a dry drilled shaft excavation shall be supported such that the free fall of the concrete is less than 80 feet at all times. 701.4.13.2.1 Adjustment of Concrete Free Fall or Rate of Concrete Flow. If the free fall concrete causes the shaft excavation to cave or slough, the contractor shall control the movement of concrete by reducing the free fall of the concrete or the rate of flow of concrete into the excavation. The contractor shall be responsible for proposing, developing, and after approval from the engineer, implementing corrective work.
5/1/2010
701-13
Drilled Shafts
701.4.13.2.2 Tremie Operation. Underwater placement of concrete shall not begin until the tremie is at the shaft base elevation. The discharge end of the tremie shall be constructed to permit the free radial flow of concrete during placement operations. The tremie discharge end shall remain immersed as deep as practical in the concrete, but shall be no less than 5 feet at all times. The tremie shall be supported such as to permit free movement of the discharge end over the entire top surface of the work and to permit rapid lowering when necessary to retard or stop the flow of concrete. The discharge end shall be sealed closed at the start of work to prevent water from entering the tube before the tube is filled with concrete. After placement has started, the level of the concrete in the tremie shall be maintained above the level of slurry or water in the borehole at all times to prevent water or slurry intrusion into the shaft concrete. If water enters the tube after placement is started, the tremie shall be withdrawn, the discharge end resealed, and the placement restarted. The flow of concrete shall be continuous until the work is completed. 701.4.13.2.3 Removal of Tremie Orifice from Concrete. If at any time during the concrete pour, when using the wet construction method, the tremie line orifice is removed from the fluid concrete column and discharges concrete above the rising concrete surface, the entire drilled shaft will be considered defective. In such a case, the contractor shall remove the reinforcing cage and concrete, complete any necessary sidewall cleaning or over-reaming as directed by the engineer, and repour the shaft. Corrections made by the contractor will be noncompensable and any effect on time of performance non-excusable. 701.4.13.3 Concrete Placement by Pump. Concrete pumps and lines may be used for concrete placement by either the wet or dry construction method. All pump lines shall have a minimum diameter of 5 inches and shall be constructed with watertight joints. Concrete placement shall not begin until the pump line discharge orifice is at the shaft base elevation. For the wet construction method, a plug or similar device shall be used to separate the concrete from the fluid in the hole until pumping begins. The plug shall either be removed from the excavation or shall be of a material that does not cause a defect in the shaft if the plug is not removed. The discharge orifice shall remain at least 5 feet below the surface of the fluid concrete. If at any time during the concrete pour the pump line orifice is removed from the fluid concrete column and discharges concrete above the rising concrete level, the shaft will be considered defective. In such a case, the contractor shall remove the reinforcing cage and concrete, complete any necessary sidewall cleaning or over-reaming as directed by the engineer, and repour the shaft. Corrections made by the contractor will be noncompensable and any effect on time of performance nonexcusable. 701.4.13.4 Drop Chutes. Drop chutes may be used to direct placement of free fall concrete down the center of the shaft excavations where the maximum depth of water does not exceed one inch. The free fall method of placement shall not be used in wet excavations. Drop chutes shall be a smooth tube constructed either as a continuous onepiece unit or as removable sections. Aluminum drop chutes will not be permitted. Concrete may be placed through either a hopper at the top of the tube or side openings as the drop chute is retrieved during concrete placement. The drop chute shall be supported such that the free fall of the concrete measured from the bottom of the chute is less than 80 feet at all times.
5/1/2010
701-14
Drilled Shafts
701.4.14 Construction Joints. Unless otherwise approved by the engineer, construction joints shall be made only where shown on the plans. All planned reinforcing steel shall extend uninterrupted through joints. Unless otherwise shown on the plans, horizontal joints may be constructed without keys. Surfaces of fresh concrete at horizontal construction joints shall be rough floated sufficiently to thoroughly consolidate the surface and to intentionally leave the surface in a roughened condition. Shear keys, if required, shall consist of formed depressions in the surface covering approximately one-third of the contact surface. 701.4.15 Concrete Protection and Curing. For at least 48 hours after shaft concrete has been placed, no construction operations that will cause soil movement adjacent to the shaft shall be conducted, except for movement of light construction equipment. Portions of drilled shafts exposed to a body of water shall be protected from the action of water by leaving the forms in place for at least seven days after concrete placement or until the shaft concrete reaches a minimum strength of 2500 psi. After placement, the temporarily exposed surfaces of the shaft concrete shall be cured to prevent loss of water by use of one or more of the approved methods. Curing shall be in accordance with Section 502. 701.4.16 Construction Tolerances. During excavation of the shaft, the contractor shall make frequent checks on the plumbness, alignment and dimensions of the shaft. Any deviation exceeding the allowable construction tolerances specified herein shall be corrected with a procedure approved by the engineer. Drilled shaft excavations constructed in such a manner that the concrete shaft cannot be completed within the required tolerances will not be accepted. Correction methods shall be submitted by the contractor for the engineer’s approval. Drilled shaft construction shall not begin until approval has been obtained. When a shaft excavation is completed with unacceptable tolerances, the contractor shall propose, develop and, after approval from the engineer, implement corrective work. Redesign drawings and computations submitted by the contractor shall be signed by a professional engineer registered to practice in the State of Missouri. The following construction tolerances will apply to drilled shafts unless stated otherwise in the contract documents: a) Temporary casing diameters shall provide a final shaft diameter as shown on the plans. When approved by the engineer, the contractor may provide a larger casing at the contractor’s expense. b) Shafts shall be constructed such that the center of the top of the shaft is within 3 inches of plan position in the horizontal plane at the plan elevation for the top of the shaft. c) The vertical alignment of a vertical shaft excavation shall not vary from the plan alignment by more than ¼ inch per foot of depth. The alignment of a battered shaft excavation shall not vary by more than ½ inch per foot of the distance along the axis of the shaft from the prescribed batter. d) After all the shaft concrete is placed, the top of the reinforcing steel cage shall be no more than 6 inches above and no more than 3 inches below plan position. e) The top elevation of the shaft shall be no more than one inch above or 3 inches below the plan top of shaft elevation. f) The bottom of the shaft excavation shall be normal to the axis of the shaft within a tolerance of ⅜ inch per foot of shaft diameter. 5/1/2010
701-15
Drilled Shafts
701.4.17 Integrity Testing. The completed shaft shall be subjected to the specified testing methods, such as concrete coring or sonic logging testing, to determine the extent of any defects that may be present. Work and material required for testing shall be furnished by the contractor and will be paid for in accordance with the contract documents. If testing reveals voids or discontinuities in the concrete that, as determined by the engineer, indicate that the shaft is not structurally adequate, the shaft will be rejected. The contractor shall then repair, replace or supplement the defective shaft in a method approved by the engineer. The construction of additional drilled shafts shall be discontinued until the contractor demonstrates the adequacy of the shaft construction method to the satisfaction of the engineer. Any additional work required by the contractor as a result of shaft defects will be noncompensable and any effect on time of performance non-excusable. 701.4.17.1 Concrete Coring. At locations where concrete coring is to be provided, as indicated in the contract documents or as directed by the engineer, the following will apply. Upon completion of placing concrete and after waiting a minimum of 48 hours, the top surface of concrete shall be cleaned of laitance and any unsound concrete, and then one core hole shall be drilled completely through the shaft concrete and the rock socket to approximately one foot below the bottom of the rock socket of each shaft. Provisions for the inspection of the concrete surface shall be in accordance with the applicable requirements described herein. Core holes shall be drilled at locations specified by the engineer. The holes shall be drilled to recover NX size cores. The core samples recovered shall be labeled as to the location from which the samples were taken. The samples shall be delivered to the engineer for examination. If the cores indicate defective concrete in the shaft, which in the judgment of the engineer impairs the strength of the completed shaft, the contractor shall drill additional cores as directed by the engineer. If the concrete is found to be defective, the contractor shall submit to the engineer in writing a proposal for correction, and those corrective procedures shall be approved by the engineer before such corrective work is undertaken. The cored holes in non-defective concrete shall be filled with grout such that all voids are filled. All grout used for core holes shall be in accordance with Section 1066. No direct payment will be made for grout and grouting. 701.4.17.2 Sonic Logging Testing. The contractor shall perform non-destructive integrity testing on completed drilled shafts and rock sockets using the cross-hole sonic logging (CSL) method for concrete drilled shafts. The tests shall be conducted as indicated on the plans or other contract documents, or as directed by the engineer. Sonic logging measurements and data interpretation shall be performed by a CSL consultant with at least two years of experience in CSL drilled shaft testing. The contractor shall submit the testing organization experience record to the engineer, along with a written description of the testing procedures, operation manuals for the testing equipment, and samples of previous test results indicating both sound and defective concrete. The contractor shall inform the engineer of scheduled test dates at least seven days prior to CSL testing. The contractor shall provide reasonable access to the shaft top for performance of the sonic logging testing. 701.4.17.2.1 Installation of Pipes. The contractor shall furnish and install 2-inch nominal inside diameter steel pipes, ASTM A 53, Standard Weight, for use in sonic testing of each drilled shaft. Pipes shall be installed in each drilled shaft at the locations shown on the plans, as required by the testing agency or as directed by the engineer. The pipes shall be sufficiently regular and free from defects to permit the 5/1/2010
701-16
Drilled Shafts
free and unobstructed passage of the probes. The pipe shall be installed such that all internal joints are flush. Stiffening devices such as mandrels, tape or similar material to seal the joints shall not be used. Pipe shall be watertight with clean internal and external faces, the latter to ensure a good bond between the concrete and the pipes. The pipes shall be fitted with a screw-on watertight shoe and cap and shall be securely fixed to the interior of the reinforcement cage with a minimum cover of 3 inches from the shaft periphery. The pipes shall be as near to parallel as possible, equally spaced and vertical. Where several sections of pipe are required to reach the full length, joints shall be made watertight. The pipes shall be filled with water and plugged or capped before shaft concrete is poured. The upper end of the pipe shall not be left open after the pour. The pipes shall extend at least 3 feet above the top of the concrete in the shaft to compensate for water displaced by insertion and removal of the transmitter, receiver, and cable. For shafts with a rock socket, the lower end of the pipes shall extend to the bottom of the rock socket. Care shall be taken during the drilled shaft concrete pour to not damage the pipes. If a tremie is used, the tremie shall not be permitted to rest on top of the pipes during the pour. After completion of the sonic logging and final acceptance of the drilled shaft, the contractor shall fill the access pipes with grout. 701.4.17.2.2 Sonic Logging Equipment. The sonic logging equipment furnished by the CSL consultant shall consist of all necessary supplies, support equipment and power to perform the sonic logging testing requirements as described herein. 701.4.17.2.3 Sonic Logging Test Procedure. The drilled shaft shall be tested between 2 and 40 days after concrete placement. The following procedures shall apply: a) Pipes shall be checked to ensure the pipes are free from blockages and are filled with water. b) Levels shall be taken on top of each pipe, each pipe shall be plumbed and the length shall be recorded. c) Testing shall be performed between each pair of adjacent pipes around the shaft perimeter and also in pairing combinations between each pipe with all other pipes in the shaft. d) All tests shall be carried out with the probes in the same horizontal plane unless the engineer directs that defects be further evaluated with the probes on different horizontal planes. e) The probes shall be raised simultaneously from the bottom of the pipes ensuring that all slack is taken out of the cables before the analyzer is switched on, and that the distance between transducers remains constant during the course of the test. The speed of ascent shall be less than 12 inches per second. Measurements shall be taken at 3-inch intervals or less. Anomalies indicated by longer pulse first-arrival times (FAT) and significantly lower amplitude per energy signals shall be reported. If anomalies are detected, additional tests with two or more sources per receiver vertical offsets of greater than or equal to 20 inches shall be conducted between the same tubes unless the anomaly is within 20 inches of the bottom of the shaft. 5/1/2010
701-17
Drilled Shafts
f) The contractor shall provide accurate measurements of probe depths on the logs. 701.4.17.2.4 Record of Testing. Preliminary results of the testing shall be provided on site prior to the CSL consultant leaving the site. A detailed CSL report and test data shall be submitted to the engineer within seven days. The CSL report shall be signed and sealed by a Professional Engineer. The CSL report shall include, but is not limited to, the following: project identification and dates of testing, a table and schematic showing shafts tested with accurate identification of tube coordinates and collar elevation, name of personnel that performed the tests and interpretation and those personnel’s affiliation, equipment used, data logs, interpretation, analysis, and results. The data logs shall include XY plots of FAT, amplitude and velocity versus depth. CSL data shall be processed to provide easy to understand 2D cross-sections between tubes for all tube pair combinations. These plots shall be annotated by the CSL consultant as appropriate to delineate anomalous results. If offset surveys are performed as part of 3D tomography, data plots shall include 3D volumetric images for the entire shaft, color-coded, to indicate velocity variations along the shaft. Locations and geometry of anomalies or unconsolidated zones shall be identified in 3D color images with detailed discussion. The results for CSL and 3D surveys shall be based on the percentage decrease in velocity as correlated to the following Concrete Condition Rating Criteria (CCRC). The velocity datum of good concrete shall be established by averaging the velocities in the good concrete along the drilled shaft. Deviations from the velocity datum shall be used for determining the Concrete Condition Rating. Concrete Condition Rating Criteria
5/1/2010
Concrete Condition Rating
Rating Symbol
Velocity Reduction
Good
G
0 to 10%
Questionable
Q
10% to 25%
Poor
P/D
>25%
Water
W
V= 4760 to 5005 ft./sec
No Signal
NS
No signal received
701-18
Indicative Results
Acceptable concrete Minor concrete contamination or intrusion. Questionable quality concrete Defects exist, possible water slurry contamination, soil intrusion, and or poor quality concrete. Water intrusion, or water filled gravel intrusion with few or no fines present. Soil intrusion or other severe defect absorbed the signal, tube debonding if near top.
Drilled Shafts
701.4.17.2.5 Correction of Unacceptable Results. The contractor shall immediately inform the engineer of any suspected anomalies, honeycombing or poor concrete quality detected by testing. The contractor and CSL consultant shall duly perform further tests as directed by the engineer to evaluate the extent of any detected anomalies. Core drilling, or other investigative methods as approved by the engineer, shall be performed to further investigate the anomaly. If a defect is confirmed, the contractor shall bear all costs involved with the shaft coring, grouting and remediation. Within 14 days of the completion of testing, the contractor shall provide a report signed and sealed by a Professional Engineer registered in the State of Missouri providing the results of the additional investigations and recommendations to accept or repair the shaft. The report shall also contain recommendations for modification of construction procedures to prevent defects for subsequent shaft installations. The dates of the completion of drilling, cleaning, steel placement and concrete pour shall also be provided. Construction above the top of shaft shall not be performed until the shaft has been accepted by the engineer. 701.5 Drilled Shaft Load Tests. All load tests, when required by the contract documents, shall be completed and submitted to the engineer for review and approval before construction of any production drilled shafts. The locations of load test shafts, the maximum loads to be applied, the test equipment to be furnished by the contractor, and the actual sequence of the load testing shall be as shown on the plans or as specified in the contract documents. After completion of testing, test shafts not used as production shafts shall be cut off at an elevation 3 feet below the finished ground line. The portion of shafts cut off shall be disposed of by the contractor, at the contractor's expense, in a manner approved by the engineer. 701.6 Method of Measurement. 701.6.1 Drilled Shaft. Accepted drilled shafts will be measured for payment to the nearest 0.10 linear foot of length along the axis of each shaft complete-in-place. For shafts without a rock socket, measurement will be from the plan top of the shaft elevation to the bottom of the shaft. For shafts with a rock socket, measurement will be from the plan top of the shaft to the top of the rock socket. "Top of the rock socket" will be defined as the upper elevation at which sound rock occurs across the entire width of the shaft, as determined by the engineer. Reinforcing steel will be measured for payment in accordance with Section 706. 701.6.2 Rock Socket. The accepted rock sockets, if required, will be measured for payment to the nearest 0.10 linear foot of length along the axis of each rock socket in-place from the top of sound rock elevation, as determined by the engineer and in accordance with Section 701.6.1, to the bottom of the rock socket as built. In the event that additional rock socket construction is directed by the engineer, the additional length will be measured to the nearest 0.10 linear foot. Reinforcing steel will be measured for payment in accordance with Section 706. 701.6.3 Technique Shafts. Accepted technique shafts, if required, will be measured for payment to the nearest 0.10 linear foot of length along the axis of each shaft in-place from the plan top of the shaft elevation to the bottom of the rock socket or shaft as built for each size of acceptable technique shaft drilled, including rock socket. Reinforcing steel will be measured for payment in accordance with Section 706.
5/1/2010
701-19
Drilled Shafts
701.6.4 Television Camera Inspection. Payment for one complete television camera inspection of each shaft, including the rock socket when applicable, will be included in the payment for drilled shafts. Any additional television inspections required by the engineer due to extending the rock socket to a greater depth or when supplementary inspections are required by the engineer and no defects are found, will be measured for payment as supplementary television camera inspection, per each. 701.6.5 Foundation Inspection Holes. Measurement for payment for foundation inspection holes will be to the nearest 0.10 linear foot of length along the axis of each hole by the linear foot. For shafts designed in side friction, measurement will be from the top of the rock socket to the bottom of the foundation inspection hole. For shafts designed in end bearing, measurement will be from the bottom of the rock socket to the bottom of the foundation inspection hole. If the engineer directs foundation inspection borings more than 10 feet below the anticipated bottom of the rock socket elevation as shown on the plans, measurement for payment for that portion of the boring in excess of 10 feet below anticipated bottom of the rock socket elevation as shown on the plans will be to the nearest 0.10 linear foot of excess. 701.6.6 Concrete Coring. Measurement for payment for concrete cores will be to the nearest 0.10 linear foot of length along the axis of the shaft from the top of concrete to a point as determined by the engineer, and may extend the entire length of the shaft plus one foot below the bottom of the rock socket. 701.6.7 Sonic Logging Testing. Sonic logging testing of drilled shafts, as required, will be measured for payment per each. 701.6.8 Drilled Shaft Load Tests. Load tests will be measured for payment per each load test performed. 701.7 Basis of Payment. 701.7.1 Drilled Shaft. Payment will be considered full compensation for all steel casing required, costs of drilling, excavation, slurry, cleaning, an acceptable method of inspection as required, furnishing and placing concrete, grouting and incidental work and material required by the contract documents. Payment for any drilled shaft installed and accepted will be at the contract unit price per linear foot for the diameter of the drilled shafts specified, irrespective of the character of the material actually encountered during excavation. No additional compensation will be made for concrete required to fill an oversized casing or for oversized excavation. If the method of construction requires that drilled shaft casing be seated into the sound rock such that the bottom of the casing is below the determined top of sound rock elevation, payment for excavation below the top of the sound rock layer (top of the rock socket) will be included in the payment for the rock socket. If sound rock is encountered within the excavation at which point a rock auger, core barrel or other rock-removing specialty tool must be used by the contractor before the top of the sound rock elevation to be used as "top of the rock socket" is confirmed by the engineer, that work will be paid for as rock socket excavation. Payment for reinforcing steel will be in accordance with Section 706.
5/1/2010
701-20
Drilled Shafts
701.7.2 Rock Socket. Payment will be considered full compensation for drilling, excavation, slurry, cleaning, dewatering, an acceptable method of inspection as required, furnishing and placing concrete, and incidental work and material according to the contract documents. For payment purposes the length of any rock socket installed and accepted shall be paid for at the contract unit price per linear foot for the diameter of the rock socket specified, irrespective of the character of the material actually encountered during excavation. In the event that the engineer orders additional rock socket construction, payment for the additional length will be at the rate of 150 percent of the contract unit price per linear foot of rock socket up to a maximum additional length of 8 feet. Any work necessary to extend the length of the rock socket more than the additional 8 feet, will be paid for as changes in the work in accordance with Section 104.3. Payment at the adjusted rate will be considered full compensation for the additional excavation into rock, all additional concrete, except reinforcing steel, including any and all splices, and all incidentals necessary to complete the work down to the elevation designated by the engineer. Reinforcing steel will be paid for in accordance with Section 706. 701.7.3 Technique Shafts. Payment for technique shafts will be in accordance with the contract unit prices for the appropriate drilled shaft and rock socket diameters. Payment will be considered full compensation for any steel casing required, all costs of drilling, excavation, an acceptable method of inspection as required, furnishing and placing concrete, grouting and incidental work, and material necessary to satisfactorily construct the technique shafts according to the contract documents. Reinforcing steel will be paid for in accordance with Section 706. 701.7.4 Unexpected Obstructions. Contract adjustment, in time or amount, resulting from encountering any obstructions in the work covered by Section 701 will be made only if the obstruction constitutes a differing site condition, as defined by the contract. Contract adjustments will be determined only under the terms of the contract for adjustments in time or compensation due to encountering a differing site condition. Contract adjustments will be allowed only to the extent, in type and amount of contract adjustment, that such adjustment is expressly allowed for or permitted by the contract documents, specifically: (1) Sections 109.4 through 109.4.3 for cost adjustment; (2) Section 109.11 for any compensable delay to the work to deal with the obstruction, but not for any effect upon the unchanged work; and (3) Section 108.14 to determine any adjustment in contract time. 701.7.5 Television Camera Inspection. Payment for one complete television camera inspection of each shaft, including the rock socket when applicable, will be included in the payment for drilled shafts. Any additional television inspections required by the engineer due to extending the rock socket to a greater depth, or when supplementary inspections are required by the engineer and no defects are found, will be paid for at the contract unit price for supplementary television camera inspection, per each. Payment will not be made for supplementary television camera inspections that reveal defects due to the contractor’s operation. Payment for television camera inspection will be considered full compensation for moving in equipment, flushing turbid water from the shaft, conducting the actual scanning as specified, furnishing video tape, removing equipment, and all tools, labor and any incidentals necessary to complete the work. The number of supplementary television camera inspections may vary from the estimated quantities, but the contract unit price shall prevail regardless of the variation.
5/1/2010
701-21
Drilled Shafts
701.7.6 Foundation Inspection Holes. Payment for foundation inspection holes will be at the contract unit price and will be considered full compensation for drilling or coring the holes, extracting and packaging the samples or cores, laboratory testing, delivering the samples or cores to the specified location and for all other expenses necessary to complete the work. If the engineer directs foundation inspection borings more than 10 feet below the anticipated bottom of rock socket elevation as shown on the plans, payment for that portion of the boring in excess of 10 feet below the anticipated bottom of the rock socket elevation as shown on the plans will be at the rate of 150 percent of the contract price per linear foot of excess. If, for shafts designed in end bearing, the foundation inspection hole is drilled prior to shaft construction or prior to rock socket excavation, coring of the rock above the bottom of the rock socket will be noncompensable. 701.7.7 Concrete Coring. Payment for concrete coring will be considered full compensation for all material, labor, tools, equipment, grouting and incidentals necessary to complete the work. The number of feet of cored holes may vary from the estimated quantities, but the contract unit price shall prevail regardless of the variation. 701.7.8 Sonic Logging Testing. Payment for sonic logging testing of drilled shafts as required by the engineer will be made at the contract unit price per each for sonic logging testing. No payment will be made for supplementary sonic logging testing to evaluate defects. Payment for sonic logging testing will be considered full compensation for providing all equipment, access pipes, conducting the actual probing measurements as specified, furnishing reports, removing equipment, and all tools, labor and any incidentals necessary to complete the work. The number of sonic logging inspections may vary from the estimated quantities, but the contract unit price shall prevail regardless of the variation. 701.7.9 Drilled Shaft Load Tests. Payment will be at the contract unit price and will be considered full compensation for all costs related to the performance of the load tests as specified by the contract documents. 701.7.10 Welding Inspection. If evidence of poor welding is found, radiographing or other non-destructive testing of welds required by the engineer will be noncompensable and any effect on time of performance non-excusable.
5/1/2010
701-22
Drilled Shafts
Section 702
Bearing Pile
702.1 Description. This work shall consist of furnishing and driving concrete, steel, and timber piles to the bearing and penetration required, at the location shown on the plans. 702.2 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item Section Reinforcing Steel for Concrete .......................................................................... 1036 Item Specification Steel Strand ......................................................................................AASHTO M 203 Cast In Place Pile Shells (Thick Shell Type) Welded or Seamless Steel Pipe ................................................ ASTM A 252 Closure Plates ......................................................................AASHTO M 270 Fluted Pipe .......................................................................... SAE-1010 or SAE-1015 Forged Steel Tips or Noses ....................................................................... SAE-1020 Structural Steel Pile .........................................................AASHTO M 270, Grade 50 702.2.1 Cast-In-Place Concrete Piles. Cast-in-place concrete piles shall consist of Class B-1 concrete cast in pre-driven metal shells. The metal shells shall conform to the shape, size and minimum shell thickness shown on the plans, or to an approved equivalent section. All materials, proportioning, air-entrainment, mixing, slump, and transporting of Portland cement concrete shall be in accordance with Section 501. Metal shells driven with or without a core or mandrel shall be of sufficient thickness or shall be reinforced so that they will hold their original form without distortion after being driven. Metal pile shells shall be free from water, soil, and other deleterious matter when concrete is cast in them. The contractor shall maintain on the job at all times prior to and during the filling of the shells, a light suitable for use in their inspection. 702.2.2 Structural Steel Piles. Structural steel piles shall be of the series rolled as Hbearing piles. They shall be of the size, weight, and structural shape designated on the plans. Piles shall not have a camber or sweep in excess of ⅛ inch multiplied by the length of pile in feet divided by 5. Steel piles shall be stored on platforms, skids, or other supports at the site of the work and shall be supported at not more than 15-foot intervals. 702.2.4 Pile Lengths. The pile lengths shown on the plans are approximate. The contractor shall be fully responsible for the lengths he furnishes for driving to obtain the specified penetration and bearing. Sub-surface investigations made by the County are for design purposes only.
12/12/2012
702-1
Bearing Pile
702.2.5 Test Piles. Test piles shall be the same material and size as the permanent piles, except that if treated timber piles are specified for the structure, untreated timber test piles may be used if not driven in a permanent location. Test piles of precast concrete shall, in general, be driven in permanent position. Test piles shall be of such length as to permit driving the tips to an elevation 10 feet below that indicated by plan lengths unless otherwise specified. 702.2.6 Certifications. For structural steel piles and thick shells for cast-in-place piles, the contractor shall furnish two copies of a certification from the pile manufacturer or fabricator setting out the designated specifications with which the material complies. Heat numbers must be clearly shown on each pile at time of installation and must match certifications. 702.2.7 Precast Concrete Piles. Precast concrete piles shall be manufactured of Class A-1 concrete to the shape and size shown on the plans or to an approved equivalent section. All materials, proportioning, air-entrainment, mixing, slump, and transporting of Portland cement concrete shall be in accordance with Section 501. Precast piles shall be straight, with a centerline variation of not more than ½ inch / 25 feet of length of pile. Precast concrete piles shall be lifted and handled by a suitable bridle attached to the pile at points shown on the plans. Unless the concrete is steam cured in accordance with Section 703.3.17, removal of precast concrete from casting beds shall not begin for at least 48 hours after casting and not then until a compressive strength of 1,500 psi has been attained. If the concrete is steam cured, removal shall not begin until a compressive strength of 1,500 psi has been attained. Curing shall be continued for at least 24 hours after a compressive strength of 2,400 psi has been attained. Precast piles shall not be transported or driven until at least 7 days after casting and then only if the compressive strength of 2,400 psi has been attained. Compressive strength of concrete shall be determined by tests of standard cylinders made of concrete from the same batches and cured in the same manner as the piles. 702.2.8 Precast-Prestressed Concrete Piles. Precast-prestressed concrete piles may be furnished in lieu of precast concrete piles. They shall be manufactured in accordance with Section 705 using Class A-1 concrete. End anchors shall not be released until the concrete has attained a compressive strength of 4,000 psi as determined by tests of standard cylinders made of concrete from the same batches and cured in the same manner as the piles. 702.3 Equipment. 702.3.1 Driving Equipment. The contractor shall furnish pile driving equipment adequate for handling the length of pile to be placed in the leads and for driving the total length of pile to the tip penetration and bearing required. Piles shall be driven with power-driven hammers, or by a combination of power-driven hammer and water jets. Power-driven hammers are defined as hammers operated by steam, air, or diesel power. For determining the energy per blow of diesel power hammers without a fully enclosed ram, 75 percent of the manufacturer's energy rating for the hammer will apply. If the contractor desires to check a diesel power hammer against an approved steam hammer on a specified type of pile at a particular site, he may do so at his expense, and the checked rating of the diesel powered hammer will be used in determination of pile bearing values at that site. Diesel hammers which have a fully enclosed ram shall be equipped with a gauge and accompanying charts which evaluate the equivalent manufacturer's rated energy being produced under any driving condition.
12/12/2012
702-2
Bearing Pile
702.3.2 Leads. Pile driver leads shall be constructed in such manner as to afford freedom of movement of the hammer, and they shall be held in position by guys or stiffener braces to insure support to the pile during driving. Inclined leads shall be used for the driving of battered piles. 702.3.3 Followers. Followers may be used in the driving of piles only if approved in writing by the engineer. When a follower is used, one pile of every group of 10 shall be driven without a follower to determine the available bearing value of the group. 702.3.4 Water Jets. Water jets used to aid in driving piles shall be sufficient in number to deliver a volume and pressure of water at the jet nozzles that will freely erode the material adjacent to the pile. The use of water jets shall be discontinued before the final penetration is reached, and the piles shall be driven to secure a final penetration of not less than 2 feet if the nature of the soil permits. 702.3.5 Hammer Energy. The minimum energy of hammer shall not be less than shown in Table 1.
Table 1 - Hammer Energy Type of Pile
Energy Required Foot Pounds (minimum)
Steel Shells for Cast-in-Place
3 times the weight in pounds, including mandrel if used, being driven, but not less than 8,000.
Structural Steel
The largest of the following: a) 3 times the weight being driven, in pounds. b) 225 times the bearing value, in tons. c) 8,000.
Precast Concrete
Weight being driven, in pounds, but not less than 8,000.
Timber
8,000
702.3.6 Concrete Testing Equipment. Equipment for field determination of compressive strength of concrete shall be furnished by the contractor at the location of manufacture of precast and precast-prestressed piles. The contractor shall furnish a sufficient number of compression test cylinder molds of a type meeting the approval of the engineer. The contractor shall furnish sufficient personnel for cleaning and preparing reusable molds. The testing machine may be of any mechanical or hydraulic type capable of applying and measuring the required load and shall comply with the accuracy tolerances and corrections specified in AASHTO T 67-74, Section 17.1 and Section 18. Approximately the last one-half of the load shall be applied at a rate of between 1,200 and 3,000 psi per minute.
12/12/2012
702-3
Bearing Pile
702.4 Construction Requirements. 702.4.1 Test Piles. The contractor shall furnish and drive test piles at locations designated. Where required, test piles shall be driven full length, or to refusal, or to a capacity 50 percent greater than that required on the design plans. In all cases the test piles shall be driven to not less than the minimum tip elevation shown on the plans for permanent piles. Test piles shall be driven with the same type of equipment as will be used for driving the permanent piles. Before driving test piles, the excavation shall be completed to an elevation not more than 2 feet above the proposed grade at the point where a test pile is to be driven. Test piles not driven in a permanent location shall be cut off, or pulled and backfilled, as approved by the engineer. 702.4.2 Bearing Piles. Foundation piles shall not be driven until after the excavation for the footing has been substantially completed. The heads of piles shall be protected against damage during driving. The procedure incident to the driving of piles, shall not subject them to excessive and undue abuse. Any pile broken or damaged by reason of internal defects or by improper driving, or driven out of its proper location shall be removed and replaced, or a second pile may be driven adjacent thereto if this can be done without detriment to the structure. 702.4.3 Preboring. Where piles are to be driven through more than 5 feet of compacted embankment, whether constructed under this contract or a previous contract, prebored holes will be required entirely through the embankment to the lowest elevation of the natural ground line adjacent to the embankment, or as designated on the plans. The holes shall be of a diameter not less than that of the pile. The space remaining around any type pile after it is driven shall be completely filled with a non-excavatable ready-mix flowable fill (controlled low strength material) having a compressive strength as shown in Section 625. Other locations where preboring for piles shall be required will be shown on the plans. At such locations, holes shall be prebored to the elevation specified prior to pile placement. The holes shall have a diameter not less than that of the pile and shall be large enough to avoid damage to the pile being driven through the hole in hard material. The size of the hole shall be approved by the engineer before preboring is started. Pilot holes of lesser diameter than the pile shall not be extended below the pile tip. After the pile is placed in the hole and before driving begins, the space remaining around the pile shall be filled with sand or other approved material before and maintained full during the driving of the pile. The pile shall then be driven in accordance with the requirements of Section 702.4.11. 702.4.4 Pile Placement Tolerances. Final position of piles shall be not more than ¼ in./ft. from the vertical or from the batter line shown on the plans. The maximum variation of the head of the pile from the position shown on the plans shall be not more than 2 inches, except that piles in footings entirely below the finished ground line may vary not more than 6 inches. All piles pushed up by the driving of adjacent piles, or by any other cause, shall be re-driven to required bearing and penetration. Improperly driven, broken, or otherwise defective shells shall be removed and replaced, or otherwise corrected to the satisfaction of the engineer.
12/12/2012
702-4
Bearing Pile
702.4.5 Pile Point Reinforcement. This item shall consist of furnishing and installing manufactured pile point reinforcement on structural steel piles at locations as noted on the plans and in accordance with the applicable provisions of Section 712 except as modified by these Special Provisions. Each point shall be made in one (1) piece of (x) Cast Steel with the minimum web and flange thickness being (t) times that portion of the pile being attached thereto. Materials (x)
Thickness (t)
ASTM A27 65/35 ................................................................................... 2.0 ASTM A148 90/60 ................................................................................. 1.6 The point shall extend onto the pile a minimum of one-half inch (½") for both faces of the web and for the end one-fourth of the inside face of each flange. The web portion of the point shall protrude a minimum of 0.2 times the flange width below the pile with the flange portion transitioning to a protrusion of not less than its thickness at the extreme ends. The point shall be attached to the pile with a full penetration weld along each flange. Weld backing shall be furnished for the total width of each flange, whether it is totally by point extension or combination of point extension and attached backing plate. The point extension onto the web of the pile may be omitted if alternating one and one-half inch by one-fourth inch (1½" x ¼") fillet welds are placed on each side of the web. Welding of the point to the pile shall be by an experienced welder. Properly dried low hydrogen electrodes of the E70XX series shall be used with adequate protection from the elements as set forth in Section 1080. The contractor shall be fully responsible for the adequacy of the welds during driving. Payment for the above described work, including all materials, equipment, labor and any other incidental work necessary to complete this item, shall be considered as completely covered by the contract unit price for "Pile Point Reinforcement", per each. 702.4.6 Splices. Extending and splicing of piles is not desirable and full-length piles shall be driven wherever possible and practicable. The number of splices used shall be held to a minimum. If extensions and splices are permitted or required by the engineer, they shall be made as follows: 702.4.6.1 Steel shells and structural steel piles shall be spliced by a certified welder. Properly dried low-hydrogen electrodes of the E7018 series shall be used with adequate protection from the elements as set forth in Section 1081. The contractor shall be fully responsible for the adequacy of welds during driving. Steel shells for cast-in-place concrete piles shall be spliced as shown on the plans. Sections used for splicing shall be at least 5 feet in length, and not more than two splices per pile shell will normally be permitted. Structural steel piles shall be spliced with a butt-weld as shown on the plans. The contractor will be permitted to furnish lengths of structural steel piles which incorporate not more than one splice per pile for lengths up to and including 40 feet. Not
12/12/2012
702-5
Bearing Pile
more than two splices will be permitted in each pile furnished for lengths exceeding 40 feet. In preparation of piles prior to driving the use of individual sections less than 8 feet in length will not be permitted. Additional field splices necessary to extend structural steel piles to reach adequate bearing material shall, as far as practicable, be limited to one per pile. 702.4.6.2 Precast and precast-prestressed concrete piles driven below plan elevations shall be extended by build-up construction. The forms for extensions of concrete piles shall remain in place at least 24 hours. 702.4.6.3 Timber piles driven below plan elevations shall be withdrawn and replaced by longer piles or, if approved in writing by the engineer, they may be spliced. If splices are permitted, they shall be of the butt-joint type. The added piece shall conform closely in diameter to that of the main pile at the point of splice. Piles shall be sawed square and the butt joints shall bear evenly over the entire surface. The joint shall be banded with a 4-foot length of iron pipe at least 12 inches in diameter, centered on the joint, and held in position by ⅝ inch lag screws 6 inches long, with three lag screws in the pile and three in the splice. The sawed and trimmed surfaces of treated piling shall be given two heavy brush coats of copper napthenate before the splice is assembled. 702.4.7 Cut-Offs. Tops of all piles shall be cut off square at cut-off elevations. Pile tops which support timber caps or grillages shall conform to the plane of the bottom of the superimposed structure. The heads of all treated timber piles shall be covered with a protective cap made by applying a coat of hot roofing pitch and a sheet of 0.024 inch galvanized metal. The cap material shall measure at least 6 inches more in diameter than the diameter of the pile, and shall be bent down over the pile, and the edges neatly trimmed and secured with large head galvanized or copper nails. Payment for compliance with this section will be included in the price for pile in place. 702.4.8 Protective Coatings. Before the coatings are applied, the steel shall be thoroughly cleaned. Steel shells and structural steel piles in end bents shall be coated with a heavy coating of an approved bituminous paint applied for a length of 3 feet below the bottom of the concrete cap. All exposed steel piles shall be coated with bituminous paint 3 feet below and 1 foot above the finished ground line. All other exposed surfaces of steel shells and structural steel piles, including bracing, shall be painted in accordance with Section 1081. Protective coatings below the normal low water line will not be required. 702.4.9 Time Restrictions. Concrete footings shall not be placed on cast-in-place piles until at least 12 hours after the last pile in the footing has been cast. No piling shall be driven within a radius of 20 feet of concrete that has taken initial set and has not attained a compressive strength of at least 1,500 psi.
12/12/2012
702-6
Bearing Pile
702.4.10 Dynamic Bearing Formulae. The following formulas shall be used to determine the nominal (ultimate) bearing value of piles when other methods of determination are not specified in the contract documents: P = 1.75(E)0.5log10(10N) – 100 P = Nominal Axial Pile Compressive Resistance value or 2.5(Design Bearing value) measured during pile driving in kips. E = Developed hammer energy in foot-pounds. This is the kinetic energy in the ram at impact for a given blow and may be assumed equal to the ram weight times the stroke. N = Number of hammer blows for 1.0 inch of pile permanent set in blows/inch. 702.4.10.1 The above formulas will be applicable only if: a) The hammer has an unrestricted fall. b) The pile head is not broomed, crushed or splintered. c) There is no appreciable bounce of the hammer after striking the pile. d) The penetration is at a uniform or uniformly decreasing rate. 702.4.10.2 For piles driven to a batter, the normal (ultimate) allowable bearing value, P, in the equations provided in Section 702.4.10 shall be divided by the pile batter factor, B, in order to calculate the value of N, the number of hammer blows for 1.0 inch of pile permanent set. B =
0.1 (10 - m) , pile batter factor (1 +m2)
m =
the tangent of the angle of batter to a vertical line
702.4.11 Minimum and Maximum Limits of Pile Driving. Piles shall be driven to the minimum penetration indicated on the plans. If no minimum penetration is shown on the plans, piles shall have a tip elevation of at least 10 feet below the bottom of the supported footing or 10 feet below the natural ground line, whichever is lower, unless specifically authorized otherwise by the engineer. Piles other than structural steel piles shall be driven to attain a bearing value not less than that shown on the plans, determined in accordance with Section 702.4.10. Structural steel piles shall, in general, be driven to practical refusal which is defined as a pile bearing value of 1.9 times the design bearing value. In general, timber piles shall not be driven to a bearing value in excess of 5 tons, nor concrete piles to a bearing value in excess of 10 tons, over the design bearing value.
12/12/2012
702-7
Bearing Pile
702.5 Method of Measurement. 702.5.1 Test Piles. Test piles will be measured to the nearest linear foot of pile authorized and driven. 702.5.2 Load-Bearing Piles. Piles in place will be the actual length of all piles, except test piles, measured to the nearest foot for that portion of each pile that remains permanently in the structure. 702.5.3 Preboring. Final measurement will not be made except for authorized changes during construction or where appreciable errors are found in the contract quantity. Where required, measurement of prebored holes required under the provisions of Section 702.4.3 will be made to the nearest linear foot of each hole specified or directed by the engineer. The revision or correction will be computed and added to or deducted from the contract quantity. 702.5.4 Pile Point Reinforcement. Pile point reinforcement will be measured per each. 702.6 Basis of Payment. 702.6.1 Test Piles. Test piles will be paid for at the contract unit bid price. Test piles when driven and used as permanent piles in place will be paid for as test piles and not as piles in place. 702.6.2 Bearing Piles. The accepted quantity of bearing pile will be paid for at the unit bid price for each of the pay items included in the contract. No direct payment will be made for incidental items necessary to complete the work unless specifically provided as a pay item in the contract. 702.6.3 Cut-Offs. No direct payment will be made for pile cut-offs. 702.6.4 Preboring. No direct payment will be made for prebored holes through compacted embankments, non-excavatable ready-mix flowable fill used to fill the prebored holes, nor for that excavation required to apply protective coatings. 702.6.5 Pile Point Reinforcement. No direct payment will be made for pile point reinforcement when shown on the plans or required by specification. 702.6.6 Splices. No direct payment will be made for any splices. 702.6.7 Protective Coatings. No direct payment will be made for painting exposed surfaces of steel shells, structural steel piles, and bracing.
12/12/2012
702-8
Bearing Pile
Section 703
Concrete Masonry Construction
703.1 Description. This work shall consist of constructing culverts, bridges, retaining walls, and other structures of Portland cement concrete, and the manufacture, transportation, and erection of precast concrete slab units for bridges. 703.2 Materials. 703.2.1 All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item Section Bearing Pad ..................................................................................................................... 1038 Joints for Concrete Structures ...................................................................................... 1057 Joint Sealing Material .......................................................................................................... 1057 Precast Concrete Box Culvert and Bridge Sections .................................................... 1049 703.2.2 All materials, proportioning, air entraining, mixing, slump, and transporting of Portland cement concrete shall be in accordance with Section 501 or Section 704, as applicable. 703.2.3 Changes in sources of cement and aggregates will be permitted only with the written approval of the engineer. Aggregates of essentially the same characteristics, except as noted in Section 1005, and cements resulting in concrete of the same color, shall be used in any individual unit of the structure. The superstructure is considered an individual unit of the structure unless otherwise shown on the plans. 703.3 Construction Requirements. 703.3.1 Falsework. Falsework for concrete masonry construction shall be adequate to support and hold the forms true to lines, camber, and grades shown on the plans. The Contractor shall submit detailed plans for falsework, but the submission of the plans will not relieve the contractor of the responsibility for obtaining satisfactory results. The falsework shall be constructed in accordance with the submitted plans. The submittal of detailed falsework plans for small structures may be waived by the engineer. Falsework and forms for single and multi-span concrete frames and for continuous concrete slab and girder type bridges shall be provided for the full length of each continuous or monolithic unit and for the full width of the structure before starting concrete placement in that unit. Timber used in falsework shall be sound, in good condition, and free from defects which might impair its strength. Timber falsework piles shall be sound, reasonably straight, free from defects, and long enough to obtain the required bearing without splicing. They shall be accurately cut to the proper grade, and the use of shims or blocking shall be held to a minimum. Screw jacks shall be placed at approved locations to secure and maintain the required camber. Means shall be provided by the contractor for accurately determining settlement of the falsework while it is being loaded. The Contractor shall furnish responsible personnel who shall correct the settlement by adjusting the jacks. These personnel shall be on duty at all times while the falsework is being loaded and until settlement ceases.
9/1/2023
703-1
Concrete Masonry Construction
703.3.2 Forms. Forms for concrete shall be built true to the lines and grades designated and be mortar-tight and of sound materials adequate to prevent distortion during the placing and curing of concrete. All concrete shall be formed unless otherwise specified. A concrete pad of approved thickness may be used as a form for the unexposed bottom of end bent beams on piles. No direct payment will be made for the concrete pads. Form work plans, if required by the Engineer, shall be submitted by the Contractor before form work is started. If during or after placing the concrete, the forms sag or bulge, the concrete affected shall be removed, the forms realigned, and new concrete placed. Construction camber to take care of shrinkage or settlement impairing the strength of the structure by the reduction of depth will not be permitted. The forms shall be designed for a fluid density of 150 lb./cu.ft., and in addition, for a live load of 50 lb./sq.ft. on horizontal surfaces and 30 lb./sq.ft. on vertical surfaces for impact and vibration. 703.3.2.1 Face lumber of forms for exposed surfaces of concrete shall present a smooth dressed surface free of loose knots, knot holes, and other defects. The spacing of supports and the thickness of face lumber shall be adequate to prevent distortion due to the pressure of the concrete. Face lumber shall have a minimum nominal thickness of 1 inch for solid lumber or ¾ inch for plywood. Form material shall be placed with horizontal joints. Triangular molding, smooth on three sides and having ¾ inch width on each of the two form sides, shall be used to bevel all exposed edges of the structure, except where special bevels are shown on the plans. A ¾-inch drip strip will be constructed on the outside edge of all bridge decks. 703.3.2.2 Forms reused shall be in good condition. Form lumber which is unsatisfactory in any respect shall not be used. 703.3.2.3 Design and construction of forms shall permit their removal without damage to the concrete. Cofferdam braces or struts which will extend through any exposed concrete section will not be permitted. Forms under copings and around offsets may be given a draft of not more than 1 in./ft. to permit removal without damage to the concrete. For narrow walls where access to the bottoms of the forms is not otherwise obtainable, an opening shall be provided so that chips, dirt, sawdust, or other extraneous material may be removed immediately prior to placing concrete. 703.3.2.3.1 Material utilized in supporting or securing falsework or forms for bridge decks must be constructed as to be held in place independently of the shear connectors or deck reinforcing steel. Any deck supporting hardware to remain embedded in the deck or haunch area must be so constructed as to allow for removal to a depth of 1 inch for patching. Also, all hardware that remains in the concrete shall be epoxy coated or galvanized. Where blocking or wedges are required to secure or support forms or brackets, they must form an integral part of the unit and must be securely attached to the form or bracket. 703.3.2.4 Form lining will be permitted and will be required for exposed curved surfaces. Liners shall be of plywood or of an approved composition board and shall be at least ¼ inch in thickness.
9/1/2023
703-2
Concrete Masonry Construction
703.3.2.5 Fiber tubes for column forms above the ground line shall have a finish free of gaps or overlaps in the inside ply and shall be coated inside with a waterproofing material which will not stick or bond to or discolor the concrete surface of the column. Fiber tubes for column forms from 6 inches below the finished ground line down may show seams, shall be waterproofed, and need not be removed. 703.3.2.6 Metal forms and combination wood and metal forms may be used when approved by the Director. The forms shall have ⅜ inch plywood fastened to the interior face of the forms to eliminate ridges in the concrete. The minimum size of the plywood shall be 4 feet by 8 feet, with smaller sizes allowed only as the shape of the structure would dictate. The requirement for ⅜ inch plywood to eliminate ridges will not be applicable where the exterior faces of the structure will be covered or for non-exposed areas on box culverts. 703.3.2.7 Oiling of the inside of all forms will be required except for those having composition linings. The oil used shall be light, clear paraffin base oil or other approved material which will not discolor or damage the exposed concrete surface. The coating shall be applied before placing reinforcing steel. 703.3.2.8 Ties and spreaders and all metal appliances used inside of forms to hold them to correct alignment and location shall be so constructed that after removal of forms, the metal may be removed to a depth of at least 1 inch below the surface of the concrete. Metal tie rods used inside the forms where concrete will have an exposed surface shall be a type which will not produce a cavity at the surface of the concrete greater than 1½ inch in diameter. Bolts and rods used as ties shall not be removed by pulling them through the concrete. Wire ties and pipe spreaders will not be permitted, and metal or wood spreaders which are separate from form ties shall be removed as concrete is being placed. A boltthrough method of supporting forms for massive substructure units may be used with the approval of the engineer. Epoxy coated or galvanized coil ties and threaded rods may be permitted to stabilize barrier curb formwork. 703.3.2.9 Cavities produced by the removal of metal tie rods shall be carefully filled at the time of form removal with mortar composed of approximately one part cement to two parts sand. White cement shall be added to the mortar if necessary to obtain the required color. In order to reduce the shrinkage, no mortar shall be placed in the cavities until 45 minutes after the initial mixing. In lieu of the above, any approved non-shrinking, non-staining type of mortar may be used. After the cavities are filled, the surface shall be left smooth, even, and uniform in color and texture. Tie rod cavities in surfaces against which backfill is to be placed shall be filled with mortar or an approved plastic compound meeting the requirements of Section 1057. Patching of tie rod cavities in the interior surfaces of box girders will not be required. At the time the wall forms are removed, in addition to filling the tie holes, all fins and irregular projections are to be removed, all surface voids filled, the exposed faces rubbed to a surface which is smooth, even, and uniform in color and texture, and immediately thereafter cured as directed. 703.3.2.10 Fiber tubes shall be properly designed for the use indicated and fabricated of spun-wound or laminated paper. The outside surface shall be waterproof. Tubes shall be stored under cover and kept off damp ground until ready for use. Distortion of the tubes shall be prevented during storage. The ends shall be covered with suitably designed caps which shall be mortar tight. If material used for capping tubes expands when moist, a preformed joint filler ¼ inch in thickness shall be used around the perimeter of the caps.
9/1/2023
703-3
Concrete Masonry Construction
703.3.2.11 Steel tubes shall have a minimum thickness of 0.024 inch and shall be designed for the use indicated and fabricated to insure against damage or excessive distortion in handling, storage, and placing. The diameter of the tube shall be as specified on the plans with a tolerance of plus zero and minus ¾ inch. The ends of tubes shall be covered with suitably designed metal end caps which are mortar tight. Excessive rusting of tubes will be reason for rejection. 703.3.2.12 Tubes for producing voids in concrete slab superstructures shall be accurately located in positions indicated on the plans and shall be positively anchored to the joists carrying the floor forms. Anchors and ties shall be designed to leave a minimum of supporting material exposed in the bottom of the finished slab of the completed structure. Supporting material shall be epoxy coated or be equipped with plastic coated feet. Details of proposed anchorage and ties for the tubes shall be submitted for approval before work is started on the bridge superstructure. One ¾ inch weephole shall be provided near each end of each tube. Weepholes shall be placed in straight lines parallel to bents. They shall extend through the forms and be kept open at all times. Tubes shall be protected from moisture and heat until concrete is placed. Distortion of tubes after placing of concrete shall not increase their vertical axis by more than ½ inch. 703.3.2.13 Falsework and form removal from under any structural concrete unit shall not be started until the concrete has attained at least the compressive strength shown in Table 1. The falsework support of all concrete spans of a continuous or monolithic series shall be first released from the center of all spans, and release shall then proceed simultaneously from all span centers each way toward adjacent bents. Release shall be in such manner as to permit the concrete to gradually and uniformly take stresses due to its own weight. Compressive strength will be determined by tests made in accordance with St. Louis County methods.
TABLE 1 Class of Concrete
Compressive Strength (Psi, min.)
B-1, B-2, and B-2 Mod
3,000
B
2,700
X (Lightweight)
3,000
703.3.2.14 Except as provided in Section 703.3.6, forms for vertical surfaces of bridge superstructure shall be removed as soon as the concrete is self-supporting, generally within 24 hours after placement, to permit prompt patching of tie holes.
9/1/2023
703-4
Concrete Masonry Construction
703.3.3 Placing Concrete. Placing concrete in any unit of a structure shall not begin until preparations for placing and finishing are satisfactory to the Engineer. Concrete shall be placed in the forms in layers as near final position as practicable with minimum handling. Each placement shall be completed in a continuous operation with no interruption in excess of 45 minutes between the placing of contiguous portions of concrete. Where a finishing machine is to be used, it shall be moved over the area to be finished, immediately prior to placing concrete in any bridge deck pour, to facilitate checking reinforcement cover and slab thickness. This checking shall be made in the presence of the Engineer and with the screeds in the finishing position. Placing of concrete for bridge decks shall proceed uniformly for the full width of the placement. Once begun, placing of concrete in the superstructure of a continuous or monolithic series of spans shall proceed as rapidly as good construction practice will permit until all the concrete in that series is placed. Vibrators having a minimum frequency of 4,500 impulses per minute shall be used to thoroughly consolidate the concrete in the forms and around the reinforcing steel. Sufficient vibrators shall be on hand to insure continuous placement of the concrete without delay. They shall not be used for moving concrete from place to place nor shall they penetrate or disturb previously placed layers of concrete which have taken initial set. Vibration shall not be prolonged so as to cause segregation of the materials. Reinforcing steel protruding through transverse or longitudinal headers shall not be disturbed until the concrete is at least 24 hours old. 703.3.3.1 Where placing operations involve dropping the concrete more than 5 feet, the concrete shall be deposited through vertical sheet metal or other approved pipes. These pipes shall be made in sections not to exceed 4 feet in length. In chutes, the velocity of the concrete shall be retarded by the use of baffles or chokers, or by the use of a series of short chutes to reverse the direction. Open troughs and chutes shall be either metal or metal lined. Where concrete is placed in the interior of pneumatic caissons, it may be deposited through air locks or other approved devices, and the requirement of dropping the mix not more than 5 feet will be waived. 703.3.3.2 Concrete shall be worked under and around the reinforcing steel without displacing the steel. Forms and reinforcing steel above concrete being placed and placing equipment shall be kept clean and free from coatings of hardened concrete. Water used for flushing the equipment shall be discharged clear of the concrete and forms. 703.3.3.3 Concrete shall be placed around the tubes forming voids in slab spans using methods to prevent the displacement of the tubes. For tubes having an inside diameter greater than 14 inches, the concrete shall be placed in three layers. The first layer shall extend from the floor forms up to a plane ¼ tube diameter above the bottom of the tubes and the second layer to ¾ tube diameter. For tubes 14 inches or smaller, the concrete shall be placed in two layers, with the lower layer extending to the middle of the tube. Each layer, after placing, shall be vibrated and allowed to settle before the next succeeding layer is placed, which layer shall be deposited while the concrete in the layer below is still plastic enough to permit intermixing the two layers by use of a vibrator.
9/1/2023
703-5
Concrete Masonry Construction
703.3.3.4 The sequence of placement of concrete for roadway slabs on a continuous series of spans will be shown on the plans together with the minimum rates of placement required for the basic sequence and for any permissible combinations thereof. The Contractor shall observe the basic sequence of placement. If the Contractor wishes to request to alter the placing sequence or to combine units, he shall submit a request in writing for approval. Requests to combine parallel units by eliminating longitudinal construction joints shown on the plans, thus increasing finishing widths, will not normally be approved. 703.3.3.5 Concrete for substructure units shall be placed in the dry unless otherwise authorized by the Engineer. If the supporting material at plan elevation of the bottom of a pile footing is not sufficiently stable to support the concrete it shall be stabilized, or the bottom of the footing shall be formed to adequately support the concrete. No direct payment will be made for the stabilizing of material or forming under pile footings. 703.3.3.6 Depositing concrete under water will be permitted when provided for in the contract or upon written permission of the Engineer. The concrete shall be placed by means of a tremie or a bottom dump bucket. The tremie shall consist of a tube having a diameter of not less than 10 inches and shall be equipped with a hopper of suitable capacity. The bottom dump bucket shall have a capacity of not less than ⅓ cubic yard. The concrete shall be placed in its final position in still water and shall not be vibrated or disturbed after being deposited. Concrete placed under water and for seal courses shall be seal concrete in accordance with Section 501. No additional compensation for seal concrete will be given unless previously stipulated in the contract. 703.3.3.7 Equipment provided for conveying and placing concrete by mechanically applied pressure shall have adequate capacity and be suitable for the intended work. Pumping equipment shall be placed so as to prevent transmission of vibration to freshly placed concrete. It shall be so operated as to produce a continuous stream of uniform concrete. The system through which the concrete is pumped shall be manufactured so that no aluminum parts will come into contact with the concrete. An approved backup system will be required for all deck pours. 703.3.3.8 At the completion of concrete placement, the last concrete used from the pipeline shall be ejected in a manner that will prevent contamination or segregation of the concrete. 703.3.3.9 Concrete used for filling cavities or crevices, or low areas as authorized by the Engineer and as required in Section 206 shall be Class B concrete. This concrete shall be unformed mass concrete placed separately from and prior to the placing of footing concrete. 703.3.3.10 When a closure pour is specified on the bridge plans, or is necessary for other requirements, the closure pour between slabs poured independently shall be expansive Class B-2 concrete. Unpolished aluminum powder shall be added to the Class B-2 concrete as recommended by the powder manufacturer or as approved by the Engineer for controlled expansion. A shrinkage compensating cement may be substituted for the unpolished aluminum powder and cement. If a shrinkage compensating cement is substituted, the type and amount shall be approved by the Engineer.
9/1/2023
703-6
Concrete Masonry Construction
703.3.3.10.1 Prior to placing the closure pour, the Contractor shall release the falsework to allow the initial deflection in the slab extension. The Contractor shall obtain approval from the Engineer prior to placing the closure pour. 703.3.3.10.2 The slab area to be in contact with the closure pour shall be sandblasted to remove all foreign matter and shall be cleaned to remove all dirt and loose material. After the slab area has been cleaned and any damaged epoxy coating on the reinforcing bars repaired, an epoxy-bonding compound shall be applied to the slab area to be in contact with the closure pour. The concrete bonding compound and application shall be in accordance with Section 623. 703.3.3.10.3 Immediately following application and before the concrete bonding compound has set, the closure pour shall be placed. 703.3.4 Joints in Concrete Construction. Construction and expansion joints in concrete masonry shall be located where provided on the plans except that in case of an unforeseen contingency, an emergency construction joint may be permitted. 703.3.4.1 Surfaces of construction joints shall be roughened or scored unless shear keys are shown on the plans. Shear keys shall be placed in construction joints as shown on the plans or as directed by the Engineer. No direct payment will be made for additional shear keys required by the Engineer, but not shown on the plans. The face edges of all joints shall be carefully finished, and feather edges shall be avoided. When the placing of concrete is temporarily discontinued, the concrete after becoming firm enough to retain its form shall be cleaned of laitance and other objectionable material and shall be thoroughly wetted before placing new concrete. Contraction joints in floor slabs of truss bridges may be sawed. Waterstops and flashings as required on the plans shall be continuous if practicable. If splices are shown on the plans or permitted by the Engineer, they shall be watertight. 703.3.4.2 Gray sponge rubber compound expansion joint material shall be of the dimensions shown on the plans. Splices shall be held to a practicable minimum and shall be made by lacing with copper wire or soft-drawn galvanized steel wire. All joint material shall be securely stitched to one face of the concrete with Number 10 gage copper wire or Number 12 gage soft-drawn galvanized steel wire. Unless joint sealing is specified, the gray sponge rubber material shall be left exposed for its full length with clean and true edges. 703.3.5 Concrete Finishes. Riding surfaces shall be finished true to the alignment, grade, cross section, and camber shown on the plans. These surfaces shall be finished by use of an approved mechanical finishing machine. On skewed structures, the finishing machine shall be adjusted to finish the surface approximately parallel to the skew if the angle of skew exceeds 45 degrees or if the angle of the skew exceeds 30 degrees and the ratio of placement width divided by span length equals or exceeds 0.8. Use of vibratory screeds will not be approved whether or not they are a part of the proposed finishing machine.
9/1/2023
703-7
Concrete Masonry Construction
703.3.5.1 Machine finishing shall be with an approved self-propelled mechanical finishing machine. The Engineer may waive its use on isolated irregular shaped areas of the bridge surface. The finishing machine shall travel on adjustable rails or guides set to proper grade and supported outside the limits of the finished riding surface. Where a longitudinal joint is shown on the plans, the finishing machine rails, or guides shall be placed as close as practicable to the longitudinal joint. The rails shall be supported to limit the full operating load deflection between supports to ⅛ inch or less. They shall in general be placed parallel with the centerline of roadway or the longitudinal axis of the area to be finished. Where supports are so located that fresh concrete must be placed around them, the rails or guides shall be furnished in sections of 10 feet or less and placed above the concrete surface. The sections and supports shall be removed and the holes filled with concrete immediately after the final straightedging. The finishing machine shall make sufficient passes to obtain the specified cross section and surface finish. The final pass of the machine shall be of maximum practicable length and shall be coordinated with the rate of placement. Finishing machine loads will not be permitted on concrete less than 48 hours old. 703.3.5.2 Where hand finishing of riding surfaces is permitted, the surface shall be struck off to the design section by a rigid metal shod template. The template shall be supported on rails or guides that can be adjusted to produce the design section and slab thickness. The rails or guides shall be supported above or outside the concrete surface. The surface behind the template shall be finished with a longitudinal float. The longitudinal float shall have a rigid metal shod smoothing surface which is a true plane not less than 10 feet long and 8 inches wide. The float shall be operated from movable bridges with a combined longitudinal and transverse motion. Each transverse pass shall overlap the previously floated area by approximately one-half the length of the float. 703.3.5.3 Sufficient work bridges shall be provided to complete the work in an orderly and continuous manner. Work bridges shall be supported outside the limits of concrete placement. 703.3.5.4 Straightedging. The riding surface shall be checked with a 10-foot straightedge immediately after the final finishing operation. The straightedge shall be pulled lightly across the surface from one edge of the finished area to the other without interruption. Reaching from outer edges to the center of the finished area will not be permitted. Each transverse pass shall overlap the previously straightedged portion by approximately one-half the length of the straightedge. The straightedge or float shall not be used to cut or move concrete from its finished position. Any irregularities, bumps, or improperly finished areas shall be refinished, and the surface again checked by repeating the straightedge operation. 703.3.5.5 Roadway Finish Texture. The roadway surface, except within 12 inches of the inside face of the curbs, shall be textured as soon as the condition of the concrete will permit. The roadway finishing shall otherwise conform to the applicable portions of Section 502. Hand operated devices producing a satisfactory texture will be permitted.
9/1/2023
703-8
Concrete Masonry Construction
703.3.5.6 Surface Test. As soon as curing has been completed, the riding surface will be thoroughly straightedged by the engineer and all variations exceeding ⅛ inch in 10 feet will be plainly marked. Areas more than ⅛ inch high shall be removed by an approved device consisting of multiple cutting edges leaving a grooved surface finish comparable to that produced by the broom. The use of a bush hammer or other impact device will not be permitted. 703.3.5.7 Unless an armored joint is shown on the plans, construction and expansion joints in the roadway surface shall be carefully edged and left free of all mortar and concrete. These joints shall be sealed with joint sealing material if required by the plans. Joints shall be dry and shall be cleaned immediately before they are sealed. Required joint sealing shall be done prior to surface sealing the bridge deck. 703.3.5.8 Surface finish for concrete masonry units, other than those specified in Section 703.3.14, shall begin immediately following removal of the forms. All exposed surfaces shall receive a surface finish that will completely remove all fins and irregular projections. Form tie cavities, holes, honeycomb spots in other than exposed surfaces, and other defects, shall be thoroughly cleaned, saturated with water, and carefully pointed with a mortar in accordance with Section 703.3.8. Repaired surfaces shall be satisfactorily cured. 703.3.5.9 Bridge seats shall be finished with a wood float to a smooth even surface. Where lead plates or fabric pads are used to seat steel bearing plates, the area under the lead plates or fabric pads shall be finished to within ⅛ inch above plan elevation and shall be dressed to a uniform, level bearing with a carborundum brick or power grinder after the concrete has set sufficiently to fix the larger particles of sand. Where elastomeric bearing pads are used, the finishing of ⅛ inch above plan elevation and grinding of the bridge seat area will not be required. Wells for anchor bolts shall be completely filled with an expansive type of mortar meeting the requirements of Section 1066 after the steel has been erected and adjusted. In lieu of wells, anchor bolt holes may be drilled in accordance with Section 712.5.3. Keyways, anchor bolt wells and holes, and other depressions which might collect water and freeze shall be sealed. 703.3.6 Curing. Curing of exposed concrete masonry surfaces shall be in accordance with Section 502 except as follows: Riding surfaces and other surfaces to be surface sealed shall be cured with mats of jute, cotton, or other suitable fibers. Curing mats shall be applied as soon as the concrete has set sufficiently that no marring of the surface or distortion will result. The mats at the time of placement shall be sufficiently wet to prevent moisture absorption from the finished surface. The mats for curing riding surfaces shall be kept continuously wet by use of a sprinkler, soaker hose, or similar means until the concrete has attained at least the compressive strength shown in Table 1, but in no case for less than 5 days. For use as a vapor barrier, covering of the deck with plastic sheeting will only be permitted with prior approval of the Engineer and will not relieve the Contractor of the requirement to keep the deck continuously wet by use of a sprinkler, soaker hose, or similar means. The mats for curing other surfaces shall be kept continuously wet for 72 hours. The mats shall then remain in place until they are dry or, if not dry, for at least 24 hours after the end of the wet curing period.
9/1/2023
703-9
Concrete Masonry Construction
703.3.6.1 Surfaces to be damp proofed, and railroad bridge decks to be waterproofed, shall not be cured with membrane. Such surfaces may be cured by the use of the prime coat. 703.3.6.2 If permitted by the Engineer, footings may be cured by submersion. 703.3.6.3 Curing compound for bridge decks and other surfaces to be sealed shall be liquid membrane-forming curing compound Type 1-D in accordance with Section 1055 for bridge deck curing compounds, except that if diamond grinding is specified, either Type 1D or Type 2 liquid membrane-forming curing compound in accordance with Section 1055 may be used for the surfaces to be textured by diamond grinding. 703.3.6.3.1 The material shall be approved by the Engineer prior to use and shall be applied at the Manufacturer's recommended rate, but no less than 150 square feet per gallon. 703.3.6.3.2 When conventional texturing is specified, fresh concrete shall be sprayed immediately with a curing compound following texturing as specified in Section 703.3.5.5. The application of the interim curing compound shall progress such that no more than 10 linear feet of the textured concrete surface is exposed without curing compound at any time. 703.3.6.3.3 When diamond grinding is specified in lieu of conventional deck texturing, fresh concrete shall be sprayed immediately after surface floating to smooth surface with a curing compound as specified in Section 703.3.6.3. 703.3.6.3.4 The concrete shall be covered with clean mats as soon as the interim curing compound has dried sufficiently to prevent adhesion, and the concrete surface will support the curing mat without marring or distorting the finish, but no more than 90 minutes after the concrete is floated or textured. The mats shall be sufficiently wet at the time of placement to prevent moisture absorption from the finished surface. The Contractor shall control the run-off so as not to cause a traffic hazard or soil erosion. The continuous wet cure shall be maintained a minimum of seven days and until the concrete has attained a minimum compressive strength of 3,000 psi. 703.3.6.3.5 Steam curing or curing by complete submersion in water will be permitted for precast members. If steam curing is applied, the jets shall not impinge directly on the concrete or on the forms, free circulation around the units shall be maintained, the steam shall be thoroughly saturated at all times, and the temperature around the concrete shall be raised no more than 40°F per hour and shall not exceed 160°F at any time. After the steam curing period, the temperature inside the chamber shall be reduced at a rate of no more than 40°F per hour until the temperature has reached about 20°F above the temperature of the air to which the concrete will be exposed.
9/1/2023
703-10
Concrete Masonry Construction
703.3.6.3.6 Light material and equipment weighing less than 1,000 pounds may be carried onto the bridge deck after the deck concrete has been in place at least 24 hours, provided curing is not interfered with, and the surface texture is not damaged. Vehicles, material, and equipment needed for construction activities and weighing less than 4,000 pounds, shall not be moved onto any span until after the last placed deck concrete has attained a compressive strength of at least 3,200 psi. Loads in excess of the above shall not be moved onto the bridge deck until the deck concrete has reached the compressive strength specified on the plans. 703.3.6.3.7 Structures shall not be opened to any public vehicular traffic until at least 14 days after the last placement of deck concrete and until such concrete has attained the compressive strength specified on the plans. 703.3.7 Bridge Deck Surface Texturing. For conventional texturing, the roadway surface shall be textured in accordance with Section 703.3.5.5 prior to the application of the curing compound. 703.3.7.1 When diamond grinding is specified, following the curing period and the attainment of design strength, the deck surface shall be diamond ground in accordance with the following: 703.3.7.1.1 The bridge deck shall be diamond ground in accordance with Section 627, except traffic control and closure for grinding operations shall be as specified by other portions of the contract documents, except as noted herein. Grinding may proceed after design compressive strengths are attained and shall be completed prior to opening to any traffic other than construction traffic. 703.3.7.1.2 Bumps and high areas shall be removed prior to the start of final grinding operations in accordance with Section 703.3.5.6. Typically, ⅛ inch, and no more t h a n ¼ inch shall be removed from the plan profile of the deck. The final surface shall be textured to the satisfaction of the Engineer. 703.3.7.1.3 The surface of the approach slabs and deck shall be ground simultaneously in a longitudinal manner to a distance 2 feet from the barrier curb. 703.3.8 Surface Sealing for Concrete. Bridge decks, except those which are to have a bituminous surface, shall be sealed with one application of an approved penetrating concrete sealer in accordance with Section 736. The penetrating concrete sealer shall also be applied to: 1) The top surface of the concrete bridge approach slab; 2) Top and roadway faces of sidewalks, curbs, parapets, medians, and barriers. The surfaces of deck patching shall not be sealed unless the rest of the deck is being sealed. The surface of a Latex Modified Concrete overlay shall not be sealed. The surface of all other dense concrete overlays shall be sealed.
9/1/2023
703-11
Concrete Masonry Construction
703.3.9 Hot Weather Concreting. When the weather forecast predicts temperatures of 90°F, or higher, the Contractor shall schedule placing and finishing of bridge deck concrete during hours in which the ambient temperature will be lower than 90°F. The mixed concrete when placed in the forms shall have a temperature no higher than 90°F. The forms and reinforcing steel shall be cooled by acceptable methods such as covering with wet burlap for at least 12 hours prior to the placing of concrete. The concrete shall be protected with wet curing mats as soon as it has hardened sufficiently to allow placement of the mats. 703.3.10 Cold Weather Concreting. Concreting shall proceed on all structures, except bridge superstructures, whether or not heating is required, unless it can be definitely established that the over-all progress of the project will not be affected. Placing of concrete in the superstructure of a continuous or monolithic series of spans once begun shall be continued within the provisions of cold weather concreting procedures until all the concrete in that series is placed. Concrete placed in cold weather shall be protected from freezing during the curing period by the use of a heated weatherproof enclosure in accordance with Section 1055.4.3.5, "Heated Enclosures". Concrete shall not be placed on frozen ground, against reinforcing steel, formwork, or concrete surfaces with temperatures lower than 35°F. No concrete shall be placed where the ambient temperature is below 35°F, and concrete in bridge superstructures shall not be placed where the ambient temperature is below 45°F. Insulated forms, in accordance with Section 1055.4.3.4, "Form Insulating Materials for Winter Concreting", for cold weather protection may be used at approved locations in lieu of enclosures, if the method will keep the temperature of the concrete between 40°F and 80°F during the curing period. The Contractor shall secure prior approval of the Engineer for the type of insulation, method of insulation, and the locations at which it is proposed for use. 703.3.10.1 Cold Weather Production and Delivery. The capability of the production facility to produce and deliver cold weather concrete within the mixing and placing temperature limits for the least dimension of the structure specified in the contract documents shall be evaluated and verified in accordance with Section 501.8.1. 703.3.10.2 Cold Weather Protection, Compressive Strength and Curing Limitations. Curing of superstructure concrete and substructure units above ground surface, retaining walls, and box culverts of more than 15 square feet shall be within a weatherproof enclosure when the ambient temperature is below 40°F during the curing period. Temperature within the enclosure shall be uniformly maintained between 40°F and 80°F for not less than 7 days nor more than 14 days. Heating may be discontinued after 7 days provided the concrete has attained at least the applicable strength shown in Table 1 as determined by maturity or field cured concrete cylinders. When dry heat is used, at least 40 percent relative humidity shall be maintained. The Contractor shall provide adequate ventilation and fire protection at all times and shall maintain proper temperature and humidity conditions within the housing during the curing period. The exposed surfaces of the concrete shall be kept moist either by the application of steam or wet burlap mats. When curing is complete, the temperature within the enclosure shall be lowered gradually at a rate not to exceed 3°F per hour, until the outside temperature is reached. Substructure concrete below ground surface may be protected by submersion provided the temperature of the water is maintained between 40°F and 80°F for 7 days.
9/1/2023
703-12
Concrete Masonry Construction
703.3.10.3 Concrete headwalls for pipe culverts, drop inlets, and box culverts of 15 square feet or less opening, may be placed without air temperature limitations, but the Contractor is not relieved of responsibility for proper protection from freezing during placing and curing of the concrete. 703.3.11 Extending and Widening Structures. Extending and widening of existing concrete structures shall be in accordance with the details shown on the plans. A continuous groove at least 1 inch deep shall be sawed in the faces of the existing concrete as a guide for the line of break to prevent spalling. Surfaces of existing concrete which are to come in contact with new concrete shall be thoroughly cleaned, saturated with water, and painted with a neat cement grout of painting consistency. The new concrete shall be placed immediately after the cement grout has been applied. If new concrete is to be placed against the natural finish of existing concrete work, the surface shall be roughened by bush hammering before being cleaned and treated. Before applying a new concrete riding surface, any existing bituminous surfacing shall be removed, and the exposed concrete surface roughened by bush hammering before being cleaned and treated. No direct payment will be made for work incidental to joining new concrete to existing concrete. 703.4 Method of Measurement. Concrete masonry will be computed from the dimensions shown on the plans, or as revised in writing by the Engineer, and will be computed to the nearest 1⁄10 cubic yard for each structure. No deduction will be made for the space occupied by reinforcing steel, conduit, or piles. Deductions will be made for the space occupied by the tubes in voided slabs. Any revision or correction will be computed and added to or deducted from the contract quantity. 703.4.1 Measurement of concrete quantities in seal courses will be made for the actual quantity placed, except that this quantity will be limited to that included within vertical planes 18 inches outside the neat lines of the footings proper, and to the maximum depth shown on the plans or as authorized by the Engineer. 703.4.2 Measurement of concrete quantities used to fill cavities or crevices will be made for the accepted quantity placed below the authorized elevation of the structure footing. 703.4.3 Final measurement for diamond grinding will not be made except for authorized changes during construction or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added to or deducted from contract quantity. 703.5 Basis of Payment. The accepted quantity of concrete masonry, complete in place, will be paid for at the unit bid price for each of the pay items included in the contract. 703.5.1 No direct payment will be made for incidental items necessary to complete the work unless specifically provided as a pay item in the contract. No direct payment will be made for concrete required to fill overbreak where footings or walls are cast against vertical faces of rock or shale excavation. No direct payment will be made for concrete required to fill areas of overexcavation where footings or walls are cast against the vertical faces of the neat footing lines in lieu of forms.
9/1/2023
703-13
Concrete Masonry Construction
Section 704
Concrete Masonry Repair
704.1 Description. This work shall consist of removing deteriorated concrete, preparing the repair site, forming where required, placing and finishing new concrete or qualified special mortar and applying epoxy in the required areas. 704.2 Materials. All material shall be in accordance with Division 1000, Material Details, and specifically as follows. The qualified special mortar shall be from the qualified rapid set concrete patching material listing available from Construction and Materials or MoDOT’s web site. Item Section Concrete .......................................................................................501 Concrete Bonding Compound and Epoxy Mortar .........................623 Gradation E Coarse Aggregate ................................................. 1005 Type III Cement ......................................................................... 1019 Type III Epoxy & Epoxy Polymer Concrete Overlay .................. 1039 Water ......................................................................................... 1070 704.3 Types of Repair. 704.3.1 Repairing Concrete Deck (Half-Soling). This work shall consist of partial removal and replacement of bridge deck concrete in the required areas. 704.3.2 Deck Repair with Void Tube Replacement. This work shall consist of partial removal and replacement of bridge deck concrete and removal and replacement of the deteriorated void tube in the required areas. 704.3.3 Full Depth Repair. This work shall consist of complete removal and replacement of the bridge deck concrete in the required areas. 704.3.4 Modified Deck Repair. This work shall consist of the removal and replacement of visibly loose or spalled bridge deck concrete and placement of concrete in the areas where the reinforcing steel is exposed. The repair concrete for these areas shall be Class B-1. 704.3.5 Superstructure Repair (Unformed). This work shall consist of repairing the deteriorated concrete on the bottom of the bridge deck in the required areas with a qualified special mortar. 704.3.6 Slab Edge Repair. This work shall consist of repairing the edge of the bridge deck by removing deteriorated concrete and patching the required areas with a qualified special mortar. All repairs made within 4 inches of the edge of the bridge deck, regardless of the repair thickness, will be considered slab edge repair. Portions of the bridge deck areas requiring repair that extend more than 4 inches from the edge of the bridge deck shall be repaired as superstructure repair (unformed) or full depth repair.
5/1/2010
704-1
Concrete Masonry Repair
704.3.7 Substructure Repair (Formed). This work shall consist of formed substructure repair. The required areas shall be patched with Class B-1 concrete. Coarse aggregate shall be Gradation E in accordance with Section 1005. 704.3.8 Substructure Repair (Unformed). This work shall consist of unformed substructure repair. The required areas shall be patched with a qualified special mortar. 704.3.9 Epoxy Sealing. This work shall consist of applying an epoxy material to the concrete in the required areas. 704.4 Construction Requirements. 704.4.1 Removal Requirements. The type of repair and areas to be repaired will be outlined by the engineer. All loose, deteriorated and unsound concrete in the required repair areas shall be removed by conventional hand / mechanical, hydro demolition or other approved equipment to a depth as specified herein and as directed by the engineer. Slight deck imperfections surrounded by sound concrete shall be cleaned of all dirt, loose material and deteriorated concrete. If reinforcing steel is not exposed, deck repair work will not be required. 704.4.1.1 Bridge Decks to be Covered with Asphalt or Concrete Wearing Surface. The existing bridge deck shall be scarified for the concrete wearing surface as specified in the contract documents and in accordance with Section 505. Slight bridge deck imperfections of 0.5 inch or less in depth below the prepared deck surface that are surrounded by sound concrete, and the reinforcing steel is not exposed, shall not be halfsoled. These areas shall be cleaned by hand tools, sand or hydro blasting to remove all dirt, loose material and deteriorated concrete before the application of the asphalt or concrete wearing surface. Asphalt or concrete for these areas shall be placed monolithic with the wearing surface in accordance with Section 403 or Section 505. 704.4.1.2 Bridge Decks to be covered with Epoxy Polymer Concrete Overlay. Preparing and cleaning the existing bridge deck shall be in accordance with Section 623. 704.4.1.3 Conventional Hand / Mechanical Equipment. Conventional hand/mechanical equipment consisting of jackhammers no heavier than the 35-pound class shall be used for concrete removal. For bridge decks rated 5 or below, the jackhammers shall not be heavier than the 65-pound class. Chipping hammers from the 15-pound class shall be used to remove concrete from beneath any reinforcing bars, where required. The bits shall be sharp in order to reduce pounding. Jackhammers shall be operated to minimize damage to the sound concrete around the patch area. Other methods that would be less damaging to the concrete and reinforcement may be used with approval from the engineer. 704.4.1.4 Patch Repair Hydro Demolition Equipment. The hydro demolition equipment shall be capable of removing concrete to the specified depth and shall be capable of removing rust and concrete particles from exposed reinforcing bars. All water used in hydro demolition shall be potable in accordance with Section 1070. Stream or lake water will not be permitted. The contractor shall take necessary precautions during hydro demolition to prevent damage to the remaining structure and adjacent property as a result of runoff. Slab drains receiving runoff from the contractor’s operation shall be temporarily plugged. The discharge water shall not be released from the site until the broken concrete, aggregate and other settleable solids have been removed through filtration, 5/1/2010
704-2
Concrete Masonry Repair
sediment basins or other approved methods. The contractor shall control dust and run-off in accordance with applicable governmental regulations. Environmental protection shall be in accordance with Section 107. Hydro demolition shall not impede or interfere with maintaining traffic. Heavy equipment, such as vacuum trucks for removal of concrete debris, will not be permitted to place wheel loads on the deck areas where deteriorated concrete has been removed. 704.4.1.5 Concrete Removal. A boundary perimeter with one-inch vertical sides shall be established outside the deteriorated area. The deteriorated concrete shall be removed as required to provide good sound concrete on which new concrete can be placed and satisfactorily bonded to the reinforcing bars. The areas of repair shall be made approximately rectangular with the sides generally perpendicular to the surface being repaired. These areas shall be carefully removed such that reinforcement is not disturbed or damaged. For full depth repair, a saw cut outside the deteriorated area shall also be made on the bottom of the bridge deck, except on voided slab, solid slab and box girder bridges without entry access. Other acceptable methods for saw cutting the bottom of the deck may be used with approval from the engineer. No more than one-fourth of the column perimeter shall be removed at any one time, and no more than one-eighth of the column perimeter if the repair is completed under live load. Once the one-quarter or oneeighth limit has been reached, the column shall be repaired before any further column removal is done. 704.4.1.6 Reinforcing Bar Exposed. All exposed reinforcing bars shall be thoroughly cleaned by sand or hydro blasting to the satisfaction of the engineer. 704.4.1.6.1 Superstructure and Substructure Repair. The concrete within the boundary area for superstructure repair (unformed), substructure repair (formed) and substructure repair (unformed) shall be removed a minimum of one inch beyond the inside edge of any exposed reinforcing bars, including the main reinforcement. 704.4.1.6.2 Deck Repairs. The minimum depth of repair for repairing concrete deck (half-soling) or modified deck repair shall expose the upper layer of the top mat of reinforcing steel. When the bond between existing concrete and a reinforcing bar has been destroyed, or more than half the diameter of a reinforcing bar is exposed, the concrete adjacent to the reinforcing bar shall be removed to a depth that will permit the concrete to bond to the entire periphery of the bar. A minimum of one-inch clearance shall be maintained. 704.4.1.6.3 If a reinforcing bar is exposed during slab edge repair, the concrete adjacent to the bar shall be removed to a depth that will permit a qualified special mortar to bond to the entire periphery of the bar. A minimum of one-inch clearance shall be maintained. 704.4.1.7 Reinforcement Repair. Particular care shall be taken not to disturb or damage reinforcing bars. All exposed reinforcing bars shall be thoroughly cleaned by sand or hydro blasting. Cut or broken bars or bars with 10 percent or more cross sectional area lost shall be spliced 24 diameters on each side of the damage with new bars of the same size in accordance with Section 706. Damaged existing epoxy coated reinforcement shall be repaired in accordance with Section 710.3.3.
5/1/2010
704-3
Concrete Masonry Repair
704.4.1.8 Material Disposal. All material removed shall be disposed of in accordance with Section 202. 704.4.2 Preparation of the Repair Area. 704.4.2.1 Patch Preparation Requirements. After removal of deteriorated concrete, the area to be repaired shall be sand or hydro blasted to remove all foreign matter, dirt, freestanding water and loose material. The hydro demolition process will not require sand or additional hydro blasting unless the bonding surface of the repair area becomes contaminated or unsatisfactory prior to placement of new concrete. The area to come in contact with new concrete shall be cleaned as stated above, saturated with water and painted with a concrete bonding compound or an epoxy mortar prior to the placement of new concrete. A concrete bonding compound shall be used for all structures with the following exception. An epoxy mortar shall be used on box girder, voided and solid slab structures and on structures where a cathodic protection system is to be installed. 704.4.2.2 Epoxy Sealing Preparation. The area to be sealed shall be cleaned by sand blasting. Prior to sealing the concrete, all loose particles and foreign matter shall be removed using oil-free and water-free compressed air or a vacuum of at least 90 psi. 704.4.3 Applying Epoxy. The area to be sealed shall be sealed with a qualified Type III epoxy or epoxy material for epoxy polymer concrete overlay. Sealing shall be completed before the application of any overlay. The cleaning, sealing and epoxy application shall proceed only as approved by the engineer, in accordance with the manufacturer's written recommendations. The epoxy application and rate of coverage shall be in accordance with manufacturer’s recommendations, with a maximum coverage of 100 square feet per gallon. 704.4.4 Placement of New Concrete. 704.4.4.1 Concrete Placement Requirements. Concrete shall be placed before the concrete bonding compound or epoxy mortar has begun to set. Deck repair concrete shall be placed in the repair area to match the top of the original deck surface. For bridges to be covered with concrete wearing surface, deck repair concrete shall be placed in the repair area up to the bottom of the proposed concrete wearing surface. The finished repair area shall have a light broom texture for bonding of the deck seal, except bridges to be covered with concrete wearing surface shall have a rough surface for bonding of the concrete wearing surface. All joints shall be formed to match any existing joint pattern. 704.4.4.2 Concrete Requirements. Concrete for concrete deck repair shall be Class B2, except that solid slab, voided slab and box girder structures shall be the same class as the existing deck concrete and as specified in Sections 704.3.4 and 704.4.4.3. The repair area shall not be opened to any traffic until the concrete has reached a compressive strength of 3200 psi. Type III cement may be used to accelerate the set. The coarse aggregate shall be Gradation E in accordance with Section 1005. Accelerating additives containing chlorides will not be permitted.
5/1/2010
704-4
Concrete Masonry Repair
704.4.4.3 Bridge Decks with Cathodic Protection System. Concrete for repairing the concrete deck shall be Class B-1. The repair area shall not be opened to any traffic until the concrete has reached a compressive strength of 3200 psi. Type III cement may be used to accelerate the set. The coarse aggregate shall be Gradation E in accordance with Section 1005. Accelerating additives containing chlorides will not be permitted. All halfsole repairs made on the deck shall be Class B-1 concrete that has a maximum chloride ion content of 5 pounds per cubic yard. All full depth repairs made on the deck shall be chloride-free Class B-1 concrete from the bottom of the deck to within one inch of the lowest rebar of the top layer of reinforcing steel. The remainder of the repair shall be Class B-1 concrete with a maximum chloride ion content of 5 pounds per cubic yard. 704.4.4.4 Curing. The repaired areas shall be cured in accordance with Section 703. The cleaning and application of the epoxy polymer concrete overlay to the deck shall proceed only as approved by the engineer in accordance with the manufacturer’s written recommendations. 704.5 Method of Measurement. The extent of repair may vary from the estimated quantities, but the contract unit price shall prevail regardless of the variation. Final measurement will not be made for preparation of the existing deck. No duplication of measurement will be made for full depth repair, repairing concrete deck (half-soling), deck repair with void tube replacement, slab edge repair, superstructure repair (unformed) or modified deck repair. No duplication of measurement will be made for substructure repair, unformed and formed. 704.5.1 Repairing concrete deck (half-soling), deck repair with void tube replacement, full depth repair, modified deck repair, superstructure repair (unformed) and substructure repair (formed and unformed) will be measured to the nearest square foot. 704.5.2 Slab edge repair will be measured to the nearest linear foot. 704.5.3 No measurement will be made for epoxy sealing. 704.6 Basis of Payment. Accepted quantities of concrete masonry repairs will be paid for at the contract unit price for each of the pay items included in the contract. No direct payment will be made for epoxy sealing.
5/1/2010
704-5
Concrete Masonry Repair
(This Page Intentionally Left Blank)
5/1/2010
704-6
Concrete Masonry Repair
Section 705
Prestressed Concrete Members for Bridges
705.1 Description. This work shall consist of the fabrication and installation of prestressed concrete members, complete in place, in the superstructure of bridges. This work covers both pretensioned and post-tensioned members. 705.2 Materials. 705.2.1 All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item Section Prestressed Concrete Members for Bridges ............................. 1029 Reinforcing Steel for Concrete Structures ................................. 1036 705.2.2 Calcium Nitrite Corrosion Inhibitor. Calcium nitrite corrosion inhibitor shall be used in the construction of the precast, prestressed concrete deck beams on this project. Calcium nitrite, at the rate of 2 percent (2%) of calcium nitrite by weight of cement, shall be added to the concrete utilized in the manufacturing of the prestressed concrete deck beams and the construction of the vertical curbs for the exterior beams. An aqueous solution of an approved calcium nitrite shall be added. The water in such solution shall be counted as mixing water for the purpose of determining the water-to-cement ratio of the concrete. The calcium nitrite, which acts as an accelerator, may be used in conjunction with other compatible admixtures to control setting time and workability of concrete. It must be added to the mix immediately after the air-entraining and retarding admixtures have been introduced to the batch. The use of a calcium nitrite admixture must be indicated on the shop drawings. No direct payment will be made for furnishing and using calcium nitrite corrosion inhibitor. 705.3 Equipment. Prestressing equipment shall be in accordance with Section 1029. 705.4 Construction Requirements. 705.4.1 Post-Tensioned Members. Post-tensioned members shall be in accordance with Section 1029. 705.4.2 Erection. Erection of the structure shall be in accordance with the working drawings. Camber of beams, measured as the differential between adjacent beams in the final location, shall be no more than ⅛ inch per 10 feet of span, and in no case greater than 1 inch. The butt joints between precast panels shall be caulked to prevent excessive grout leakage between panels.
5/1/2010
705-1
Prestressed Concrete Members for Bridges
705.5 Method of Measurement. Measurement of prestressed concrete members, complete in place, in the finished structure will be based on contract plan quantities. Final measurement will not be made, prestressed concrete members will be computed to the nearest linear foot for each structure and each type of prestressed concrete member. 705.6 Basis of Payment. Accepted prestressed concrete members will be paid for at the contract unit price for each of the pay items included in the contract.
5/1/2010
705-2
Prestressed Concrete Members for Bridges
Section 706
Reinforcing Steel for Concrete Structures
706.1 Description. This work shall consist of furnishing and placing reinforcing steel of the shape, size, and grade required. 706.2 Materials. 706.2.1 All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Reinforcing Steel for Concrete .................................................. 1036 706.2.2 Reinforcing steel shall be accurately cut and bent to the dimensions and shapes indicated on the plans, preferably at the mill or shop. Cutting and bending tolerances for reinforcing steel shall be in accordance with the Concrete Reinforcing Steel Institute's manual of standard practice. 706.3 Construction Requirements. 706.3.1 Reinforcing steel shall be protected from damage at all times. When placed in the work, it shall be free from dirt, oil, paint, grease, loose mill scale, thick rust, and other foreign substances. Thin powdery rust need not be removed. All reinforcing steel required for superstructure concrete, such as slabs, girders, beams, etc., and top slabs of concrete box culverts of more than 4-foot span, shall be held securely in correct position by means of approved metal bar supports and ties. These supports shall be manufactured and placed in accordance with the typical details shown on the plans for the various types of superstructures. Reinforcing bars shall be positively secured against displacement. For bridge decks and top slabs of culverts, bars in the top mat shall be firmly tied with wire at each cross or lap. At other locations, the bars shall be firmly tied at the alternate crossings, or closer. The steel shall be tied in correct position and inspected, before any concrete is placed. Such inspection will not relieve the contractor of responsibility for constructing the unit in accordance with the plans. Care shall be exercised to maintain proper clearance between the forms and the reinforcement. Measurements to reinforcing steel shall be made to the centerline of bar, except where clear distance from face of concrete is shown on the plans. Before concrete is placed, any dried mortar shall be cleaned from the reinforcing steel. 706.3.1.1 Reinforcing steel bar supports for concrete structures shall generally be in accordance with the bar support specifications of the Concrete Reinforcing Steel Institute's manual of standard practice. Additionally, bar supports will be required, as directed by the engineer, in walls and columns to insure the required concrete cover. Reinforcing steel bar supports shall be epoxy or plastic coated for bridge superstructures and have plastic capped feet at all other exposed locations. When concrete is being placed on subgrade, full-size cement brick shall be used to support the reinforcing steel. Bar supports used to support the upper mat of steel, in multiple mats, shall be full height, providing the proper clearance. Standees resting on the lower mat of bars will not be permitted.
5/1/2010
706-1
Reinforcing Steel for Concrete Structures
706.3.2 Bars shall not be spliced except where shown on the plans or as permitted by the engineer. The use of splices shall be avoided at points of maximum stress. Where possible, splices shall be staggered and arranged to develop the full strength of the bar. Splices shall be made only as shown on the plans or as authorized by the engineer. 706.3.3 Mechanical bar splice systems, as shown on the plans, shall be capable of developing 125 percent of the specified yield strength of the bar being spliced and shall be installed in accordance with the manufacturer's recommendations and as modified herein. 706.3.3.1 The contractor shall furnish to the engineer a manufacturer's certification stating that the mechanical bar splice systems are in accordance with this specification. The certification shall include or have attached specific results of tests showing yield and ultimate tensile load capacities. 706.3.3.2 The splicing system may attach directly to the bars being coupled or may be of a type that provides reinforcing bars of like size that lap with the bars being joined. A threaded type splice system will be required where clearance considerations require the splicing device to be placed flush to the face of the construction joint for the initial concrete placement. 706.3.3.3 Reinforcing bar lengths shown in the bill of reinforcing steel may require modification to accommodate the specific mechanical bar splice system that will be used. The contractor shall determine the actual reinforcing bar lengths to accommodate the manufacturer's recommendations for installation of the mechanical bar splices. 706.3.3.4 Mechanical bar splice systems that require laps with the reinforcement shall not be used for voided slab and solid slab bridges. Systems that require laps shall be Grade 60 deformed bars in accordance with Section 1036. Epoxy-coated bars shall have epoxycoated mechanical bar splices. 706.4 Method of Measurement. Measurement will be made to the nearest 10 pounds for each structure. The weight paid for shall be the theoretical weight of plain bars, and no allowance will be made for the clips, wire, supports, and spacers, standees or other fastening devices for holding the reinforcement in place. Allowance will not be made for an overrun in scale weights of bars. Final measurement will not be made except for authorized changes during construction, or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. 706.5 Basis of Payment. The accepted quantity of reinforcing steel, complete in place, will be paid for at the contract unit bid price. No additional payments will be made for test samples required under provisions of the contract. No direct payment will be made for reinforcing steel bar supports, cost to be included in the reinforcing steel contract unit price.
5/1/2010
706-2
Reinforcing Steel for Concrete Structures
Section 707
Conduit System on Structure
707.1 Description. This work shall consist of furnishing and placing all material and equipment and performing all work necessary to create a complete conduit system as shown on the plans. 707.2 Materials. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item Section Electrical Conduit....................................................................... 1060 Pull and Junction Boxes for Bridge Conduit .............................. 1062 707.3 Construction Requirements. 707.3.1 Conduit systems shall be free from corrosion, restrictions, sharp edges and debris. The ends of conduit runs shall be protected by bushings and shall be temporarily capped if conductor cable is not installed immediately. Conduit shall be rigidly held in place to prevent misalignment during placement of concrete. Reinforcing bars shall not be cut, bent, displaced or otherwise altered unless authorized by the engineer. All joints shall be rigid and waterproof. A ½ inch diameter drain hole in all low points of conduits and junction boxes where exposed, and a ½ inch rigid steel conduit drop from the low point if the conduit and junction boxes are encased in concrete, shall be provided for drainage of water. Exposed ends of such drains shall be covered with either a commercial bronze or a stainless steel insect screen having an open area between 60 percent and 70 percent, held in place with a conduit bushing. 707.3.2 After placing concrete, the conduit around which the concrete is placed shall be tested by the contractor, in the presence of the engineer, for continuity and freedom from obstruction by pulling a steel ball through the entire length. The steel ball shall have a diameter ½ inch smaller than the inside diameter of the conduit being tested. Galvanized pull wires shall be installed in conduit for pulling wiring by others. 707.3.3 Junction box covers shall have a waterproof seal securely fastened in place. Junction boxes shall be drilled and tapped for all conduit connections. 707.4 Method of Measurement. The work provided herein will not be measured for payment, but will be considered a lump sum unit. 707.5 Basis of Payment. The accepted conduit system on structure will be paid for at the contract lump sum price.
5/1/2010
707-1
Conduit System on Structure
(This Page Intentionally Left Blank)
5/1/2010
707-2
Conduit System on Structure
Section 710
Epoxy Coated Reinforcing Steel
710.1 Description. This work shall consist of furnishing and placing epoxy-coated reinforcing steel of the shape, size and grade shown on the plans, and in accordance with Section 706, except as modified herein. 710.2 Materials. 710.2.1 All material shall be in accordance with Division 1000 Material Details, and specifically as follows: Item Section Epoxy Coated Reinforcing Steel................................................ 1036 710.2.2 Epoxy coated reinforcing steel shall not be flame-cut. 710.3 Construction Requirements. 710.3.1 Handling. All systems for handling epoxy-coated bars shall have padded contact areas. If, in the judgment of the engineer, the coating is damaged to the extent that the coating can no longer provide the intended protection and cannot be satisfactorily patched, the material shall be returned to the coating applicator for repair or shall be replaced. 710.3.2 Placement. 710.3.2.1 Epoxy-coated bars shall be held securely in the correct position with approved metal bar supports coated with plastic or epoxy or on plastic bar supports, and shall be held in place by use of plastic-coated tie wires or molded, plastic clips. When placing epoxy-coated bars, the bars shall be prevented from coming into contact with other steel items such as drains and shear connectors. 710.3.2.2 The contractor shall prevent damage to the epoxy coating when placing and vibrating concrete. In order to prevent damaging the coated bars, the vibrator head shall be covered with a sheet of rubber, and shall be equipped with a rubber tip with a maximum diameter of 2½ inches. Another resilient material may be substituted for rubber as approved by the engineer. 710.3.2.3 After the reinforcing bars are secured to approved bar supports, a final visual inspection will be made, and all uncoated or damaged areas shall be coated or repaired in accordance with Section 710.3.3 as directed by the engineer. 710.3.3 Repairing Bars. All damaged areas of epoxy coating shall be patched with the material specified in Section 1036, and in accordance with the manufacturer's recommendations. All sheared or cut ends of bars, end areas left bare during the coating process, and any areas where the entire coating is removed shall be patched. All repairs shall be completed as soon as practical, and in the case of bare end areas and sheared ends, before visible oxidation of the surface occurs.
5/1/2010
710-1
Epoxy Coated Reinforcing Steel
710.3.4 Mechanical Bar Splices. Requirements for mechanical bar splice systems shown on the plans shall be in accordance with Section 706. Epoxy coated mechanical bar splices shall be used with epoxy-coated reinforcing steel, and if the epoxy coating is damaged, shall be repaired in accordance with Section 710.3.3 as directed by the engineer. 710.4 Method of Measurement. Measurement of epoxy coated reinforcing steel will be made for plan weight of uncoated bars in accordance with Section 706.4. 710.5 Basis of Payment. 710.5.1 The accepted quantity of epoxy-coated reinforcing steel, including any approved mechanical bar splice systems, complete in place, will be paid for at the contract unit price. 710.5.2 Repair of damaged epoxy coating will be at the contractor's expense.
5/1/2010
710-2
Epoxy Coated Reinforcing Steel
Section 711
Protective Coatings for Exposed Concrete Surfaces
711.1 Description. This work shall consist of the surface preparation and application of protective coatings for sealing and protecting exposed concrete elements. The locations and elevations of the protective coatings shall be as shown on the bridge plans. The work involving temporary coating on weathering steel bridges shall also include the removal of the temporary coating. 711.2 Materials. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item Section Protective Coating Material ....................................................... 1059 711.3 Construction Requirements. 711.3.1 Protective Coating - Concrete Bents and Piers (Urethane). This protective coating shall consist of a modified urethane or polyurethane elastomer. New concrete shall cure a minimum of 28 days prior to application of the protective coating. The coating shall be applied to dry surfaces. The surface preparation and application shall be in accordance with the manufacturer's recommendations. The coating shall be applied to obtain a minimum dry film thickness of 40 mils. Any unevenly applied film that causes ponding of water shall be given additional coats as directed by the engineer. 711.3.2 Protective Coating - Concrete Bents and Piers (Epoxy). This protective coating shall consist of a two-component, modified polyamide converted epoxy, clear or gray in color. New concrete shall cure a minimum of 28 days prior to application of the protective coating. The coating shall be applied to dry surfaces. The surface preparation and application shall be in accordance with the manufacturer's recommendations. The coating shall be applied to obtain a minimum dry film thickness of 6 mils. 711.3.3 Concrete and Masonry Protection System. This protective coating shall consist of a clear penetrating siloxane or silane based sealer. The surface preparation and application shall be in accordance with the manufacturer's recommendations. Field approval of the proposed material will be in accordance with Section 1059. 711.3.4 Sacrificial Graffiti Protection System. This system shall consist of a clear coating that can be removed with a hot water wash. The surface preparation and application shall be in accordance with the manufacturer's recommendations. Field approval of the proposed material will be in accordance with Section 1059.
5/1/2010
711-1
Protective Coatings for Exposed Concrete Surfaces
711.3.5 Temporary Coating - Concrete Bents and Piers (Weathering Steel). This protective coating shall consist of a clear temporary coating applied to the concrete substructure for protection against staining from weathering steel girders during initial weathering. The surface preparation and application shall be in accordance with the manufacturer's recommendations. The concrete substructure shall be cured a minimum of 14 days prior to application, unless otherwise specified by the manufacturer. The coating shall be applied to the concrete substructure before the erection of structural steel. The temporary coating shall be removed by the contractor after construction of the deck and curbs is complete, or as directed by the engineer. 711.4 Basis of Payment. The accepted quantity of protective coatings for exposed concrete surfaces will be paid for at the contract lump sum price.
5/1/2010
711-2
Protective Coatings for Exposed Concrete Surfaces
Section 712
Structural Steel Construction
712.1 Description. This work shall consist of the field construction of bridges and structures made of structural steel and miscellaneous metals. 712.2 Materials. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Shear Connectors ..................................................................... 1037 Paint for Structural Steel............................................................ 1045 Structural Steel Fabrication ....................................................... 1080 Coating of Structural Steel......................................................... 1081 712.3 Handling, Transporting, Storing and Erecting. Fabricated material shall be properly braced and supported at all times to prevent damage from torsional, vertical and lateral deflections. Members or shipped material showing possible damage during handling, transporting, storing or erecting will be subjected to nondestructive tests as directed by the engineer. The costs of these tests will be at the contractor’s expense. Fabricated structural steel shall be stored on suitable supports. Trough sections shall be stored in a manner to provide drainage. Any material that has become bent shall be straightened before being assembled or shall be replaced, if necessary. Material intended for use in the finished structure shall not be used by the contractor for erection or temporary purposes unless such use is provided for in the contract, or with written approval from the engineer. 712.4 Falsework. Staging and falsework necessary for the erection of the structure shall be furnished and placed and, upon completion of the erection, removed by the contractor. If required, plans for falsework shall be submitted to the engineer before starting the work, but the engineer's acceptance of the plans will not relieve the contractor of the responsibility for obtaining satisfactory results. 712.5 Erection. Erection of all parts of the structure shall be in accordance with the erection diagram or working drawings. Surfaces to be in permanent contact shall have all burrs and loose scale removed. Before erection, machine finished surfaces shall be cleaned of the protective coating, other than the primer permitted by the contract, and contact surfaces shall be given a heavy coat of graphite and oil. Connections match-marked in the shop shall be erected in accordance with those match marks. Interchange or reversal of match-marked connections will not be permitted. Any damage or distortion of members will not be permitted. 712.5.1 Fit-up and Drifting. Truss spans, plate girders and continuous I-beams shall be supported to maintain required camber during erection. High-strength bolted field splices and primary connections, except for trusses and structures carrying live load erection stresses, shall have no less than one-half of the holes fitted with bolts and cylindrical drift pins using one-third fitting up bolts and two-thirds pins. Splices and primary connections carrying erection traffic during erection or truss connections shall have no less than three-fourths of the holes filled with drift pins and bolts using one-third fitting up bolts and two-thirds pins. The specified ratio of pins to bolts shall apply to each element of the splice, for example, top flange, web and bottom flange of girders. Fitting up bolts shall be the same diameter as the
5/1/2010
712-1
Structural Steel Construction
high-strength bolts. Drift pins shall be at least 1/32 inch larger than the high strength bolts to provide a driving fit. Fitting up bolts shall be placed uniformly to draw the entire splice tight. All fitting up bolts and drift pins shall be properly installed before beginning high strength bolt installation. Bolts used for fitting up shall not be used in the final assembly. Holes that do not match shall be reamed only with approval from the engineer. Drifting that would distort the metal will not be permitted. 712.5.2 Bearings. The lead plates or preformed rubber and fabric pads shall be approximately ⅛ inch thick and ½ inch greater in length and width than the bottom bearing plates under which the plates are to be placed. Lead plates shall weigh approximately 8 psf. Preformed rubber and fabric pads shall be in accordance with Section 1038. Shop drawings will not be required for lead plates or preformed rubber and fabric pads. Lead plates or preformed rubber and fabric pads will be considered incidental to bearings, and payment will be considered as covered under the contract unit price for bearings. 712.5.3 Anchor Bolts. Anchor bolts for steel superstructures shall be set in the substructure units in accordance with the details shown on the plans. When anchor bolts are set during the placing of concrete, the bolts shall be accurately located and held firmly in place by a method that permits proper finishing of the surface of the concrete, and shall remain in place until the concrete has set. Where permitted or required, the anchor bolt wells may be omitted, and in lieu thereof, holes drilled into the substructure. The anchor bolt holes shall be drilled in the exact location shown, to the required depth and perpendicular to the plane of the bridge seat. The drilled holes shall be no smaller than the diameter of the holes in the steel bearing plates or castings. When the anchor bolts are set in holes or wells, the hole or well shall be clean and dry prior to grouting with an expansive mortar in accordance with Section 1066. Excess mortar forced out of the holes shall be removed. The location of anchor bolts in relation to the center of slotted holes provided in movable plates and shoes shall be varied to compensate for the movement of spans due temperatures above or below 60° F. Nuts on anchor bolts through moving parts of expansion bearings shall be adjusted to provide ample clearance for free movement of the span. 712.5.4 Grouting. Grouting under bearing plates and castings to build the bearing plates and castings to the proper grade will not be permitted. Steel shims the full size of the plate of the bearing device may be used for this purpose. Shims shall be placed between the bottom of the stringers and the top of bearing plates, if practical, and shall be straightened to a plane surface. 712.6 Field Welding. All field welding shall be performed in accordance with Section 1080. 712.6.1 Certification. All field welders shall be certified to weld on all steel products incorporated in MoDOT projects. 712.6.2 Testing. Field welders shall be qualified by a test facility with an established accredited AWS Certified Welder Program as defined in AWS Standard QC 4-89 or by an independent testing laboratory furnished by the contractor. If specimens are to be tested at an independent testing laboratory, the tests shall be witnessed and properly documented by the engineer. All tested specimens and radiographs, including the laboratory's test report certifying the test results, shall be delivered to the engineer for final acceptance or rejection. If the field welder was tested and certified by a facility with an established accredited AWS Certified Welder Program, as defined in AWS Standard QC 4-89, the tested specimens and radiographs will not be subject to the engineer's review. A copy of the welder's certification 5/1/2010
712-2
Structural Steel Construction
from the AWS test facility shall be delivered to the engineer. 712.6.3 Issuance of Cards. Qualification cards will be issued by the engineer for field welders working on County projects. No individual may weld on a County project unless the engineer can confirm the individual has continued to weld on County projects with the processes and in the positions for which the individual was initially certified, without an interruption exceeding 12 months. The engineer may require recertification if there is specific reason to question the welder's ability. 712.6.4 Welding Procedures. Welding procedures shall be submitted for review prior to welding, at the engineer's request. 712.7 High-Strength Bolt Installation. 712.7.1 Bolted Parts. The slope of surfaces of bolted parts in contact with the bolt head and nut shall not exceed one in 20 with respect to a plane normal to the bolt axis. All bolted parts, including underhead bearing areas and joint surfaces within the grip of the bolt, shall fit solidly together when assembled in the snug tight condition, and shall not be separated by gaskets or any other interposed compressible material. When assembled, all joint surfaces, including those adjacent to the bolt heads, nuts or washers, shall be free of scale, dirt, burrs, other foreign material and other defects that would prevent solid seating of the parts. Contact surfaces within friction-type joints shall be free of oil and paint, except in accordance with Section 1081.3.9, lacquer, rust inhibitor and galvanizing. All bolts, nuts and washers shall be free of rust, burrs, dirt, other foreign material and other defects that would prevent proper tensioning. All nuts for coated high-strength bolts shall be properly lubricated with a visible water-soluble lubricant. All nuts for uncoated high-strength bolts shall be properly lubricated with a water-soluble lubricant that is oily to the touch. 712.7.2 Snug Tightness of Connections. Regardless of the method of final tightening used to install the fasteners, the joint and all fasteners shall first be brought to the snug tight condition. Snug tight will be defined as the tightness where all faying surfaces of the joint are in firm contact as attained by a few impacts of an impact wrench or the full effort of a person using an ordinary spud wrench. Snug tightening shall progress systematically from the most rigid part of the connection to the free edges. Bolts shall be retightened in a similar manner as necessary until all bolts are simultaneously snug tight, and the section is fully compacted with the bolted parts of the joint in full contact. 712.7.3 Bolt Tension. Each fastener shall be tightened to provide, when all fasteners in the joint are tight, at least the minimum bolt tension shown below for the size and grade of fastener used. Threaded bolts shall be tightened by methods described in Sections 712.7.5, 712.7.6, or 712.7.7. If required because of bolt entering and wrench operation clearances, tightening may be done by turning the bolt while the nut is prevented from rotating. On nonparallel abutting surfaces where bevel washers will not be required, the nut shall be torque against the non-sloping surface. Nuts shall be placed on the inside face of exterior girders, the top of girder flanges or in other situations the least exposed position, except if inaccessible for turning, on a sloping surface or otherwise approved by the engineer. Impact wrenches, if used, shall be of adequate capacity and sufficiently supplied with air to perform the required tightening of each bolt in approximately 10 seconds. Bolts or nuts, once tensioned and subsequently loosened (turned), shall not be used as permanent bolts or nuts. Bolt tension calibration devices shall be calibrated and certified as to accuracy by a private testing lab within one year before usage, or at any time the tensioning process indicates that the 5/1/2010
712-3
Structural Steel Construction
calibration is in error. Bolt Tension Bolt Size (in.)
Minimum Bolt Tension (lb x 1000) A 325
A 490
½
12
15
⅝
19
24
¾
28
35
⅞
39
49
1
51
64
1⅛
56
80
1¼
71
102
1⅜
85
121
1½
103
148
712.7.4 Washers. All fasteners shall have a hardened washer under the nut or bolt head, whichever is turned in tightening. All fasteners over all oversized or slotted holes shall also have a hardened washer under the non-turned element. Where an outer face of the bolted parts has a slope of more than one in 20 with respect to a plane normal to the bolt axis, a smooth beveled washer shall be used to compensate for the lack of parallelism. 712.7.5 Calibrated Wrench Method. When calibrated wrenches are used to provide the bolt tension specified in Section 712.7.3, the wrench setting shall be such as to induce a bolt tension 5 to 10 percent in excess of the specified value. Wrenches shall be calibrated at least once each working day by tightening in a device capable of indicating actual bolt tension no less than three typical bolts of each diameter from the bolts to be installed. Power wrenches shall be adjusted to stall or cut out at the selected tension. If manual torque wrenches are used, the torque indication corresponding to the selected tension shall be noted and used in the installation of all bolts of the tested lot. Nuts shall be in tightening motion when torque is measured. After the joint has been brought to a snug tight condition, all bolts in the joint shall be tightened by progressing systematically from the most rigid part of the joint to the free edges. When using calibrated wrenches to install several bolts in a single joint, the wrench shall be returned to "touch up" bolts previously tightened, which may have been loosened by the tightening of subsequent bolts, until all are tightened to the selected tension. During tightening, there shall be no rotation of the part not turned by the wrench. 712.7.6 Turn-of-Nut Method. When the turn-of-nut method is used to provide the bolt tension, there shall first be enough bolts brought to a snug tight condition as defined in Section 712.7.2 to ensure that the parts of the joint are brought into full contact with each other. Following this initial operation, bolts shall be placed in any remaining holes in the connection and brought to snug tightness. All bolts in the joint shall then be tightened additionally by the applicable nut rotation specified below, with tightening progressing systematically from the most rigid part of the joint to the free edges. During this operation, there shall be no rotation of
5/1/2010
712-4
Structural Steel Construction
the part not turned by the wrench. Nuta Rotation from Snug Tight Condition Disposition of Outer Faces of Bolted Parts Bolt Faces normal to bolt axis
One face normal to bolt axis and other face sloped not more than 1:20 (bevel washer not used)
Both faces sloped not more than 1:20 from normal to bolt axis (bevel washers not used)
Up to and including 4 diameters
⅓ turn
½ turn
⅔ turn
Over 4 diameters but not exceeding 8 diameters
½ turn
⅔ turn
Over 8 diameters but not exceeding 12 diameters
⅔ turn
⅚ turn
⅚ turn
Bolt length measured from underside of head to extreme end of point
a
1 turn
Nut rotation shall be relative to bolts, regardless of the element (nut or bolt) being turned. For bolts installed by one-half of a turn and less, the tolerance will be ± 30 degrees. For bolts installed by two-thirds of a turn and more, the tolerance will be ± 45 degrees.
712.7.7 Load Indicating Bolt Method. Tightening by this method will be permitted, provided it can be demonstrated by the following procedure that the bolt has been tightened, at a minimum, to the bolt tension indicated in Section 712.7.3. Three bolts of a representative length and of the same grade, diameter and condition as those under inspection shall be placed individually in a calibration device capable of indicating bolt tension. There shall be a washer under the part turned in tightening each bolt. Each bolt specified shall be tightened in the calibration device until the spline drive has sheared off. When this method is used to provide the bolt tension, all bolts in the joint shall be tightened in stages to prevent or minimize slackening of the installed bolts. The first stage shall be to tighten all bolts to a snug tight condition at which point all of the faying surfaces of the joint shall be firmly in contact. The final stage of tightening to full tension shall be accomplished by progressing systematically from the most rigid part of the joint to the free edges. 712.7.8 Bolt Length. When snug tight, the beginning of the bolt threads shall be even with or project slightly beyond the nut. When properly tensioned, the bolt projections beyond the nut shall be as such to prevent the nut from engaging the thread runout. 712.7.9 Bolt Tension Calibration Device. A Skidmore-Wilhelm Calibrator or an acceptable equivalent tension measuring device will be required at each job site during erection. Periodic testing, at least once each working day when the calibrated wrench method is used, shall be performed to assure compliance with the installation test procedures required for the tightening method used, and to perform pre-installation job site rotational-capacity testing. Bolts too short for the Skidmore-Wilhelm Calibrator may be tested using direct tension indicators (DTI). The DTI shall be calibrated in the Skidmore-Wilhelm Calibrator using longer bolts. Bolt tension calibration devices shall be calibrated and certified as to accuracy by a private testing laboratory within one year before usage or at any time the accuracy is questionable.
5/1/2010
712-5
Structural Steel Construction
712.7.10 Rotational-Capacity Testing. The rotational-capacity test shall be performed on each rotational-capacity lot prior to the start of bolt installation. Hardened steel washers shall be part of the test, regardless if washers will not be required as part of the installation procedure. Bolt, nut, and washer when required, combinations as installed shall be only from the established and tested rotational-capacity lot. 712.7.11 Weathered Bolts. Weathered or rusted bolts or nuts not in accordance with Sections 712.7.1, 712.7.3 and 712.7.10, shall be cleaned and relubricated prior to installation. Recleaned or relubricated bolt, nut and washer assemblies shall be retested in accordance with Section 712.7.10 prior to installation. 712.7.12 Inspection. The engineer will observe the installation and tightening of bolt assemblies to determine that the selected tightening procedure is properly used, and will determine that all bolt assemblies are tightened. The following verification inspection will be used: a) Either the engineer, or the contractor in the presence of the engineer, will use an inspecting torque wrench and bolt tension calibration device furnished by the contractor. b) Five bolt assemblies of a representative length, and of the same grade, diameter and condition as those under inspection will be placed individually in a calibration device capable of indicating bolt tension. There will be a washer under the part turned in tightening each bolt. Each bolt specified will be tightened in the device by any convenient means to the minimum tension specified in Section 712.7.3. The inspecting torque wrench then will be applied to the tightened bolt, and the torque necessary to turn the nut or head 5 degrees, approximately one inch at 12-inch radius, in the tightening direction will be determined. Of the five values obtained, the highest and the lowest values will be disregarded, with the average of the remaining three being taken as the job inspecting torque to be used in the manner specified in Section 712.7.12. The inspecting torque will be re-established at intervals of no more than 30 calendar days or at any time appreciable changes are encountered. c) Bolts represented by the sample prescribed in Section 712.7.12 that have been tightened in the structure will be inspected by applying, in the tightening direction, the inspecting wrench and the wrench’s job inspecting torque to 10 percent of the bolts, but no less than two bolts, selected at random in each connection. If no nut or bolt head is turned by this application of the job inspecting torque, the connection will be accepted as properly tightened. If any nut or bolt head is turned by the application of the job inspecting torque, this torque shall be applied to all bolts in the connection. All bolts whose nut or head was turned by the job inspecting torque shall be tightened and re-inspected. d) Calibrated wrench tightening will be verified during actual installation in the assembled steel work. The wrench adjustment selected by the calibration shall not produce a bolt or nut rotation from snug tight greater than permitted in Section 712.7.6. 712.8 Field Coating. Field coating of structural steel shall be in accordance with Section 1081.
5/1/2010
712-6
Structural Steel Construction
712.9 Steel Bar Dams. Steel bar dams placed at expansion devices on existing bridges to serve as headers for surfacing material shall be installed in a manner that will not interfere with the movement of the expansion devices. 712.10 Method of Measurement. 712.10.1 Steel and Iron. Payment for structural steel and wrought iron weights will be based on contract plan quantities. The theoretical weight of the various sections will be used to compute the contract plan quantities of the material incorporated in the completed structure. No allowance will be made for overrun in scale weights or for erection bolts, excess field bolts or similar items, or the weight of any coating, galvanizing or weld material. 712.10.2 Bolts. The weight of steel bolts for steel-to-steel connections will be included in the contract plan quantities for fabricated structural steel on the basis of following weights per 100 bolts: Bolt Weights a
a
Bolt Size (in.)
Weight (lb.)
⅝
40
¾
65
⅞
95
1
135
These specified weights will be considered to cover the head, nut, any required washers and only that part of the bolt extending outside the grip of steel.
712.10.3 Connection to Concrete or Timber. The weight of bolts connecting steel to concrete or timber will be included for payment as fabricated structural steel, and the full weight of the bolts will be computed. 712.10.4 Castings. Castings will be computed on the basis of the theoretical weight of the material in the completed structure, and no allowance will be made for overrun in scale weights or for the weight of any coating material, galvanizing material or other protective coatings. 712.10.5 Accuracy of Weights. Weights of structural steel, wrought iron and castings will be computed to the nearest 10 pounds of the total weight of each class of material in the completed structure. 712.10.6 Coatings. For recoating or overcoating, the contract documents will indicate the estimated number of tons to be coated for informational purposes. 712.10.6.1 Weight Measurement. If the contract specifies a unit of measurement of coating steel structures in tons, the weight of the steel to be cleaned and coated will be based on plan quantities to the nearest 1/10-ton. The weight will not vary with the number of coats applied.
5/1/2010
712-7
Structural Steel Construction
712.10.6.2 Surface Area Measurement. If the contract specifies a unit of measurement of coating steel structures in square feet, the area of the girders or stringers to have surface preparation performed or to be coated will be computed to the nearest 100 square feet. The bearings, diaphragms, stiffeners and all other miscellaneous steel within the limits of surface preparation or of the field coatings will not have the area computed and will be considered completely covered by the area computations of the girders or stringers. The area will not vary with the number of coats applied. Final measurement will not be made. 712.10.6.3 Lump Sum Measurement. Measurement will not be made when the contract specifies units of measurement per lump sum. 712.10.7 Bar Dams. A steel bar dam shall consist of the complete assembly on both sides of the expansion joint and will be considered a unit. 712.10.8 Shear Connectors. The weight of shear connectors will be based on the theoretical weight and will be included for payment in the weight of material to which the connectors are attached. 712.11 Basis of Payment. 712.11.1 Fabricated Steel. Payment for fabricated structural steel, fabricated wrought iron, steel castings and gray iron castings will be based on the contract plan quantities. Any change in the contract plan quantities based on approved change orders will be paid for at the contract unit price. Payment for the shop prime coat, including inaccessible areas, will be included in the cost of fabricated structural steel, and no direct payment will be made. No direct payment will be made for coating bolted field connections, touch-up, galvanizing, applying protective coating to machined surfaces or for cleaning coatings and rust streaks from finished concrete. 712.11.2 Hardware. Bolts for attaching timber members to any part of a structure will be classified as hardware and no direct payment will be made. 712.11.3 Coatings. Payment for surface preparation and applying field coatings to the structural steel, if specified as a contract item, will be based on the contract plan quantities. Any change in the contract plan quantities, based on approved change orders, will be paid for at the contract unit price. If no contract item is specified for surface preparation or applying field coatings, no direct payment will be made. Payment for the shop applied coatings, including inaccessible areas, will be considered completely covered by the cost of the fabricated structural steel. No direct payment will be made for the surface preparation or applying field coatings to the bearings, diaphragms, stiffeners and all other miscellaneous steel within the limits of surface preparation or of the field coatings. No direct payment will be made for stencils, paint and painting specified in Section 1081. No direct payment will be made for field touch-ups specified in Section 1081. 712.11.4 Bar Dams. The accepted number of steel bar dams will be paid for at the contract unit price.
5/1/2010
712-8
Structural Steel Construction
Section 713
Bridge Guard Rail
713.1 Description. This work shall consist of furnishing and erecting steel beam guard rail as designated on the plans, including beams, posts, and all appurtenances, complete in place. 713.2 Materials. All materials shall conform to the general requirements of Division 1000, Materials Details, and specifically as follows: Item
Section
Guard Rail, Guard Cable, and Guard Fence Materials ............. 1040 713.3 Construction Requirements. Anchor bolts for posts shall be set with suitable templates in exact position and securely fixed to prevent displacement during the concreting operations. If posts are to be set on concrete, the areas upon which their bases are to bear shall be dressed smooth to a true plane by grinding or rubbing. Posts shall be aligned by the use of shims so that in final adjustment no post shall deviate more than ½ inch from true alignment. 713.4 Method of Measurement. Measurement of bridge guard rail will be made to the nearest linear foot for each structure, measured along the face of the beam and from center to center of end posts. Final measurement of the completed bridge guard rail will not be made except for authorized changes during construction, or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. 713.5 Basis of Payment. The accepted quantity of bridge guard rail, complete in place, will be paid for at the unit bid price for each of the pay items included in the contract.
5/1/2010
713-1
Bridge Guard Rail
(This Page Intentionally Left Blank)
5/1/2010
713-2
Bridge Guard Rail
Section 715
Vertical Drain at End Bents
715.1 Description. This work shall consist of furnishing and installing a vertical drain system consisting of drain core, geotextile fabric, perforated and unperforated drain pipe, couplers and a rodent screen as shown on the plans or as directed by the engineer. 715.2 Materials. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Geotextile ...............................................................................1011 Geocomposite Drainage Material ............................................ 1012 Miscellaneous Drainage Material ............................................ 1013 Corrugated Metallic-Coated Steel Pipe Underdrain ................. 1022 715.3 Construction Requirements. 715.3.1 The contractor shall install the vertical drain system in accordance with the manufacturer's recommendations. 715.3.2 If the core of the drain is not perforated, modifications shall be made to the core to provide adequate drainage into the drain pipe as approved by the engineer. 715.3.3 Vertical and horizontal joints shall be constructed to form an uninterrupted drain face after compaction is completed. All joints shall have an overlap of geotextile to prevent any intrusion of fill material into the drain. Horizontal joints shall be designed to drain downward. Any cracks or openings in the drain adjacent to the fill will be cause for rejection of the drain, and the drain shall be replaced by the contractor, at the contractor’s expense. 715.3.4 The backfill material shall be placed and compacted in accordance with Section 206. The backfill shall be placed in such a manner as to prevent damage to the vertical drain system. The backfill material shall be as approved by the engineer. 715.4 Method of Measurement. The work provided herein will not be measured for payment, but will be considered completely paid for as a system, per each. 715.5 Basis of Payment. The accepted vertical drain system, complete in place, will be paid for at the contract unit price for vertical drain at end bents, per each. No direct payment will be made for excavation, backfilling, compaction, drain pipe or other material and work.
5/1/2010
715-1
Vertical Drain at End Bents
(This Page Intentionally Left Blank)
5/1/2010
715-2
Vertical Drain at End Bents
Section 716
Neoprene Bearings
716.1 Plain and Laminated Neoprene Bearing Pads. 716.1.1 Description. This work shall consist of furnishing and installing complete factoryproduced plain or laminated neoprene bearing pads as shown on the plans or as directed by the engineer. 716.1.2 Materials. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Elastomeric Bearing Pads .......................................................1038 716.1.3 Construction Requirements. The neoprene pads shall be bonded to the bearing seat with an epoxy adhesive, in accordance with the bearing manufacturer's recommendations for bonding neoprene to concrete to prevent sliding. 716.1.4 Method of Measurement. Measurement will be made per each. The plain neoprene bearing pad, complete in place, shall include the plain neoprene bearing pad and any incidental materials needed to complete the work. The laminated neoprene bearing pad, complete in place, shall include the laminated neoprene bearing pad and any incidental material needed to complete the work. 716.1.5 Basis of Payment. The accepted quantity of plain neoprene bearing pads will be paid for at the contract unit price. 716.2 Laminated Neoprene Bearing Pad Assembly. 716.2.1 Description. This item shall include furnishing and installing complete factory produced bearings as shown on the plans or as directed by the engineer. 716.2.2 Materials. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Elastomeric Bearing Pads .......................................................1038 716.2.3 Construction Requirements. All sole plates shall be furnished with the bearings as a complete unit and directly welded to the girder or stringer as shown on the plans. The neoprene pads shall be bonded to the bearing seat with an epoxy adhesive in accordance with the bearing manufacturer’s recommendations for bonding neoprene to concrete to prevent sliding.
5/1/2010
716-1
Neoprene Bearings
716.2.4 Method of Measurement. Measurement will be made per each. The laminated neoprene bearing pad assembly, complete in place, shall include the steel sole plate, laminated neoprene bearing pad, anchor bolts, heavy hexagon nuts, coating and any incidental material needed to complete the work. 716.2.5 Basis of Payment. The accepted quantity of laminated neoprene bearing pad assemblies will be paid for at the contract unit price. 716.3 Type "N" Polytetrafluoroethylene (PTFE) Bearings. 716.3.1 Description. This work shall consist of furnishing and installing complete factory produced Type “N” PTFE bearings as shown on the plans or as directed by the engineer. 716.3.2 Materials. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Type "N" PTFE Bearings.........................................................1038 716.3.3 Construction Requirements. All sole plates shall be furnished with the bearings as a complete unit and directly welded to the girder or stringer as shown on the plans. At the time of installation, the stainless steel sliding face of the upper element and the PTFE sliding face of the lower element shall have the surface finish specified and shall be free of all dust, dirt, moisture or any other foreign matter. The neoprene pads shall be bonded to the bearing seat with an epoxy adhesive in accordance with the bearing manufacturer’s recommendations for bonding neoprene to concrete to prevent sliding. The top and bottom plates shall be properly aligned before gluing pads. 716.3.4 Method of Measurement. Measurement will be made per each. The type "N" PTFE bearing, complete in place, shall include the steel sole plate, stainless steel plates, PTFE face on the stainless steel plates, laminated neoprene bearing pad, anchor bolts, heavy hexagon nuts, coating and any incidental material needed to complete the work. 716.3.5 Basis of Payment. The accepted quantity of type "N" PTFE bearings will be paid for at the contract unit price.
5/1/2010
716-2
Neoprene Bearings
Section 717
Neoprene and Silicone Joint Systems
717.1 Preformed Compression Seal. 717.1.1 Description. This work shall consist of furnishing and installing a preformed compression seal for joints as shown on the plans or as directed by the engineer. Structural steel for the joints shall be furnished and installed as shown on the plans. 717.1.2 Materials. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Preformed Compression Seals ...............................................1073 717.1.3 Construction Requirements. 717.1.3.1 Shop Drawings. Shop drawings for structural steel for expansion devices shall be prepared in accordance with Section 1080. The dimensions of the seal shall be shown on the shop drawings for the armored joint. Shop drawings will not be required when the seal is placed against concrete or existing armor steel. 717.1.3.2 Installation. The preformed compression seal shall be installed in joints in one continuous piece without field splices. Factory splicing will be permitted for joints in excess of 53 feet. The area of steel armor to come in contact with preformed compression seal lubricant adhesive shall be sand blasted prior to installing the seal. Sand blasting will be considered acceptable when the steel surfaces have been cleaned to an SSPC-SP10 degree of cleanliness. The lubricant adhesive shall be applied in a continuous film to the sides of the seal and to the joint surfaces just prior to placing the seal in the joint. The seal shall be installed with an installation tool recommended by the manufacturer, in a manner that prevents the seal from being damaged and from being in tension. Twisting, curling and nicking the seal will be prohibited. Lubricant adhesive on top of the installed seal shall be removed before drying. Unless the installation tool is capable of installing the seal without elongation prior to placement, the seal shall be pre-cut to the exact length for the joint plus ends as shown in the contract documents. The pre-cut seal shall be installed and measured for stretch. The seal shall be removed and reinstalled if the seal stretch length exceeds five percent of the pre-cut length. 717.1.4 Method of Measurement. Final measurement will not be made except for authorized changes during construction or where significant errors are found in the contract quantity. Where required, the preformed compression seal will be measured to the nearest linear foot based on measurement from roadway face of curb to roadway face of curb along the centerline of the joint. The revision or correction will be computed and added to or deducted from the contract quantity. No measurement will be made of portions of the joint that extend past the roadway face of curbs. 717.1.5. Basis of Payment. Preformed compression seals, including all material, coating, equipment, labor, fabrication, installation and any other incidental work necessary to complete this work, will be paid for at the contract unit price.
5/1/2010
717-1
Neoprene and Silicone Joint Systems
717.2 Strip Seal. 717.2.1 Description. This work shall consist of furnishing and installing a watertight strip seal for joints as shown on the plans or as directed by the engineer. The structural steel for the joints shall be furnished and installed as shown on the plans. 717.2.2 Materials. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Strip Seals ..............................................................................1073 717.2.3 Construction Requirements. 717.2.3.1 Shop Drawings. Shop drawings shall be prepared for the armored joint in accordance with Section 1080. The drawings shall show in detail the type, size, location of anchors, and sequence of installation. The extrusion in the steel armor shall be of a dimensional tolerance that prevents the gland of the strip seal from slipping loose. The upper lip of the extrusion shall extend over the bottom lip to avoid pinching the gland when the expansion device is in a closed position. Shop drawings will not be required when the seal is placed in existing steel extrusions. 717.2.3.2 Installation. The area of steel armor to come in contact with strip seal lubricant adhesive shall be sand blasted prior to installing the seal. Sand blasting will be considered acceptable when the steel surfaces have been cleaned to an SSPC-SP10 degree of cleanliness. The strip seal shall be made watertight with a lubricant adhesive for bonding the neoprene gland to the steel extrusion as recommended by the manufacturer. The contractor shall obtain the services of a qualified technical representative, approved by the manufacturer of the expansion system and acceptable to the engineer, to assist during the installation. The installation shall not occur without the technical representative being present. 717.2.4 Method of Measurement. Final measurement will not be made except for authorized changes during construction, or where appreciable errors are found in the contract quantity. Where required, the strip seal will be measured to the nearest linear foot, based on measurement from the roadway face of curb to roadway face of curb along the centerline of the joint. Portions of the joint that extend past the roadway face of curbs will not be measured for payment. The revision or correction will be computed and added to or deducted from the contract quantity. 717.2.5. Basis of Payment. Strip seals, including all material, coating, equipment, labor, fabrication, installation, technical assistance, and any other incidental work necessary to complete this work, will be paid for at the contract unit price. 717.3 Silicone Expansion Joint Sealant. 717.3.1 Description. This work shall consist of furnishing and installing the backer rod and silicone expansion joint sealant for joints as shown on the plans or as directed by the engineer. Structural steel for the joints shall be furnished and installed as shown on the plans. 5/1/2010
717-2
Neoprene and Silicone Joint Systems
717.3.2 Materials. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Silicone Expansion Joint Sealant ............................................ 1057 717.3.3 Construction Requirements. The contractor shall furnish to the engineer the manufacturer's written product information, installation procedures and instructional information at least two weeks prior to installation. The contractor shall obtain the services of a qualified technical representative approved by the manufacturer of the expansion system and acceptable to the engineer, to assist during the installation. The contractor, the technical representative and the engineer shall meet to review and clarify installation procedures and requirements prior to starting the work. The start of surface preparations and sealant installation shall not occur without the technical representative being present. The technical representative shall be present for at least one day at the start of surface preparations and sealant installation. 717.3.3.1 Shop Drawings. Shop drawings for structural steel for expansion devices shall be prepared in accordance with Section 1080. The dimensions of the seal shall be shown on the drawings for the armored joint. Shop drawings will not be required when the sealant is placed against concrete or existing armor steel. 717.3.3.2 Surface Preparation. The concrete or steel surface shall be prepared for priming and sealant placement. New portland cement concrete shall be fully cured and allowed to dry a minimum of seven days. The joint shall be cleaned of all gravel, loose material and other contaminates before sand blasting. Areas that will be in contact with the sealant shall be sand blasted with a clean, hard aggregate that will leave little to no dust residue. Sand blasted concrete surfaces will be considered acceptable when areas that will be in contact with the sealant have a roughened surface with clean, exposed aggregate. The surface shall be free of foreign matter or plastic residue. Sand blasted steel surfaces will be considered acceptable when the steel surfaces have been cleaned to an SSPC-SP10 degree of cleanliness. After sand blasting is completed, the joint shall be cleaned of debris using oil-free and water-free compressed air or a vacuum, either being at least 90 psi. 717.3.3.3 Priming. Priming shall immediately follow sand blasting and cleaning and will only be permitted to proceed when the air and substrate temperatures are at least 40°F and rising. Sand blasting, priming and sealing shall be performed on the same day. The entire sand blasted surface shall be primed. Application and drying times for primers shall be in accordance with the manufacturer’s recommendations. All leftover primer shall be properly disposed. 717.3.3.4 Joint Installation. The backer rod shall be installed as specified on the plans and in accordance with the manufacturer’s recommendations. All voids in the installed backer rod shall be filled to prevent sealant leakage. 717.3.3.5 Sealant Placement. The sealant thickness and recess depth shall be as shown in the contract documents and shall be measured during installation at approximately 2 foot intervals. Adjustments to correct sealant thickness to within ± ⅛ inch 5/1/2010
717-3
Neoprene and Silicone Joint Systems
tolerance shall be made before the sealant begins to set. Sealant placement will only be permitted when the air and substrate temperatures are above 40°F, below 90°F and 5°F above the dew point. The joint surfaces shall be kept clean and dry during sealing. The joint shall remain clean and dry during the sealing operation. Sealing shall be performed using a pneumatic gun in accordance with the manufacturer’s recommendations. End of seal treatment at vertical faces of curbs, sidewalks or parapets shall be as recommended by the manufacturer and as shown in the contract documents. Sealant placed incorrectly shall be removed and replaced at the contractor's expense. 717.3.4 Method of Measurement. Final measurement will not be made except for authorized changes during construction, or where appreciable errors are found in the contrast quantity. Where required, the silicone expansion joint sealant will be measured to the nearest linear foot based on measurement from the roadway face of curb to roadway face of curb along the centerline of the joint. The revision or correction will be computed and added to or deducted from the contract quantity. Portions of the joint that extend past the roadway face of curbs will not be measured for payment. 717.3.5 Basis of Payment. Silicone expansion joint sealant, including all materials, coating, equipment, labor, fabrication, installation, technical assistance and any other incidental work necessary to complete this work, will be paid for at the contract unit price. 717.4 Silicone Joint Sealant for Saw Cut and Formed Joints. 717.4.1 Description. This work shall consist of sealing the saw cut and formed joints as shown in the contract documents. 717.4.2 Materials. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Silicone Joint Sealant for Saw Cut and Formed Joints.............. 1057 717.4.3 Construction Requirements. 717.4.3.1 Saw Cut Joints. Joints shall be sawed as shown on the plans as soon as the concrete has hardened sufficiently to permit sawing of a neat straight joint with minimal raveling, and before uncontrolled shrinkage cracking occurs. All joints shall be sawed to the required dimension and cleaned by sand blasting, wire brushing or other methods approved by the engineer in accordance with the manufacturer's recommendations. Joint interfaces shall be fully cured and dry, or free of moisture at the time of installation. All loose particles shall be removed by oil-free and water-free compressed air or a vacuum of at least 90 psi before the application of the backer rod and sealant. 717.4.3.2 Formed Joints. Any joints 0.25 inch or greater shall be cleaned and packed with backer rod and silicone joint sealant. Any joints less than 0.25 inch shall be cleaned and caulked with silicone joint sealant as shown on the plans. All joint interfaces shall be cleaned by grinding, saw cutting, sand blasting, wire brushing, or other methods approved by the engineer in accordance with the manufacturer’s recommendations. New portland cement concrete shall be fully cured and allowed to dry a minimum of seven days. The 5/1/2010
717-4
Neoprene and Silicone Joint Systems
joint interfaces shall be free of moisture at the time of installation. All loose particles shall be removed by oil-free and water-free compressed air or vacuum of at least 90 psi before the application of the backer rod and sealant. 717.4.3.3 Joint Backer Rod. The backer rod shall be used in the joint slot to ensure the sealant adheres to the sidewalls or interface of the joint. All joint areas requiring a backer rod shall be packed with a closed-cell, expanded polyethylene foam to obtain the appropriate depth of the sealant. The backer rod shall be slightly oversized for the joint width, and shall be resilient, compressible in nature, nonabsorbent, non-shrinking and compatible with the sealant. 717.4.3.4 Sealant Placement. Sealant shall be placed in the proper configuration as shown on the plans. Joint sealer shall be protected from dust and other foreign matter until cured to a tack-free condition. The sealant shall fill the joint from the bottom to slightly below the surface currently being applied. Immediately after placement and before a skin forms, the sealant shall be tooled to force the sealant against the joint face and to recess the bead approximately ⅛ inch. 717.4.4 Method of Measurement. No measurements will be made. 717.4.5 Basis of Payment. No direct payment will be made for this work.
5/1/2010
717-5
Neoprene and Silicone Joint Systems
(This Page Intentionally Left Blank)
5/1/2010
717-6
Neoprene and Silicone Joint Systems
Section 720
Mechanically Stabilized Earth Wall Systems
720.1 Description. This work shall consist of furnishing and constructing mechanically stabilized earth wall systems in accordance with these specifications, as shown on the plans or as directed by the engineer. 720.2 Materials. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Concrete ...................................................................................501 Select Granular Backfill for Structural Systems ....................... 1010 Geotextile ...............................................................................1011 Miscellaneous Drainage Material ............................................ 1013 Reinforcing Steel for Concrete ................................................1036 Resin Anchor Systems ............................................................1039 Mechanically Stabilized Earth Wall System Components ........ 1052 720.2.1 Whenever a wall system is located adjacent to and within ten feet of the limits of a permanent roadway, the steel reinforcement used in the concrete elements of the wall system shall be epoxy coated. This requirement will not apply to soil reinforcement and corresponding attachments used for connecting the reinforcement to the wall system units. 720.2.2 Reinforcement for wall system units shall be either Grade 60 deformed bars or an equivalent welded steel wire fabric. Reinforcement for coping or top cap units shall be Grade 60 deformed bars. 720.2.3 Joint material for large block wall systems shall be used in accordance with the wall manufacturer’s recommendations. 720.2.4 The unit fill that is used for small block wall systems shall consist of a granular backfill in accordance with Gradation D or E of Section 1005. 720.2.5 Class B or B-1 air entrained concrete shall be used for the coping or top cap units used for the wall system. Class B or B-1 concrete shall be used for cast-in-place concrete leveling pads used for the wall system. 720.3 Design Requirements. 720.3.1 Only the mechanically stabilized earth wall systems shown in the bridge prequalified products listing will be allowed for use by the contractor. The bridge prequalified products list may be obtained through Bridge or MoDOT’s web site. Any deviations from the prequalified wall system details previously submitted to Bridge shall be specifically outlined in the cover letter submitted with the design plans, details, and computations.
5/1/2010
720-1
Mechanically Stabilized Earth Wall Systems
720.3.2 Small block wall systems will be permitted for uses where the wall height does not exceed ten feet. This limit may be exceeded up to a maximum height of 12 feet to accommodate peaks in the wall or to accommodate lengths of the wall that do not exceed more than ten percent of the total wall length. The height of the wall will be determined by measuring from the top of the concrete leveling pad to the top of the cap on the wall. 720.3.3 The contractor shall submit six complete sets of the manufacturer’s design plans, details, and computations for each individual wall structure to the engineer. All submitted information shall be clear and complete, and thoroughly checked before the information is submitted. All submitted information shall be legible and of sufficient contrast to be suitable for archiving in accordance with MoDOT’s current practice for archiving. Submitted information determined to be unsuitable for archiving purposes will be returned for corrective action. 720.3.4 The contractor will be solely responsible for the content of the design plans, details, and computations that are submitted, and for the performance of the wall system. The contractor shall be solely responsible for ensuring that the information submitted by the manufacturer is in accordance with all contract plans and specifications and with the wall system used. Completed design plans shall contain all material, fabrication and construction requirements for erecting the wall system complete in place. The completed design plans shall show the longitudinal and lateral layout of the drainage systems used for the wall system. 720.3.5 All design plans, details, and computations submitted for distribution shall be signed, sealed, and stamped in accordance with the laws relating to architects and professional engineers (Chapter 327, RSMo). 720.3.6 Mechanically stabilized earth wall systems shall be designed in accordance with the AASHTO specifications shown on the plans and in accordance with additional publications or specifications referenced within the AASHTO specifications. The seismic performance category, angle of internal friction for the selected granular backfill for structural systems and other design requirements shown on the plans shall be incorporated into the design of the wall system. 720.4 Construction Requirements. 720.4.1 Small Block Wall Systems. 720.4.1.1 The contractor shall use a unit fill to fill the voids of the blocks for the wall system. This unit fill shall extend a minimum distance of 12 inches beyond the extreme back face of the wall system. Each course of the wall system shall have the unit fill in place before the next course of the wall system is placed. 720.4.1.2 Precast top cap units shall be used on small block wall systems. The top cap units shall be permanently attached as shown on the plans, utilizing either a resin anchor system or an equivalent detail. 720.4.1.3 Any equivalent details used shall be part of the prequalified mechanically stabilized earth wall system details on file for the manufacturer of the wall system.
5/1/2010
720-2
Mechanically Stabilized Earth Wall Systems
720.4.2 Large Block Wall Systems. 720.4.2.1 A Class 1 geotextile filter cloth shall be placed between the wall and the select granular backfill for structural systems at all joints between the individual wall system units. 720.4.2.2 Precast or cast-in-place coping shall be placed on large block wall systems in accordance with the design plans. Capstone may be used in lieu of coping whenever coping is specified on the design plans. When coping is used, the maximum distance between construction joints shall be 30 feet. 720.4.3 Drainage Requirements. A drainage system shall be provided at the base of the wall system near the facing elements and at the interface of the select granular backfill for structural systems and the retained backfill. The drainage system shall consist of a perforated pipe wrapped in a Class 2 geotextile to prevent clogging of the perforations. The pipe shall be placed in such a manner that water drains freely from the pipe. When the wall length is such that the slope of the pipe becomes excessive in the engineer’s judgment, lateral drain pipes shall be installed underneath the concrete leveling pad. 720.4.4 Foundation Preparation. The foundation for the wall system shall be graded level for a width equal to or exceeding the length of the reinforcing strips, or as shown on the plans. Prior to wall construction, the foundation, if not on rock, shall be compacted as directed by the engineer. Any foundation soils found to be unsuitable shall be removed and replaced, as directed by the engineer. 720.4.5 Leveling Pad. An unreinforced cast-in-place concrete leveling pad shall be provided at the foundation level for each base unit of the wall system. The leveling pad shall be built to the elevations shown on the plans and shall not be raised in elevation to allow for the use of a particular wall system. The leveling pad shall be built a minimum width of 12 inches and a minimum depth of 6 inches. The concrete on the leveling pad shall be cured a minimum of 12 hours before any of the wall system panels are placed. 720.4.6 Batter Requirements. Wall systems shall be built with some inward batter, as determined by the wall system manufacturer, to accommodate the horizontal movement created by the placement and compaction of selected granular backfill for structural systems. Facing elements out of alignment shall not be pulled or pushed into proper place, as that may cause damage to the facing element or soil reinforcement strips. If misalignment occurs, the select granular backfill for structural systems and the soil reinforcement strips shall be removed and the facing elements reset to the proper alignment. 720.4.7 Select Granular Backfill for Structural Systems Placement. 720.4.7.1 Select granular backfill for structural systems shall be placed concurrently with the placement of the retained backfill. The placement of the select granular backfill for structural systems shall closely follow the erection of each course of the wall system and shall be placed in such a manner to avoid any damage or disturbance to the wall material or any misalignment of the facing elements of the wall system. Any wall system material that becomes damaged or disturbed during the installation of the wall system shall be removed, replaced, or corrected at the contractor's expense, as directed by the engineer. Whenever placement of the select granular backfill for structural systems results in the wall facing system being misaligned or distorted outside the limits of this specification, the contractor shall correct the misalignment or distortion as directed by the engineer. 5/1/2010
720-3
Mechanically Stabilized Earth Wall Systems
720.4.7.2 The select granular backfill for structural systems shall be compacted in accordance with Section 203, with the following exceptions: a) The minimum density shall be no less than 95 percent of maximum density, determined in accordance with AASHTO T 99. b) When the material used contains more than 30 percent retained on the ¾ inch sieve, a method of compaction consisting of at least four passes by a heavy roller shall be used. c) The moisture content of the material prior to and during compaction shall be uniformly distributed throughout each layer. The placement moisture content shall be no lower than three percentage points less than the optimum moisture content and shall be no more than the optimum moisture content. d) Compaction within 3 feet of the back face of the wall system shall be achieved by at least three passes of a lightweight mechanical tamper, roller, or vibratory system. e) The contractor shall ensure that runoff within the wall system construction site is directed away from the wall facing during construction, and that runoff from adjacent areas of the general construction site is directed such that runoff does not enter the wall system construction site. f) Class 1 geotextile material shall be placed between the select granular backfill for structural systems, and the retained backfill and over the top of the select granular backfill for structural systems to prevent piping of in-situ soil into the wall system. g) Tamping-type (sheep’s foot) rollers shall not be used for compaction of the select granular backfill for structural systems. 720.4.7.3 The select granular backfill for structural systems shall be initially placed parallel to the wall system, and at the rear and middle of the soil reinforcement strips, and then moved toward the facing elements of the wall system. Construction equipment shall at no time come in direct contact with the soil reinforcement strips. Each course or layer shall be compacted up to or slightly above the location of the next connection for the reinforcement strips prior to placing the next layer of reinforcement strips as designated in the erection sequence provided by the manufacturer of the wall system. 720.4.8 Construction Tolerances. 720.4.8.1 Wall systems shall be built in accordance with the dimensions and elevations specified on the plans and in accordance with the requirements of the system manufacturer. Alignments shall be maintained within the following dimensional tolerances:
5/1/2010
720-4
Mechanically Stabilized Earth Wall Systems
Dimensional Item
Dimensional Tolerance
Adjacent Face Panel Joint Gaps (Large Block Walls)
± ¾ inch
Adjacent Face Panel Joint Gaps (Small Block Walls)
± ¼ inch
Vertical and Horizontal Alignment of Facing Elements (All Wall Systems)
± 1/16 inch per foot
Soil Reinforcement Strip Elevations (All Wall Systems)
± 1 inch
720.4.8.2 Vertical alignments shall be measured along a theoretical vertical line established from the top of the wall system to the base of the wall system. For small block walls that have a built-in setback, the alignment shall be measured along the theoretical vertical line and the straight line that describes the horizontal setback. 720.4.9 Technical Assistance. The contractor shall be responsible for having a technical advisor from the wall system manufacturer available for assistance during the installation of the wall system. 720.5 Method of Measurement. 720.5.1 Measurement of mechanically stabilized earth wall systems will be made to the nearest square foot. The quantity to be paid will be measured from the wall outline as shown on the plans. No adjustments in the measured quantity will be permitted for additional wall area required to meet the minimum wall elevations shown on the plans for any particular wall system. 720.5.2 Final measurement will not be made except for authorized changes during construction or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. 720.5.3 No measurement will be made for required excavation for placement of the leveling pad for the wall system. All other excavation required for the construction of the wall system will be included in roadway items. 720.6 Basis of Payment. The accepted quantity of mechanically stabilized earth wall systems, complete in place, will be paid for at the contract unit price for each of the pay items included in the contract.
5/1/2010
720-5
Mechanically Stabilized Earth Wall Systems
(This Page Intentionally Left Blank)
5/1/2010
720-6
Mechanically Stabilized Earth Wall Systems
Section 724
Pipe Culverts
724.1 Description. This work shall consist of providing pipe or pipe arch of the diameter or shape designated, laid upon a firm bed and backfilled as specified. Where appropriate this specification will also apply to pipe arches. 724.1.1 The contract will specify either the type of pipe or the group of permissible types of pipe. If a group of permissible types is specified, the Contractor may use any of the types listed within the specified group and size range as follows: Group Ab
Group Bb
Group C
Rigid Pipe
Size
Size
Size
Reinforced Concrete Culvert Pipe
ALL
ALL
ALL
Vitrified Clay Pipe
ALL
ALL
ALL
Flexible Pipe - Metala
Size
Size
Size
Aluminum Coated Steel Pipe
ALL
ALL
ALL
Polymer Coated Steel Pipe
ALL
ALL
ALL
Aluminum Alloy Pipe
ALL
ALL
ALL
Bituminous Coated Steel Pipe
N/A
N/A
ALL
Zinc Coated Steel Pipe
N/A
N/A
ALL
Flexible Pipe - Thermoplastic
Size
Size
Size
Double Wall
≤ 30"
≤ 30"
≤ 30"
Triple Wall
30" - 60"
30" - 60"
30" - 60"
Corrugated
≤ 24"
≤ 60"
≤ 60"
Steel Reinforced
≤ 24"
≤ 60"
≤ 60"
≤ 36"
≤ 36"
≤ 36"
Pipe Material
Polypropylene Pipe
Polyethylene Pipe
Polyvinyl Chloride Pipe (PVC)
Notes: a Metal Pipe used for storm sewer applications shall be Type IA or Type IR. b Pipe used for storm sewers under the influence of a pavement section or future anticipated influence of a pavement section which has a 3,500 ADT or greater shall be Group A pipe. Pipe used in other storm sewer applications shall be Group B. No other substitutions will be allowed.
7/1/2016
724-1
Pipe Culverts
724.1.2 If the contract specifies pipe culverts by group and the Contractor elects to furnish metal pipe, the culvert shall be constructed in accordance with Section 725. If the Contractor elects to furnish vitrified clay or reinforced concrete pipe, the culvert shall be constructed in accordance with Section 726. If the Contractor elects to furnish thermoplastic culvert pipe, the culvert shall be constructed in accordance with Section 730. 724.1.3 When Group A, Group B and Group C pipe are specified, two pipe diameters will be shown on the plans at those locations. The first dimension will indicate the diameter of pipe that shall be provided if the Contractor elects to provide pipe for that location with a corrugated interior wall, and the second dimension provided in parenthesis will indicate the diameter of pipe that shall be provided if the Contractor elects to provide pipe for that location with a smooth interior wall. Helical rib (Type IA) pipe may be considered to have varying hydraulic coefficients and may be substituted in accordance with FHWA HD-5 hydraulic design of highway culverts considering the corrugation configuration at the joints. The specified diameters may be the same or different and will be dependent upon the design features for that pipe location. Regardless of which diameter of pipe is selected for a given location, the pipe flow line shall be maintained at the elevations shown on the plans. 724.1.4 The Contractor may elect to furnish pipe one size larger than specified so long as the minimum fill heights are met. No additional compensation shall be given for the larger diameter pipe or any related items necessary to construct the larger pipe. 724.2 Construction Requirements. 724.2.1 Construction Loads. Before heavy construction equipment is operated over the pipe, the Contractor shall provide adequate depth and width of compacted backfill or other cover to protect the pipe from damage or displacement. Any damage or displacement shall be repaired or corrected at the Contractor's expense. 724.2.2 Installation. Pipe installation shall be according to the plans and specifications. Care shall be taken when preparing the subgrade and compacting fill around the pipe especially in the haunch areas. The Contractor shall verify adequate compaction during construction of the pipe by performing density tests. 724.2.3 Pipe Plugs. The ends of all pipe stubs for future connections at inlet and manhole structures, and all pipe installed as part of future sewers, shall be sealed with approved plugs or caps provided by the manufacturer. The plugs shall be installed in such a manner that infiltration of soil into the pipe is prevented. 724.2.4 Weather Limitations. Pipe shall be installed in accordance with the manufacturer's guidelines. Do not install piping over frozen surfaces or in standing water. 724.2.5 Storage. Store pipe, fittings, and gaskets in clean locations protected from environmental conditions such as: (direct sunlight, mud, etc.). Do not use pipe and fittings stored in direct sunlight for periods in excess of 18 months. Store pipe on a flat surface which provides even support for the barrel with bell ends overhanging. Do not stack pipe higher than 5 feet.
7/1/2016
724-2
Pipe Culverts
724.2.6 Handling. Handle so as to insure installation in sound undamaged condition. Use equipment, tools, and methods for unloading, reloading, hauling, and laying that do not damage pipe or cause an impact. Damaged pipe will be cause for rejection. Use hooks or straps with broad, well-padded contact surfaces for lifting sections of pipe. 724.3 Performance Inspection, Performance Report, and Evaluation. 724.3.1 The Contractor shall conduct either manual performance inspection or remote performance inspection along with performance reporting and evaluation as it relates to this specification. 724.3.2 The Contractor shall notify the Engineer at least five workdays before conducting a performance inspection. The inspection shall be performed no sooner than 30 days after the completion of the finished grade when not below pavement and after the completion of the aggregate base when any portion of the culvert pipe is below pavement. The condition of the culvert pipe shall allow for an accurate inspection. The Contractor shall inspect the entire length of the pipe. The frequency of inspection shall be as follows: 1) 100% of locations for Group A pipe. 2) 25% of locations for Group B. Locations to be determined by the Engineer. Criteria for selection will include pipes under large fills or any locations of potential concern. 3) Group C pipe shall be inspected at the discretion of the Engineer. 4) If issues are found with any pipe from the performance inspection the Engineer may require that all pipe be inspected according to this specification. 724.3.3 The actual inside diameter of flexible pipe products shall be determined for the purposes of measuring deflection by averaging nine equally spaced measurements at one location in the barrel of an unloaded pipe. If the pipe has a corrugated interior, the measurements shall be from the top of corrugation to top of corrugation as viewed from the inside of the pipe. 724.3.4 The Contractor shall furnish a video recording of each inspection. The recording shall identify the date and time of the inspection, a description of the culvert pipe, the location, and the viewing direction. The recording shall be for the entire run of the culvert pipe being inspected. The Contractor shall provide sufficient enough source of light to allow all areas of concern to be readily observed on the video recording in a digital, reproducible format on one of the following media types: DVD, CD or other media type approved by the Engineer.
7/1/2016
724-3
Pipe Culverts
724.3.5 Manual Inspection. Perform a manual inspection by entering the culvert pipe to record video and to make measurements. Culverts should be entered only by inspection personnel trained in working with confined spaces and using procedures in full compliance with applicable State, Local, and Federal OSHA regulations. The manual inspection shall include the following at a minimum: 1) Measure the deflection of the culvert pipe to the nearest ¼ inch. A minimum of three measurements shall be taken: vertically from the crown to invert (12 o'clock to 6 o'clock), and at 60 degrees from vertical (2 o'clock to 8 o'clock and 4 o'clock to 10 o'clock). 2) Measure crack width using a crack comparator, micrometer, or a feeler gage capable of measuring 0.01 inch. Other measuring devices may be used if approved by the Engineer. Record the measurements and include them in the written inspection performance report including: for rigid culvert pipe, document the location, length, width, and greatest width of each crack exceeding 0.01 inch. For flexible culvert pipe (Corrugated Metal Pipe and Thermoplastic Pipe), document the location and length of all cracks. 3) For all culvert pipe, measure and record the widest gap at each joint in the run. 4) For culvert pipe with manufactured seams, measure the location, length, and width of any separation at the seam. 5) Measure the location, length, and greatest width of each crack and the widest gap at each culvert pipe entering a drainage structure or transition. 724.3.6 Remote Inspection. Perform a remote inspection by using a crawler mounted camera with low barrel distortion to record video and that has the capability to make measurements. In addition deflection shall be measured by either laser profiling and measuring technology or use of a mandrel capable of verifying deflection on a minimum of 9 points. Laser profiling and measurement technology must be certified by the company performing the work to be in compliance with the calibration criteria as per MoDOT TM 84. Reports shall be submitted by electronic media in a format approved by the Engineer. 724.3.7 Inspection Criteria. Based on the type of culvert pipe, in the measurements and acceptance criteria shall be in accordance with the table below. Also record the location of any other defect not listed in the table and describes the defect. Potential defects include, but are not limited to damaged coatings on corrugated metal pipe, racking, dents, protrusions, misalignment of line or grade, slabbing, and excessive corrugating of thermoplastic pipe. For each measurement location in a culvert pipe, record the length from the left end of the pipe according to roadway stationing.
7/1/2016
724-4
Pipe Culverts
Inspection Criteria Pipe Type
Rigid Culvert Pipe
Flexible Culvert Pipe with Hydraulically Smooth Interior
Flexible Culvert Pipe with Corrugated Interior
Measurement Equipment
Manual Video Camera Remote: Crawler mounted camera with crack measuring capability
Manual: Video Camera Remote: Crawler mounted camera with crack measuring capability and laser profiler or Crawler mounted camera with crack measuring capability and 9 point minimum mandrel
Manual: Video Camera Remote: Crawler mounted camera with crack measuring capability and mandrel
Type of Measurement
Limitations
Required Action
Soiltight in accordance with AASHTO PP 6309
Seal joints with excessive gap
Greater than 0.01 inch less than 0.10 crack
Note for future evaluation
Greater than 0.1 inch crack
Unacceptable
Joint gaps
Soiltight in accordance with AASHTO PP 6309
Seal joints with excessive gap
Crack widths
None allowed
Unacceptable
Greater than 5% less than 7.5%
Replace deficient pipe or 50% of pay item for entire line
Joint gaps
Crack widths
Deflection
Greater than 7.5% Unacceptable
Joint gaps
Soiltight in accordance with AASHTO PP 6309
Seal joints with excessive gap
Crack widths
None allowed
Unacceptable
Greater than 5% less than 7.5%
Replace deficient pipe or 50% of pay item for entire line
Deflection
Greater than 7.5% Unacceptable
7/1/2016
724-5
Pipe Culverts
724.3.8 Performance Report. The Contractor shall provide a performance report for each performance inspection per drainage structure. Each report shall include: 1) Project number and County-Route-Section. 2) Date of performance inspection. 3) Type and size of culvert pipe including any transitions in pipe run. 4) Time of video recording. 5) Location (e.g. station and offset) and viewing direction. 6) Summary of all defects including type, measurement, and location. 7) For remote inspections using a mandrel, indicate in the performance report the size of the mandrel and whether or not it was successfully pulled through the culvert pipe. 8) For remote inspections using a crawler mounted camera with laser profiler, include: a) Three dimensional model of the culvert pipe based on the laser profile measurements. b) Digital profile of culvert pipe extracted from the inspection video. c) Calculations of the ovality, capacity, and delta of the culvert pipe. d) Explanation as to why data was unattainable for any section of the culvert pipe. The Contractor shall submit a performance report to the Engineer within 5 days of completing the performance inspection of the culvert pipe run. Submit the performance report in an electronic format approved by the Engineer 724.3.9 Culvert Pipe Evaluation. The culvert pipe shall be evaluated based on the Performance report. Defects exceeding limitations in this specification will require an action plan addressing noted deficiencies. Other defects will require the Contractor to submit an action plan to the Engineer. 724.3.10 Repairs. Required repairs shall be made at no additional cost to the Department and to the satisfaction of the Engineer. The Contractor shall submit their required action plan including repair process and / or revised installation plan to the Engineer for approval at least 7 days before performing the repairs. The action plan shall provide written confirmation from the culvert pipe manufacturer that the repair methods are appropriate. Any repairs shall have a performance evaluation conducted of the repaired portion of the culvert pipe and any culvert pipe potentially affected by the repair work 30 days after the repair has been made, at no additional cost to the Department.
7/1/2016
724-6
Pipe Culverts
724.4 Method of Measurement. 724.4.1 Final measurement will not be made except for authorized changes during construction or where appreciable errors are found in the contract quantity. When two different diameters of pipe are shown on the plans for a given location for Group A, Group B or Group C pipe, the quantity of pipe installed will be based on the plan quantity for the larger diameter pipe and will not be considered as an appreciable error in the contract quantity if the smaller allowed diameter pipe is used. Where required, measurement of pipe, complete in place, will be made to the nearest foot along the geometrical center of the pipe. The revision or correction will be computed and added to or deducted from the contract quantity. 724.4.2 When concrete pipe is used, the length of the structure may be increased by no more than 3 feet as necessary to avoid cutting the pipe, but such increased length will not be included in the contract quantity for payment. 724.4.3 When PVC pipe is used, measurement will include any other pipe used to protect the pipe from exposure to sunlight. 724.5 Basis of Payment. 724.5.1 The accepted quantities of pipe, complete in place, including all necessary tees, bends, wyes, coupling bands, cutting and joining new pipe to existing pipe or structures, unless otherwise specified, will be paid for at the contract unit price for each of the pay items included in the contract. 724.5.2 The accepted quantities of corrugated metal drop inlets and metal curtain walls, complete in place, including coupling bands, toe plates, nuts and bolts will be paid for at the contract unit price for each of the pay items included in the contract. 724.5.3 Unless specified otherwise, no direct payment will be made for the following: 1) Beveling, skewing, or additional work required in laying pipe with beveled or skewed ends. 2) Work involved in elongating pipe. 3) Any required backfilling, except as specified in Section 206.6.3. 4) Construction of bedding or for bedding material. 5) Furnishing and installing plugs. 6) Material or work required for placing couplings on exposed ends of pipe. 724.5.4 Payment for removal of unsuitable material and for backfilling will be made in accordance with Section 206.6.3, unless the unsuitable material is a result of the Contractor's operations, in which case the removal and backfilling shall be at the Contractor's expense.
7/1/2016
724-7
Pipe Culverts
(This Page Intentionally Left Blank)
7/1/2016
724-8
Pipe Culverts
Section 725
Metal Pipe and Pipe-Arch Culverts
725.1 Description. This work shall consist of providing corrugated metal pipe or pipe arch of the diameter or shape designated, laid upon a firm bed and backfilled as specified. Where pipe is referred to, this specification will also apply to pipe-arch, where appropriate. 725.1.1 The contract will specify either the type of pipe or the group of permissible types of pipe. If a group of permissible types is specified, the contractor shall use any of the types listed within the specified group as follows: Group A
Group B
Group C
Reinforced Concrete Pipe Vitrified Clay Culvert and Sewer Pipe Corrugated Metallic-Coated Steel Pipe
Reinforced Concrete Pipe Corrugated Metallic-Coated Steel Pipe Corrugated Aluminum Alloy Pipe
Reinforced Concrete Pipe Corrugated Metallic-Coated Steel Pipe Corrugated Aluminum Alloy Pipe Corrugated Polyethylene Pipe
725.1.2 If the contract specifies corrugated metallic-coated steel pipe culverts of 60-inch diameter or larger, the contractor may substitute structural plate pipe of like sizes, lengths and thicknesses of steel, constructed in accordance with Section 727, at the contractor’s expense. 725.1.3 If the contract specifies corrugated metallic-coated steel pipe or corrugated aluminum alloy pipe, or if the contract specifies pipe culverts by group and the contractor elects to furnish corrugated metallic-coated steel pipe or corrugated aluminum alloy pipe, the thickness of metal and size of corrugation for the respective pipe size shall be as shown on the plans unless otherwise specified. The overfill height shown on the plans or in the contract shall be used to determine the proper sheet thickness and size of corrugation for the individual pipe culvert. The minimum cover shall be measured as shown on the plans. 725.1.4 If the contract specifies pipe culverts by group and the contractor elects to furnish vitrified clay or reinforced concrete pipe, the culvert shall be constructed in accordance with Section 726. If the contractor elects to furnish corrugated PVC culvert pipe, the culvert shall be constructed in accordance with Section 728. If the contractor elects to furnish corrugated polyethylene pipe, the culvert shall be constructed in accordance with Section 730.
5/1/2010
725-1
Metal Pipes and Pipe-Arch Culverts
725.1.5 When Group B and Group C pipe are specified, two pipe diameters will be shown on the plans at those locations. The first dimension will indicate the diameter of pipe that shall be provided if the contractor elects to provide pipe for that location with a corrugated interior wall, and the second dimension provided in parenthesis will indicate the diameter of pipe that shall be provided if the contractor elects to provide pipe for that location with a smooth interior wall. The specified diameters may be the same or different and will be dependent upon the design features for that pipe location. Regardless of which diameter of pipe is selected for a given location, the pipe flow line shall be maintained at the elevations shown on the plans. 725.1.6 Pipe used for storm sewers may be any of the pipes listed under Group B pipe, with the following exceptions. All corrugated metal culvert pipes shall be Type IA or Type IR. Sewer pipe placed beneath the paved portion of roadways with average daily traffic greater than 3500 vehicles per day shall be Group A pipe. No other substitutions will be allowed, regardless of what type or group of pipe is specified for storm sewers outside of the paved portion for these roadways. 725.2 Materials. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Corrugated Metallic-Coated Steel Culvert Pipe, Pipe Arches, and End Sections ......... 1020 Bituminous Coated Corrugated Metal Culvert Pipe, Pipe Arch, and End Sections ....... 1021 Corrugated Aluminum Alloy Culvert Pipe ...................................................................... 1024 Polymer Coated Corrugated Metal Culvert Pipe and Pipe Arches ................................ 1027 725.3 Construction Requirements. 725.3.1 Handling. All pipe shall be handled to avoid damage. Pipe having damaged coating, any localized bends in excess of five percent of the specified pipe diameter, or any dent in excess of ½ inch will be rejected, regardless of previous approvals. Rejected damaged pipe may be used if repaired to the satisfaction of the engineer. 725.3.2 Laying Pipe. 725.3.2.1 The pipe shall be carefully laid true to lines and grades shown on the plans. Riveted pipe shall be installed with the outside laps of circumferential joints pointing upstream and with no longitudinal lap placed on the bottom 120 degrees of the pipe on the sides. Any pipe that is not in true alignment or that shows any undue settlement after laying shall be taken up and re-laid at the contractor's expense. If shown on the plans or directed by the engineer, camber shall be built into the pipe structure to compensate for settlement from fill loads. 725.3.2.2 Transverse field joints shall be of such design that the successive connection of pipe sections will form a continuous line free from appreciable irregularities in the flow line. Each successive length of pipe in a field joint shall be adjusted longitudinally or circumferentially when necessary such that coupling bands will properly engage the corrugations in both lengths of pipe.
5/1/2010
725-2
Metal Pipes and Pipe-Arch Culverts
725.3.3 Bedding and Backfill Material. 725.3.3.1 Backfill material for metal culverts shall consist of crushed stone, gravel, sand, or sandy silt. 725.3.3.1.1 Crushed stone, gravel and sand shall consist of a well-graded mixture of stone fragments, gravel and sand, and shall be in accordance with AASHTO M 145, Classification A1 or A3. 725.3.3.1.2 Sandy silt soil shall consist of moderately plastic granular material with silt content higher than that of gravel or sand and shall be in accordance with AASHTO M 145, Classification A2. 725.3.3.2 Bedding material shall have a maximum particle size of 1½ inches. Backfill shall be free of organic material or frozen clumps, and shall not contain stones larger than 3 inches. 725.3.4 Installation. 725.3.4.1 Installation of Pipe for Non-Embankment Conditions. The construction sequence shall be as follows. The trench shall be excavated to the width, depth and grade shown on the plans or as directed by the engineer. Proper preparation of foundation, placement of foundation material where required and placement of bedding material shall precede the installation of all culvert pipe. Proper preparation shall include necessary leveling of the trench bottom or the top of the foundation material as well as placement and compaction of required bedding material to a uniform grade such that the entire length of pipe will be supported on a uniform base. The material in the haunch and lower side zones shall then be placed and compacted up to the springline of the pipe. 725.3.4.2 Installation of Pipe Prior to Placing Embankment. After the pipe has been laid, the material in the haunch and lower side zones shall be placed to a minimum width of one pipe diameter outside the pipe, except for pipe-arches, where placement of material shall be limited to a maximum of two-thirds the span. The pipe shall be installed and backfilled in accordance with Section 725.3.4.1. If a subtrench will be required to install the pipe to the specified grade, the width of the trench shall be as shown on the plans. Sufficient clearance shall be provided in order to attain the required compaction in the haunch and outer bedding zones. 725.3.4.3 Installation of Pipe After Placing Embankment. The roadway embankment shall be placed and compacted to the required density to a minimum elevation of one foot above the top of the pipe. A trench shall be excavated through the embankment to a depth sufficient to place the required bedding and to maintain the specified grade of the pipe, in accordance with the section shown on the plans. The pipe shall be installed and backfilled in accordance with Section 725.3.4.1.
5/1/2010
725-3
Metal Pipes and Pipe-Arch Culverts
725.3.4.4 Bedding in Unsuitable Material. If rock is encountered, the bedding depth shall be increased as shown on the plans. If soft, spongy, or unstable material is encountered, the material shall be removed and replaced with approved fill, compacted to the specified level. Payment for removal of unsuitable material and for backfilling will be made in accordance with Section 206.6.3, unless the unsuitable material is a result of the contractor’s operations, in which case the removal and backfilling will be at the contractor’s expense. 725.3.4.5 Backfill. Backfill shall be placed as soon as practical in accordance with Section 206. Suitable backfill and embankment material, free from large lumps, clods, or rocks, shall be compacted in accordance with Section 203. Care shall be taken to properly compact the backfill under the haunches of pipe-arch. The placement of the remainder of the backfill shall be a minimum of one foot above the top of the pipe and shall be brought up evenly on both sides of the pipe by working backfill operations from side to side. The side-to-side backfill differential shall not exceed 24 inches or one-third of the size of the pipe, whichever is less. Additional backfill shall be provided as necessary. After backfilling, the pipe shall have a smooth, uniform concentric shape. 725.3.4.6 Shop Elongation. Round corrugated steel pipe 48 inches or greater in diameter may be furnished round or shop elongated. The contractor shall maintain elongation during backfilling and embankment construction such that the vertical height of the opening after the embankment has been completed shall be no less than the diameter of the pipe or greater than the pre-elongated height. 725.3.4.7 Construction Loads. Before heavy construction equipment is operated over the pipe, the contractor shall provide adequate depth and width of compacted backfill or other cover to protect the pipe from damage or displacement. Any damage or displacement shall be repaired or corrected at the contractor’s expense. 725.3.4.8 Pipe Plugs. The ends of all pipe stubs for future connections at inlet and manhole structures, and all pipe installed as part of future sewers, shall be sealed with approved plugs. The plugs shall be installed in such a manner that infiltration of soil into the pipe is prevented. 725.3.5 Corrugated Metal Drop Inlets. The contractor shall install corrugated metal drop inlets of the proper size and length at the locations shown on the plans. The drop inlet shall be constructed of the same base metal and thickness of corrugated metal used in the culvert pipe and shall be in accordance with Section 1020 or Section 1024. 725.3.6 Corrugated Metal Curtain Walls. The contractor shall install metal curtain walls of the proper size and shape at locations shown on the plans. Metal curtain walls shall be constructed of the same base metal used in the culvert pipe, shall be of the thickness of metal shown on the plans and shall be in accordance with Section 1020 or Section 1024. 725.4 Inspection. The internal diameter of the barrel shall not be reduced by more than 10 percent of the pipe’s nominal inside diameter when measured no less than 30 days following completion of installation. After the roadway has been completed and before final inspection of the project, the engineer will inspect all pipe locations for proper installation. Any section of pipe found to be improperly installed shall be replaced or repaired by the contractor, at the contractor’s expense and to the satisfaction of the engineer. Repaired or replaced pipe will be re-inspected by the engineer. The contractor shall provide equipment and assistance deemed necessary by the 5/1/2010
725-4
Metal Pipes and Pipe-Arch Culverts
engineer to perform any testing. Pipe deflections will be determined by the engineer by having the contractor either pushing or pulling a mandrel through the pipe or verifying deflections by other methods approved by the engineer. Mandrels used for deflection testing may have either fixed or adjustable arms, but shall be approved by the engineer prior to use. The following will constitute improper installation: a) If any horizontal or vertical alignment is in excess of 15 percent from plan alignment, will restrict flow or will cause excessive ponding within the pipe. b) Any section of pipe with a diameter deflection greater than 10 percent, based upon the units of measurement used in fabricating the pipe. c) If settlement is greater than one inch at 5 percent or more joints. d) If the pipe shows evidence of being crushed at any location. e) If the pipe shows evidence of joint separation. 725.5 Method of Measurement. 725.5.1 Final measurement will not be made except for authorized changes during construction or where appreciable errors are found in the contract quantity. When two different diameters of pipe are shown on the plans for a given location for Group B or Group C pipe, the quantity of pipe installed will be based on the plan quantity for the larger diameter pipe and will not be considered as an appreciable error in the contract quantity if the smaller allowed diameter pipe is used. Where required, measurement of corrugated metal pipe or pipe-arch, complete in place, will be made to the nearest foot along the geometrical center of the pipe. The revision or correction will be computed and added to or deducted from the contract quantity. 725.5.2 Excavation for placing pipe, pipe-arches, corrugated metal drop inlets and metal curtain walls will not be measured, except when excavation for the installation is shown on the plans. 725.6 Basis of Payment. 725.6.1 The accepted quantities of pipe, complete in place, including all necessary tees, bends, wyes, coupling bands, cutting and joining new pipe to existing pipe or structures, unless otherwise specified, will be paid for at the contract unit price for each of the pay items included in the contract. 725.6.2 The accepted quantities of corrugated metal drop inlets and metal curtain walls, complete in place, including coupling bands, toeplates, nuts, and bolts will be paid for at the contract unit price for each of the pay items included in the contract.
5/1/2010
725-5
Metal Pipes and Pipe-Arch Culverts
725.6.3 Unless specified otherwise, no direct payment will be made for the following: a) Beveling, skewing, or additional work required in laying pipe with beveled or skewed ends. b) Work involved in elongating pipe. c) Any required backfilling, except as specified in Section 206.6.3. d) Construction of bedding or for bedding material. e) Trench excavation and backfilling, except when Class 3 Excavation is shown on the plans for a given pipe location. When shown on the plans, payment for Class 3 Excavation will made for in accordance with Section 206. f) Furnishing and installing plugs. g) Work or equipment to perform deflection testing
5/1/2010
725-6
Metal Pipes and Pipe-Arch Culverts
Section 726
Rigid Pipe Culverts, Storm Drains and Sewers
726.1 Description. 726.1.1 This work shall consist of concrete, reinforced concrete, polyvinyl chloride, Composite (ABS), and vitrified clay pipe of the diameter or shape designated, laid upon a firm bed, and backfilled as specified. 726.1.2 Unless otherwise indicated on the project plans or specifications, the following types of pipes may be used for sanitary and combined sewers: 1) Vitrified clay pipe (VCP). 2) Reinforced concrete pipe (RCP) with Type B joint for sewers 21 inches and larger. 3) Polyvinyl chloride pipe (PVC). 4) Composite sewer pipe (ABS). The following types of pipes may be used for storm water sewers (see Section 50.20, Drainage Structure Design, "Design Criteria for the Preparation of Improvement Plans"): 1) Vitrified clay storm sewer pipe (VCP). 2) Concrete storm sewer pipe. 3) Reinforced concrete storm sewer pipe (RCP). 4) High-density polyethylene storm sewer pipe (HDPE). 5) Polyvinyl chloride storm sewer pipe (PVC). 726.1.3 If reinforced concrete pipe is specified in the contract or elected for use by the contractor, pipe of a higher class may be used but payment will be made for the class of pipe specified in the contract for that culvert. 726.1.4 The type of pipe or class of bedding shall not be changed throughout the length of any individual pipe culvert. 726.1.5 The type of pipe permitted in extending an existing pipe shall, in general, conform to the type used in place, except as otherwise specified in the contract, or unless prohibited by any of the requirements set out herein.
9/1/2023 15
726-1
Rigid Pipe Culverts, Storm Drains and Sewers
726.2 Materials. 726.2.1 All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item Section Reinforced Concrete Culvert, Storm Drain and Sewer Pipe ............................................ 1026 Corrugated Poly Vinyl Chloride Pipe (PVC) Culvert Pipe ............................................... 1028 Vitrified Clay Sewer and Culvert Pipe .................................................................................... 1030 Reinforced Concrete Elliptical Culvert, Storm Drain, and Sewer Pipe .......................... 1034 Reinforced Concrete Arch Culvert, Storm Drain, and Sewer Pipe ................................. 1035 Plastic Joint Compound for Vitrified Clay, and Concrete Pipe......................................... 1057 Mortar for Pipe Joints ............................................................................................................ 1066 726.2.2 Joints. The type of joint or jointing material to be used shall be compatible with the specified sanitary and combined sewer pipe as follows: Sanitary and Combined Sewers Type Vitrified Clay Pipe (VCP) ...............................................................................................C Reinforced Concrete Pipe (RCP) - 21 inches and larger............................................... B Polyvinyl Chloride (PVC) ...............................................................................................D Composite Sewer Pipe (ABS) ....................................................................................... E The following types of joint or jointing material to be used shall be compatible with the specified storm sewer pipe as follows (see Section 50.20, Drainage Structure Design, "Design Criteria for the Preparation of Improvement Plans"): Stormwater Sewers Type Concrete Pipe - 12 inches and larger .....................................................................A or B Reinforced Concrete Pipe (RCP) - 12 inches and larger........................................A or B High Density Polyethylene Pipe (HDPE) - 12 to 24 inches ........................ASTM D3212 Polyvinyl Chloride Pipe (PVC) - 12 to 24 inches ........................................ASTM D3212 When compression joints Type A, Type B, Type C, Type D, or Type E are specified, a sample joint of a specific type, design material, resiliency, and manufacturer must be submitted to the engineer for approval before it may be used. No pipes shall be delivered to the work site without previous approval by the engineer. The Director may consider for approval a written request by the contractor to use other types, materials, methods, or kinds of joints. The request must be submitted prior to bidding the project. All pipes shall be so handled and stored that the jointing parts and the jointing materials will not deteriorate or be damaged. No joint shall be made under water. The bell, socket, or groove; and the spigot or tongue shall be clean and dry before preparing the joint for laying; and the prepared joint shall be kept clean and dry before and during laying and jointing the pipe. In cold weather, suitable measures must be taken to attain proper adhesion and workability of the jointing material and to insure a satisfactory joint. All work shall be done in
9/1/2023 15
726-2
Rigid Pipe Culverts, Storm Drains and Sewers
an approved manner by skilled workers so that the completed sewer shall have a continuous smooth uniform invert and interior surface. Care shall be used during laying and jointing of a pipe to avoid disturbing or damaging previously laid pipes and joints. 726.2.2.1 Type A Joints. Type A joints shall be constructed with approved compatible bituminous jointing material, in accordance with the requirements of this specification. Unless specifically required by the project plans and specifications, any approved bituminous sealing compound may be used. The clean, dry surfaces of the interior of the pipe bell, groove, or socket, and the exterior of the spigot or tongue and shoulders shall be primed and uniformly coated with an approved compatible bituminous primer, as recommended by the manufacturers of the sealing compound and the primer. It shall be done sufficiently in advance of applying the jointing compound to permit proper drying and hardening, and to provide a suitable uniform prepared surface for proper adhesion of jointing material. The primer shall not be heated or diluted. When pre-mixed sealing compound is used with slipjoint or tongue and groove pipe, the jointing compound shall be evenly spread on the surface of both the tongue and the groove of the joint from the tip of the shoulder in sufficient amount to completely fill and seal the joint to both surfaces of the pipe barrel when the joining surfaces have been forced together to form the completed joint. If bell and spigot pipe is used, oakum or a similar approved packing material shall be embedded in the sealing compound to support and keep the inner surfaces of the joining pipe in alignment. Protruding joint material shall be removed from the interior surface of the pipe, and the pipe joint troweled to give a continuous smooth interior pipe surface before the next pipe is laid. On the outside of the pipe, any material protruding from the solidly filled joint shall be neatly shaped, compacted, and smoothed over the joint. 726.2.2.2 Type B Joints. When used with concrete pipes, they shall be approved compression-type joints and shall conform to the requirements of the Specifications for Joints for Circular Concrete Sewer and Culvert Pipe, Using Flexible, Watertight, Rubbertype Gaskets ASTM C 443. Band-type gaskets depending entirely on cement for adhesion and resistance to displacement during jointing shall not be used. 726.2.2.3 Type C Joints. When used with vitrified clay pipes, they shall be approved factory-molded compression type joints using resilient materials. They shall conform to the requirements of the Specification for Vitrified Clay Pipe Joints Using Materials Having Resilient Properties, ASTM C 425. 726.2.2.4 Type D Joints. Shall be used with PVC pipes and they shall be elastomeric gasket joint providing a watertight seal. They shall conform to the requirements of the Specification for Joints for Drain and Sewer Plastic Pipes and Fittings Using Flexible Elastomeric Seals, ASTM C 3212. 726.2.2.5 Type E Joints. When used with composite ABS pipes, they shall be solvent cemented providing a watertight seal. They shall conform to the requirements of the Specification for Joints under ASTM D 2680, Standard Specification for AcrylonitrileButadiene-Styrene (ABS) Composite Sewer Piping.
9/1/2023 15
726-3
Rigid Pipe Culverts, Storm Drains and Sewers
726.2.2.6 Lubricants for Prefabricated Pipe Gaskets. The material to be used as a lubricant in jointing pipes or fittings fitted with flexible, watertight, rubber-type gaskets, either factory or job applied shall be compatible with the material of the gaskets and as recommended by the manufacturer. 726.2.2.7 Primers and Adhesives. The material used as a primer or adhesive for jointing materials or for prefabricated gaskets shall be compatible with the material of the gasket or jointing materials. Adhesives used to fasten flexible rubber or rubber-type gaskets shall conform to the requirements of the manufacturer of the gaskets. All primers and solvents used with ABS Composite Sewer Pipe shall conform to the Standard Specification ASTM D 2235 for Solvent Cement for ABS Plastic Pipe and Fittings and shall be applied as recommended by the manufacturer. 726.2.2.8 Adapters and Couplings. At the direction of the Engineer a connection of sanitary sewer pipe 4 inches through 15 inches of dissimilar material or of different sizes, or for the repair of sanitary sewer pipes of similar materials, may be made by means of an approved connector or adapter of the compression or mechanical seal type. The connector or adapter shall be manufactured of an approved pre-formed elastomeric material conforming to applicable sections of ASTM Standards C 425, C 443, C 564, and D 3212. Couplings of the mechanical seal type shall have tightening clamps or devices made of 300 series stainless steel with a stainless-steel shear ring and stainless-steel hardware, as specified in ASTM A 167. If a stainless-steel shear band is not used, a concrete collar as shown in the Standard Drawings shall be required. The compression joint connector or adapter and flexible coupling shall be installed as recommended and specified by the manufacturer. Each connector and adapter shall bear the manufacturer's name and required markings. 726.3 Construction Requirements. 726.3.10 Sewer Excavation. 726.3.10.1 General. The contractor shall make all excavations required for constructing all sewers, channels, and appurtenant structures as required by the project plans and specifications. Except where otherwise required by the project plans and specifications, or ordered in writing by the Director, all excavations shall be in open cut to specified widths and depths. The contractor shall be responsible for the condition of all of his excavations and shall properly and adequately protect the excavation from caving or sliding. All slides and caveins shall be handled, removed, or corrected by the contractor without extra compensation at whatever time and under whatever circumstances they may occur. Test pits may be dug by the contractor along the lines of the sewer or channel as shown on the drawings, in advance of excavation, for the purpose of determining the location of underground obstructions or conditions. No additional payment will be made for this work.
9/1/2023 15
726-4
Rigid Pipe Culverts, Storm Drains and Sewers
726.3.10.2 Open Cut Excavation. Unless otherwise shown on the plans, all excavation for construction of sewers, channels, and their appurtenant structures, shall be in open cut from the surface. The contractor shall proceed with caution in any excavation and shall use every means to determine the exact location of underground structures, pipelines, conduits, etc. in the immediate vicinity, prior to excavation in the immediate vicinity thereof. 726.3.10.3 The County has shown on the plans the readily available record of location of existing structures and facilities, both above and below the ground, but assumes no responsibility for the accuracy or completeness of this information. Utility service connections will not be shown on the plans, but reasonably can be expected in built-up areas, and if it is necessary to relocate them, it shall be the Contractor's responsibility. If the method of operation for the construction of the sewer or channel requires the removal and replacement, or the protection of any overhead wires or poles, the contractor shall make satisfactory arrangements for such work with the owner or owners of such wires and poles and no additional payment will be made. 726.3.10.4 It shall be the contractor's responsibility to protect any sewer or utility within the limits of construction. The County will not be responsible for the cost of protection, repair, or replacement of any structure, pipeline, conduit, service connection, etc., above or below the ground, which may be broken or otherwise damaged by Contractor operations. All water and gas pipes and other conduits adjacent to or crossing the trench must be properly supported and protected by the contractor. Sewer and utility services between mains and buildings shall be maintained by the contractor in as continuous an operation as reasonably can be expected. This shall be accomplished in any way the contractor may desire, provided that individual service is not inoperative for more than six consecutive hours. When a break occurs, the Contractor shall notify affected householders of the probable length of time that service will be cut off. 726.3.11.1 Limits of Excavation for Pipe Sewers. Except where otherwise shown in the project plans and specifications, or were ordered by the engineer, trenches shall be excavated to the depths shown on the plans and to the payline widths shown in Table No. 1 of the Standard Drawing C726.30. The sides of the trench shall be vertical, and the width of the trench below a level of 1 foot above the outside top of the pipe shall not exceed the payline widths for pipe sewers set forth in Table No. 1 of the Standard Drawing C726.30. 726.3.11.2 Limits of Construction for Channels. Channels shall be constructed to agree with the cross sections as shown on the project plans. Any alleged errors or discrepancies in the plans shall be brought to the attention of the County prior to disturbing the ground. Payment will be made at the unit bid price per cubic yard. Quantities will be based on cross section areas in accordance with the appropriate provisions of Section 203 and Section 204. 726.3.11.3 Length of Open Trench. The length of trench which may be opened in advance of the completed sewer shall be limited to 200 feet, except with the permission of the Engineer. In rock, the length shall be sufficient to protect the completed sewer.
9/1/2023 15
726-5
Rigid Pipe Culverts, Storm Drains and Sewers
726.3.11.4 Unauthorized Excavation. All unauthorized excavation carried beyond or below the lines and grades given by the project plans and specifications, together with the removal of such excess excavated material, and the cost of refilling the space of such overdig or unauthorized excavation, shall be at the Contractor's expense. The excess space between the undisturbed bottom and sides of excavation and pipe bedding shall be refilled and compacted with crushed limestone as directed by the Engineer. 726.3.11.5 Control of Water. While sewers and appurtenances are under construction, the Contractor shall keep all excavations free of water at his own expense. The Contractor shall provide all dams, flumes, channels, sumps, or other works necessary to keep the excavation entirely clear of water and shall provide and operate pumps or other suitable equipment of adequate capacity for dewatering the excavations. He shall avoid producing mud in the trench or channel bottom by his operations, and if necessary or so ordered, shall place crushed limestone at his own expense to maintain a firm, dry excavation bottom and base. Pipe bedding, laying, jointing, and the placing of concrete or masonry shall be done in a water-free trench or excavation which shall be kept clear of water until pipe joints, concrete, and masonry have set and are resistant to water damage. The water shall be disposed of in a manner approved by the Engineer. All gutters, pipes, drains, conduits, culverts, catch basins, storm water inlets, ditches, creeks, and other storm water facilities shall be kept in operation, or their flows be satisfactorily diverted and provided for during construction. Any facilities disturbed during construction shall be restored to the satisfaction of the engineer. All costs of handling water and providing a stable subbase during construction, shall be included in the prices bid for the various items in the contract. 726.3.11.6 Removal of Unsuitable Subgrade. Soft or spongy earth, muck, mud, unconsolidated earth fill, unsuitable fill such as decayed vegetable or organic matter, or soft friable, unconsolidated materials such as ashes or rusted cans, or any other materials unsuitable as a firm base from pipe, sewer, or structure shall be removed, as ordered by the Engineer, and shall be replaced with compacted crushed limestone. The Contractor will be paid for the additional excavation when so ordered by the Engineer as follows: Payment for excavation of unsuitable materials, and the placing as backfill material of 2-inch maximum size granular-type material (with a plasticity index not exceeding 10 and a gradation such that at least 50 percent of the material will be retained on the No. 4 sieve) to a depth approved by the Engineer that shall not exceed 3 feet. 2-inch maximum size clean stone granular-type material required in areas where unsuitable material has been removed, will be made at the invoice price plus $1 per ton for providing required material. Measurement of this backfill material will be determined from certified weight tickets delivered with the material and verified by the Engineer. No direct payment will be made for spreading, shaping, and compacting this backfill material. When the base becomes unsuitable due to neglect of the Contractor, or due to the Contractor's failure to control water in the trench or channel, no payment will be made to remove the unsuitable material, provide backfill material, and to backfill the area in an acceptable manner.
9/1/2023 15
726-6
Rigid Pipe Culverts, Storm Drains and Sewers
726.3.11.7 Rock Excavation in Sewer Trench. Trench bottoms in rock shall be excavated to a depth below the outer pipe bottom as shown on the Standard Drawings and to the maximum payline width at and below the outside top of the pipe with no point of rock being closer than 4 inches to the pipe barrel. Rock removal will be accomplished within the trench in accordance with the provisions of Section 203.2.5 and Section 203.2.5.1. The responsibility of the contractor with respect to the use of explosives in blasting includes compliance with all laws, rules, and regulations of the federal, state, and local municipalities, and the insurer governing the keeping, storage, use, manufacture, sale, handling, transportation, or other disposition of explosives. All operations involving the handling, storage, and use of explosives shall be conducted with every precaution under the supervision of a properly licensed individual. The Contractor shall take special precautions for the proper use of explosives both at, or near the top of the excavation, and in the excavation to prevent harm to human life and damage to surface structures, utilities, sewers, or other subsurface structures. The Contractor shall notify the Engineer in advance when charges are to be set off. Blasts shall not be fired until all people in the vicinity have had ample notice and have reached positions of safety. After a blast is fired, the Contractor shall cause the excavation to be thoroughly scaled. All loose, shattered rock or other loose material which may be dangerous to workers, pipe, or structure shall be removed, and the excavation made safe before proceeding with the work. The fact that the removal of loose or shattered rock or other loose material may enlarge the excavation beyond the required limits shall not relieve the contractor from the necessity of making such removal and filling the extra space. The Contractor shall not be entitled to extra compensation, therefore. 726.3.11.8 Excess or unsuitable material from sewer trench excavations shall be disposed of in accordance with the provisions of Section 203.2.16.1. 726.3.11.9 Bracing and Shoring. The contractor shall furnish, place, and maintain such sheeting, bracing, shoring, etc. as necessary or required to support the sides of the excavation to protect workers in the trench or channel and to prevent any earth movement which might in any way injure or delay the work, change the required width of excavation, or endanger adjacent pavement, utilities, sewers, buildings, or other structures above or below the ground surface. The sheeted trench width, as measured between those faces of the sheeting in contact with the earth trench wall, shall not exceed the payline width of trench below an elevation 1 foot above the top of the pipe. Walers and other bracing shall be so designed and installed as to present no obstructions to proper placement of the pipe, bedding, cradle, or encasement, nor shall they interfere with the satisfactory laying and jointing of the pipe. Sheeting, bracing, and shoring shall be withdrawn and removed as the backfilling is being done, except where and to such extent as the Engineer shall order that such sheeting, bracing, and shoring be left in place, or where the Engineer will permit the same to be left in place at the Contractor's request. In any case, the contractor shall cut off any such sheeting at least 2 feet below the surface and shall remove the cutoff material from the excavation. All sheeting, bracing, and shoring which is not left in place under the foregoing provisions shall be removed in a manner as not to endanger the completed work or other structures, utilities, sewers, or property, whether public or private.
9/1/2023 15
726-7
Rigid Pipe Culverts, Storm Drains and Sewers
726.3.11.10 Trenches and Channels with Sloping Sides. Where working conditions permit, the Contractor may excavate the upper part of the sewer trench with sloping sides above a level of 1 foot above the top of the pipe. Trench excavation below this level shall be carried out with vertical sides having a width between vertical earth sides not greater than the payline width shown in Table No. 1 of Standard Drawing C726.30. Bedding, concrete cradling, or encasement shall be specified for vertical side trenching. In a channel, the sides shall be sloped as shown on the plans, or as otherwise approved by the County. All trenches in highways, streets, or alleys shall be excavated with vertical sides. 726.3.11.11 Stanking. Where required by the plans or ordered by the engineer a line of open trench excavation will be interrupted by a stank or short section of unexcavated earth with an excavated opening beneath for constructing the pipe sewer, in order to avoid disturbing existing improvements, or to avoid the necessity of removing surface or subsurface structures. The locations of stank faces will be set by the Engineer. The excavated opening shall be sufficiently large to provide adequate working room for proper bedding, installing the pipe sewer, and compacting the backfill. The top of the opening shall be sloped sufficiently to permit solid backfilling without voids. The Contractor may undercut the stank at its face if permitted by the Engineer, but only in such amount that will maintain a depth of stank at the face not less than twice the actual trench width and will ensure safety of the improvements or structures for which stanking was required. 726.3.11.12 Excavation for Manholes, Inlets, Junction Chambers, and Other Appurtenant Structures. The Contractor shall excavate as required for all structures with foundations carried to the firm, undisturbed earth at the elevation of the underside of the structure. In rock, the Contractor shall excavate all rock at least to the minimum limits shown on the Standard Drawings for trenches, and to the grade of the bottom of the manholes, inlets, junction chambers, or other structures as required by the plans. Where the bottom of the excavation for structures is in rock, no rock shall project above the lower surface of the concrete or brick masonry base in such a manner as to reduce the required thickness of such base. All spaces between the bottom of such base and the solid rock surface shall be completely filled with the same materials used for the foundation or base, placed simultaneously as an integral part of the foundation or base. No direct payment will be made for this excavation but will be considered fully compensated in other items. 726.3.11.13 Sewer crossings of railroads, streets, and highways shall be made as shown on the project plans and as required in these specifications and the project specifications. 726.3.11.14 Septic Tanks. If the plans call for the abandonment of a septic tank, the Contractor shall pump out and properly dispose of the contents within the tank. The bottom of the tank shall be perforated to allow for drainage. If the top of the tank is concrete, it may be broken up and deposited in the tank. The sidewalls shall be lowered to at least 2 feet below final grade. The remainder of the tank shall be filled with approved granular material. Selected earth shall be used to bring the surface to final grade. The septic field will be removed and backfilled as directed by the Engineer.
9/1/2023 15
726-8
Rigid Pipe Culverts, Storm Drains and Sewers
726.4 Bedding. The project plans and specifications will indicate the specific type of bedding, cradling, or encasement required in the various sections of the pipe sewer construction. The types and detailed requirements of bedding, concrete cradling, and concrete encasement are shown in the drawings of the Standard Details of Sewer Construction. Where bell and spigot pipe are to be used, provisions must be made for suitable bell holes to avoid pipe support on the bells and to insure continuous uniform bearing and support at the specified grade for pipe barrel between pipe bells. No blocks, wedges, or other devices shall be used to support the pipe or to prevent uniform bearing of the pipe on its bedding. 726.4.1 Class A Bedding - Concrete Cradle. If a concrete cradle is required by the project plans and specifications, it shall be of low slump Class A concrete (MSD). It shall be constructed according to the details in the Standard Drawing C726.30. Backfill materials may not be placed above the concrete until it attains its initial set. 726.4.2 Class B1 bedding (Imperfect Trench) shall consist of a foundation covered with a 2inch layer of sand shaped to fit the lower part of the pipe exterior for at least 10 percent of its overall height. The sand shall be omitted for a distance of 20 feet at the upstream end when the pipe is to be used as a crossroad culvert. The pipe shall be laid by either of the following methods: a) Installation of Pipe Prior to Placing Embankment. After the pipe has been laid, and backfilled in accordance with Section 726.6, the embankment shall be placed and compacted to the required density for a lateral distance each side of the pipe of at least five times the outside diameter and to an elevation above the top of the pipe equal to the outside diameter of the pipe plus 1 foot. A trench, one outside pipe diameter wide, directly over the pipe, shall be dug through the compacted embankment to an elevation 1 foot above the top of the pipe. The trench walls shall be as nearly vertical as practicable. The trench shall be backfilled with loose dry material placed in the loosest condition practicable. Straw, hay, leaves, or sawdust may be used to fill the lower ¼ to ⅓ of the trench. b) Installation of Pipe After Placing Embankment. The roadway embankment shall be placed and compacted to the required density for a distance of at least five outside pipe diameters each side of the pipe and to a height of one outside diameter above the proposed top of the pipe. A trench, having a width of one outside pipe diameter plus 8 inches each side, shall be excavated through the fill. The trench walls shall be as nearly vertical as practicable. After laying the pipe, the trench shall be backfilled with sand in layers not exceeding 6 inches in thickness to the top of the pipe. Each layer shall be thoroughly compacted by the use of tampers or by flooding. The remainder of the trench shall be backfilled as in (a) above. 726.4.3 The standard bedding is Class C. Class C bedding shall be placed for all pipe except reinforced concrete pipe. Class C bedding will be placed in accordance with Standard Drawing C736.30. For reinforced concrete pipe a modified Class C Bedding is required. Requirements for Class C Bedding is also shown on Standard Drawing C726.30.
9/1/2023 15
726-9
Rigid Pipe Culverts, Storm Drains and Sewers
726.4.3.1 Crushed limestone and screenings for sewer bedding is divided into the following designated types: Designation: MSD 1 - Bedding For pipes 27 inches in diameter and smaller: Percent Passing by Weight Sieve Max. Min. 1 inch ......................................100 ......................................... 100 ¾ inch .....................................100 ............................................90 ½ inch .......................................60 ............................................35 #100 .........................................10........................................0 Designation: MSD 2 - Bedding For pipes 30 in. in diameter and larger: Percent Passing by Weight Sieve Max. Min. 1½ inch ...................................100 ........................................ 100 1 inch ........................................70 .......................................... 60 ¾ inch .......................................50 .......................................... 40 ½ inch .......................................35 .......................................... 25 #100 .........................................10........................................0
726.4.4 Concrete Encasement. When an encasement is required by the project plans and specifications, it shall be a low slump Class A concrete (MSD). It shall be constructed according to the details in the Standard Drawings C726.30. Backfill materials shall not be placed until the concrete attains its initial set. 726.5 Pipe Laying. 726.5.1 Pipe sewers shall be constructed of the sizes, classes, and materials, and to the alignments and grades given by the project plans and specifications. All pipe shall be inspected on delivery and such pipe as does not conform to the requirements of these specifications and which are not suitable for use shall be rejected and immediately removed from the site of work or destroyed. Prior to final acceptance, all flexible pipes shall be tested by the use of a mandrel or other approved device to ensure that no pipe deflection has occurred greater than 5 percent of the inside diameter of the pipe. These tests shall be performed without mechanical pulling devices and without additional cost to the County. All materials shall conform to the requirements of Division 1000, Materials Details.
9/1/2023 15
726-10
Rigid Pipe Culverts, Storm Drains and Sewers
726.5.2 All sanitary sewers shall sustain a maximum limit of 200 gallons per inch of diameter/day/mile of line, as required by the Missouri Department of Natural Resources Specifications, when field tested by actual infiltration conditions. 726.5.3 The grade shown on the profiles to which the work must conform is that of the pipe flowline or the low point of the pipe invert. Staking will be performed in accordance with the provisions of Section 105.8. A cut sheet must also be provided to indicate elevation to which the pipe was laid. 726.5.4 Equipment used to handle, lay, and joint pipe shall be so equipped and used as to prevent damage to the pipe and its jointing materials. All pipe and fittings shall be carefully handled and lowered into the trench. Damaged pipe or jointing material shall not be installed. Pipes shall be laid true to the lines and grades given on the stakes and cut sheets. The bell or groove end shall be laid upstream with the ends abutting to form a concentric joint without shoulders or unevenness of any kind along the invert of the pipe. Bell holes shall be dug to relieve the bell of all loads and shall be no larger than necessary. 726.5.4.1 Suitable means shall be used to force the spigot end of the pipe into the bell end without damage to the pipe and its jointing materials, and without disturbing the previously laid pipes and joints. The maximum allowable joint width measured on the inside surface of concrete pipe shall not be more than ¾ inch for pipe sized 12 through 21 inches in inside diameter; 1 inch for pipe sizes 24 through 45 inches in inside diameter; 1¼ inches for pipe sizes 48 inches and larger in inside diameter. On curved alignments only, the foregoing limits may vary a maximum of fifty percent. When the width of any joint exceeds the foregoing limits, or the infiltration/exfiltration allowables are exceeded, the engineer will determine the acceptability of the joint, the requirements for acceptable repair or will reject the joint to require re-laying and re-jointing. 726.5.4.2 Special care shall be taken to ensure that the pipes are solidly and uniformly bedded, cradled, or encased with the type of bedding, cradle, or encasement required by the project plans and specifications, and as shown on the Standard Details of Sewer Construction. No pipes shall be brought into position until the preceding length has been bedded and secured in place. Where concrete encasement is required, the pipe shall be supported at not more than two places with masonry supports of minimum size sufficient to provide the required clearance and to prevent displacement during placing of concrete. 726.5.4.3 Upon completion of laying, bedding, and jointing the pipe, and before backfilling above the springline of the pipe, the handling holes shall be solidly sealed with prefabricated plugs provided by the pipe manufacturer, set in bituminous jointing compound uniformly applied to both the joining surfaces of the plug and the inside surfaces of the hole. The plug shall fill at least 50% of the lifting hole depth with no part of the plug or cement protruding on the inside of the pipe. Water shall not be allowed to rise in the excavation until the joint materials any concrete cradle or encasement is hardened and cannot be damaged by water. Particular care shall be used to prevent disturbance or damage to the pipe and the joints during backfilling or at any other time.
9/1/2023 15
726-11
Rigid Pipe Culverts, Storm Drains and Sewers
As the work progresses, the interior of the sewer shall be cleaned of all dirt, cement, extruded joint materials, debris, and other extraneous materials. 726.5.4.4 Whenever pipe laying is stopped for any significant length of time, such as at the end of a workday, the unfinished end shall be protected from displacement, flotation, cavein, in-wash of soil or debris, or other injuries. A suitable temporary tight-fitting plug, stopper, or bulkhead shall be placed in the exposed bell, groove, or socket end. 726.5.4.5 Tees (T-junctions), wyes (Y-junctions), slants, stubs, reducers, bends, elbows, curves, radius-pipe, curved-pipe, fittings, or other special pipes shall be installed at the places shown on the project plans or were ordered by the Engineer. The fittings and special pipes shall be made of compatible material, type, and class or strength designation as the pipe required by the project plans and specifications and shall be installed in accordance with the pertinent Standard Details of Sewer Construction, and with these specifications. Wye and tee branches may be used on pipes for house connections and shall be encased in a mixture of one volume of cement and three volumes of moist sand. Wye and tee branches, slants, stubs, or other fittings installed in the pipe or built into manholes, junction chambers, or appurtenant structures for future connections shall be closed at the outer end. For pipes 21 inches in diameter or smaller, an approved stopper or cap shall be installed in the bell or socket using the same type of joint or jointing material as required for the sewer. For pipes 24 inches in diameter and larger, temporary approved masonry bulkheads to close the outer end shall be constructed of the thickness as required by the project plans and specifications. Care in backfilling shall be used so that such closure and its seal will not be disturbed. 726.5.4.5.1 Pipe plugs. The ends of all pipe stubs for future connections at inlet and manhole structures and of all pipes installed as a portion of future sewers shall be sealed with suitable plugs. The plugs shall be installed in a manner preventing infiltration of dirt into the pipe. No direct payment will be made for furnishing and installing plugs. 726.5.4.6 Elliptical Pipe. When elliptical pipe is required by the project plans and specifications, it shall meet the requirements of Division 1000, Materials Details. The standard bedding for elliptical pipe is Class C (Modified). The horizontal inside dimension shall be used to determine the size and type appurtenances to be built on the line. 726.5.4.7 Force Main. Where a force main is required by the project plans and specifications, it shall meet the requirements of Division 1000, Materials Details. The force main shall be provided with appropriate appurtenances where necessary, such as automatic air relief valves, thrust blocks, cleanouts, and cleanout manholes at low points in force main. The Standard Drawing C604.41 shows a cleanout detail. The force main shall be bedded in carefully placed selected earth backfill unless otherwise shown on the project plans and specifications.
9/1/2023 15
726-12
Rigid Pipe Culverts, Storm Drains and Sewers
The force main shall be laid on a continuous rising grade from the lift station or cleanout manhole to the manhole on the gravity sewer. After backfilling has been completed, the force main shall be tested to a pressure of 50 psi above the normal operating pressure of the system, unless otherwise specified. The leakage shall be measured by pumping into the line with a pump capable of maintaining the required pressure and metering the amount of water necessary to sustain the pressure for a period of four hours. The test, when so conducted, shall indicate a leakage of not more than 50 gallons/inch of pipe diameter/mile/day and no leaks shall become apparent on the surface of the ground. Should surface leaks become apparent, or should the leakage exceed that specified, the leaks shall be located and repaired and the line retested until it fulfills the above requirements. 726.6 Backfill. 726.6.1 After the pipe or conduit has been properly bedded, jointed, and inspected, and all measurements to record location of Y junctions, tees, etc. have been made by the Engineer, and sufficient time has elapsed for the joint materials or for any concrete or mortar to set and harden, upon permission of the engineer, the backfill may be placed. If trench is flooded before or during backfilling, or subjected to conditions which might cause flotation of the pipe before sufficient backfill has been placed, the Contractor shall take the necessary precautions to prevent flotation of the pipe, conduit, or structure. Before final acceptance of work, additional tamped earth shall be added to restore settled trench surfaces to the required level of the adjacent earth surfaces or the base or crushed rock wearing surfaces or to the finished earth base for sodding or for seeding. Where seeding or sodding are not required, the excess earth shall be uniformly and neatly mounded above the trench. 726.6.2 Backfill in trenches which are not within or immediately adjacent to pavements of concrete or pavements on stone or concrete base but are located where prevention of backfill settlement is essential, and where required on the project plans or by the Engineer and where granular fill is not desired, shall consist of selected job-excavated earth thoroughly compacted with suitable mechanical tampers to the density of adjacent undisturbed earth. Non-granular jobexcavated material shall be free from debris, organic matter, perishable compressible materials, and shall contain no stone or lumps of rock fragments larger than 6 inches in diameter, nor be in such amount that will interfere with the consolidating properties of the fill material. Care shall be taken that stones and lumps are kept separated and well distributed, and that all voids are completely filled with fine materials. The upper 3 feet of backfill in sodded or planted areas shall be free of rocks or lumps larger than 1 inch in diameter with the upper 6 inches being free of all objectionable material. The approved backfill materials shall be placed in layers not exceeding 8 inches before compaction. Backfilling shall be performed on a daily basis for all pipes unless otherwise approved by the Engineer.
9/1/2023 15
726-13
Rigid Pipe Culverts, Storm Drains and Sewers
726.6.3 Backfill - Granular or Other Compacted Materials. Backfill in trenches through pavements of concrete, or wearing surfaces on concrete or stone base, or brick, or macadam in highways, streets, rights-of-way, or wherever prevention of backfill settlement is considered essential, and where the project plans and specifications require or the Engineer orders, shall be made with granular fill from the level 6 inches above the top of the pipe to the subgrade elevation of the pavement. Granular backfill shall consist of ¾ inch minus crusher-run limestone. Designation: MSD 3 - Backfill Crushed limestone and screenings to be used for backfill shall be ¾ inch minus. Pea gravel or similar granular materials approximately uniform in size and without bonding properties shall not be used. All granular materials shall be compacted by mechanical tamping to standard maximum density (100%). 726.6.4 Backfill - Jetted. Unless ordered to be mechanically compacted by the Engineer, the trench backfill shall be uniformly flooded and poled or jetted with water by a method to be approved by the Director, and with care to avoid damage to the newly laid sewer. After the backfill in trench has substantially dried and completed its settlement, and permission has been given by the Director, any settlement below the finished grade shall be refilled with additional earth. No separate payment will be made for jetted backfill, all costs of which are included in the bid prices of other items. 726.6.5 Sewers. Sewers to be abandoned shall be securely blocked at any points of intake or discharge with a bulkhead or preformed plug. When directed by the project plan, they shall be completely filled with an approved sand-cement mixture. The proposed methods of filling and blocking the sewer, which will consist of pumping the mix, shall be submitted to the Engineer for approval. The Contractor will be allowed to remove that portion of the sewer to be abandoned in lieu of filling and blocking. If the Contractor elects to request the removal method, and it is subsequently approved, excavation and all costs for surface restoration, in addition to removing and properly disposing of the pipe, shall be included in the unit bid price for other items. 726.6.6 Emergency Utility Excavations. Emergency (as determined by the Engineer) excavations for the immediate repair of utility mains in the right of way may be backfilled with ¾ inch clean limestone or MSD 1 backfill as directed by the Engineer. All pavement excavations, except those for which plate use has been authorized, shall require a temporary asphaltic concrete wearing surface. A Special Use Permit shall be applied for within 48 hours after the emergency repairs take place. 726.7 Pipe Sewers in Tunnel in Earth. Pipe sewers in tunnel in earth shall be constructed where required by the project plans and in accordance with these specifications. If not prohibited on the plan and if otherwise practicable and desirable, the contractor may request permission to construct this sewer in a bored hole or jacked liner.
9/1/2023 15
726-14
Rigid Pipe Culverts, Storm Drains and Sewers
726.7.1 The Contractor shall carry out the work of tunneling and supporting the tunnel face, roof, walls, and floor, so that there will be no fall or flow or caving or heaving of earth or other materials into the tunnel excavation, nor any other cause for endangering human life, or any public or private property above or adjacent to the tunnel. If there should be any fall or movement of earth into the tunnel at any time, the Contractor shall proceed with the work with all necessary precautions and in such a manner as will ensure the safety of life and of all sewers, utilities, and public and private property above or adjacent to the tunnel. If any sewer or utility above or adjacent to the tunnel is endangered or has been damaged because of the tunneling operations or movements of earth, the owner shall be notified immediately and shall be given access to the work to carry out all necessary safeguards and repairs to such sewers or utilities. If any public or private property is endangered or has been damaged, it shall be repaired at the Contractor's expense. All cost and expense to the contractor of carrying out the above requirements shall be considered included in the bid prices for other bid items. 726.7.2 The Contractor shall make all excavations necessary for the construction of sewers in tunnel, whether in earth or partly in earth and in rock, shall furnish, place, and maintain all sheeting, bracing, lining, or casing required to support the tunnel floor, roof, sides, and face until the pipe and its bedding, jointing, encasement, and backfilling have been completed. All liners shall remain in place. Methods are optional with the Contractor, provided the work can be carried out expeditiously, carefully, and in compliance with these specifications. Care shall be used in trimming the surfaces of the excavated section and in placing the liners or sheeting and bracing, so that the required minimum clearance between the outside of the pipe and the final position of the liners, sheeting, and bracing in the tunnel will be attained without any deviation in sewer alignment. Sheeting or lining must be placed and held tightly against the trimmed earth surface of the excavated section so that there will be no voids between the earth and the lining or sheeting placed against it. No part of the lining, bracing, or flanges of steel liner plates shall project closer to the outside of the pipe or pipe bells than the clearance limits shown on the project plans, or a minimum of 2 inches if not shown on the plans. If timber is used for lining and bracing instead of steel liner plates, invert struts shall be placed at the required intervals but in such manner that the pipe and its bedding will be supported entirely by the original earth floor of the tunnel and not on timber lining or bracing. Timbering shall be so designed and placed that there will be no space or pockets that cannot be packed and filled. All excavated material not required for backfilling abandoned shafts shall be removed from the site and disposed of by the Contractor at his expense. 726.7.2.1 Shafts. Shafts shall be constructed at the location shown on the project plans and in accordance with the project specifications. Temporary construction shafts shall be of adequate size and properly constructed and equipped to meet all requirements of safety to personnel and to the work. All shafts shall be fenced and properly guarded from the beginning of the excavation until the completion of construction requiring the shaft. Provision shall be made at all shafts so that plumb lines suspended on the centerline of the sewer at each end of the shaft will hang freely from the surface. A substantially constructed ladder shall be provided in each shaft, and shall be kept in safe, good repair, clean and clear of debris. Lights, barricades, signs, and guards (when guards are required by the project plans or specifications, or when ordered by the Director) shall be provided and maintained to properly protect the public, the workers, and the work against injury.
9/1/2023 15
726-15
Rigid Pipe Culverts, Storm Drains and Sewers
726.7.2.2 Tunnel Plant. When necessary, requirements for power machinery and equipment within shafts and tunnels will be given in the project specifications. 726.7.2.3 Tunnel Drainage. The Contractor shall furnish and operate all necessary pumping equipment of ample capacity and make all necessary provisions to keep tunnels and shafts free of water during construction, and to satisfactorily dispose of such water. During placement of concrete, drainage and pumping shall be so arranged that concrete is placed in the dry and that no water will flow over the concrete until it has set and will not be damaged, and not sooner than two hours after initial set. The Contractor shall have on hand at all times sufficient equipment in good working order for all ordinary emergencies that are likely to arise. 726.7.2.4 Spaces Between Tunnel Excavation and Liner. Tunnel excavation shall be trimmed as nearly as practicable to exact line and grade and to such shape as will allow the construction of the sewer section as shown on the project plans. Cavities or spaces between actual surfaces of excavation and the tunnel liner plates, whether from avoidable or unavoidable causes, shall be completely filled with a uniform sand-cement grout, consisting of one part Portland cement and seven parts sand and the minimum amount of water necessary for proper placing, placed under pressure through grout-hole nipples in the steel liner plates. The grout holes shall be so located, and the grout be placed in such sequence as to ensure the complete filling of all cavities and spaces, and of carrying loads uniformly from the undisturbed material to the tunnel lining. 726.7.2.5 Pipe Laying. After the tunnel section is excavated and lined, the pipe shall be placed on and supported by steel rails or other approved supports. The supporting system shall assure line and grade and shall allow space below the pipe for concrete. Care shall be used to avoid damage to the pipe or to the liner plates. Any such damage shall be replaced when so directed by the Engineer. 726.7.2.6 Spaces Between Pipe and Tunnel Liner or Rock Surfaces. After laying the pipe, uniformly compacted Class B (MSD) concrete shall be placed to fill all spaces between the outside of the pipe and the inside surface of the lining or the prepared surface of the rock if the tunnel is in sound rock. 726.7.2.7 Removal of Temporary Shafts. Temporary shafts shall be completely abandoned. Unless otherwise specified on the project plans and specifications, all sheeting, bracing, etc. may be removed or left in place at the Contractor's option. No payment will be made for sheeting, bracing, etc., left in place at the contractor's option. If the project plans or specifications require leaving the sheeting, bracing, etc. in place, payment will be made as provided in the project specifications. 726.8 Sewer Construction in Rock Tunnels. Sewers in rock tunnels shall be constructed with a concrete lining only when required for the particular project. It shall be constructed in accordance with the project plans and specifications. 726.9 Pipe Sewers in Stanks. Pipe sewers to be constructed in stanks shall be constructed of the size, type, and class specified on the project plans and specifications. Class C bedding shall be used, and after placing the bedding the remaining space above the top of the pipe shall be packed solidly with tamped limestone and screenings. The Contractor shall carry out the work of stanking in a safe and prudent manner to avoid endangering human life or property.
9/1/2023 15
726-16
Rigid Pipe Culverts, Storm Drains and Sewers
726.10 Pipe Sewers in Bored Holes. When required or when permitted as an alternate method of construction by the project plans and specifications, or when permitted in writing by the Director upon written request by the Contractor in substitution for the method of construction shown on the plans, pipe sewers may be constructed in bored holes. The boring machine to be used shall be in good mechanical condition and capable of drilling the borehole within the required limits of accuracy. A smooth liner of sufficient strength shall be forced into the bored hole to give a tight fit against the earth sides of the borehole and still provide a uniform clearance of at least 2 inches around the pipe flange to permit pressure grouting. The liner pipe shall be carefully inspected to ensure that the carrier pipe can be properly placed. The pipe to be placed in the borehole shall be reinforced concrete pipe with gasketed joints (Type B), or ductile iron pipe of the required size and class. No plastic pipe shall be allowed. The mechanical or approved slip-joint connections between ductile iron pipe lengths shall be made carefully in accordance with the manufacturer's instructions. After placing the assembled pipe in the borehole, the ends shall be blocked to secure the proper flowline elevations at each end, and to insure the placing of grout at the bottom and sides of the pipe. If necessary or required, a skid or shoe shall be provided for the pipe bell to permit flow or grout beneath the pipe, and to prevent sagging and pockets along the pipe flowline. The assembled and jointed pipe shall be placed in the borehole only by such method that will keep the joint in compression. Any method tending to un-joint the pipe while being placed will not be permitted. The spaces between the liner and the outside of the pipe shall be filled solidly with grout placed under mechanical pressure. Before placing grout, the carrier pipe shall be carefully inspected for uniformity of grade along its alignment, and any required corrections made. Particular attention shall be given to ensuring that the pipe will be solidly supported by grout at its bottom and sides. The method of injection under mechanical pressure shall be approved by the engineer. Grout shall consist of an approved mix, and it shall be placed by inserting the grout pipe to its greatest distance to insure filling all spaces, and then gradually withdrawing the pipe as filling proceeds. Manholes at the ends of a section of sewer, part, or all of which is constructed in a bored hole, shall not be constructed until the bored section is completed, in order to allow corrections for slight deviations in line and grade. The completed sewer constructed in a bored hole shall not deviate from its required alignment more than one percent of the total length of the bored hole, nor more than 1/10 foot from its required terminal elevation. If the deviations are greater than these, the construction shall be removed and replaced unless the Director, in writing, accepts and approves the actual construction as a result of a written request made by the contractor for such acceptance and approval. When the project plans specifically state that the sewer shall be constructed in a bored hole, and unforeseen obstructions require abandonment of a partially completed borehole and the starting of a new hole, the contractor will be paid for the expense of drilling and backfilling such abandoned borehole in accordance with Section 104.3 or Section 109.4. If the Contractor was permitted or has requested and obtained approval to use a bored hole instead of the construction required by the project plans but is not successful in completing the construction by the boring method, he or she shall receive no compensation for any expenses incurred by the unsuccessful attempt. When a section of ductile iron or reinforced concrete pipe adjoins a section of dissimilar sewer pipe without an intervening manhole, a concrete collar shall be cast with their junction as shown in the Standard Drawings or on the project plans. Care shall be used to insure alignment of the inside surfaces of the pipes and their flowlines.
9/1/2023 15
726-17
Rigid Pipe Culverts, Storm Drains and Sewers
726.10.1 Boring Without the Use of Casing. Boring without casing will be permitted for small sewer lines 6 inches in diameter only when subsurface conditions are suitable and only with the prior written approval of the Director. The boring machine to be used shall be in good mechanical condition and capable of drilling the borehole within the required limits of accuracy. This machine must be capable of drilling a hole, not larger than 2 inches in diameter, the total length of the bore to determine the proper flowline within the required accuracy limits. After proper flowline is established, the 2-inch cutter head shall be removed and replaced with a trimmer head capable of cutting at established flowline, a hole to accommodate the proper sized pipe not to exceed 6 inches in diameter. 726.11 Pipe Sewers in Jacked Liner. When permitted as an alternate method of construction by the project plans and specifications, or when permitted by the Director upon written request of the contractor as an alternate to boring or tunneling, a sewer may be installed by jacking a pipe as a liner and inserting a carrier pipe of required size, type, and class. When planning to use jacking for liners, the contractor shall state in writing the kind, type, and strength of liner, the type of joint proposed, and the method of operation. Approval in writing by the Director shall be obtained in advance of starting the work. In any case, the contractor shall retain full responsibility for the adequacy of the jacking operation equipment and materials. 726.12 Sewers Installed by Jacking. When permitted as an alternate method of construction by the project plans and specifications, or when permitted in writing by the Director upon written request of the contractor as an alternate to boring or tunneling, a sewer may be installed by jacking. When planning to use jacking, the contractor shall submit full details of materials and method of operation. Approval in writing by the Director shall be obtained in advance of starting the work. In any case, the Contractor shall retain full responsibility for the adequacy of the jacking operation equipment and materials. 726.13 Grouting or Sand-Cement Backfill. When required by the project plans and specifications or by the Standard Drawings, or when ordered by the Engineer, sand-cement backfill, or grouting shall be done by the Contractor. Grout may be required to set anchors or dowels in holes drilled in rock or concrete, to fill spaces between excavated tunnel surfaces and linings of tunnels or bored holes, or voids in packed rock, etc. Grout or sand-cement backfill shall consist of a uniform mixture of Portland cement and sand, as specified for a particular purpose either in these specifications or in project specifications, and with the minimum volume of water necessary to accomplish the intended result. If ordered by the Engineer, neat cement grout shall be used. The use of special cements or admixtures for particular uses will be specified in the project specifications if required. All grouting equipment and appurtenances shall be in good mechanical working condition, of an approved type of design with ease of control to permit uniform operation without excessive pressures, and with adequate capacity to permit continuous satisfactory progress in the required grouting. Grout for filling voids or spaces shall be applied through a pipe or hose in a continuous operation without disturbance of grout which has taken initial set. The grouting operation and sequence shall be so conducted as to ensure complete filling of voids or spaces and shall be sufficient to fill all spaces without distorting or damaging the structure, or without lifting or distorting the adjacent or overlying confining materials.
9/1/2023 15
726-18
Rigid Pipe Culverts, Storm Drains and Sewers
726.14 Method of Measurement. 726.14.1 Pipe Sewers. Measurement will be made for complete pipe sewers, round or elliptical, for each size, kind, and class of pipe laid at the respective bid price per linear foot. The length for payment will be the measured horizontal distance for each type along the centerline of the pipe exclusive of the distance between the inside faces of each connected structure, sewer, manhole, inlet, junction chamber, transition section, or other similar structures. The payments made shall include all costs of labor, materials, tools, and equipment and shall be full payment for excavation; furnishing and placing backfill; furnishing and installing pipe; jointing materials; crushed limestone in replacement of over-dig; furnishing, placing, and compacting the bedding; and removal of waste materials. When approved by the Engineer, the length of pipe sewer may be increased by not more than 3 feet as necessary to avoid cutting the pipe, but such increased length will not be included in the contract quantity for payment. 726.14.2 Curved or Radius Pipe. Unless otherwise provided in the project specifications, no additional payment will be made for curved or radius pipe, which will be measured and paid for in the same manner as straight pipe. Any additional costs for curved or radius pipe shall be included in the bid price per linear foot for pipe of the size, kind, and class involved. 726.14.3 Measurement for all pipe fittings, including tees, wyes, bends, stubs, reducers, plugs, and any other items necessary to complete the pipe run will be included in measurement of sewer pipe and no separate payment will be made. 726.14.4 Measurement of concrete encasement will be computed to the nearest cubic yard. The quantity for payment will be the respective quantity per linear foot for each size pipe as tabulated in the Standard Drawings and for the actual length of sewer so encased. 726.14.5 Measurement for concrete cradle will be computed to the nearest cubic yard. The quantity for payment will be the respective quantity per linear foot for each size pipe as tabulated in the Standard Drawings and for the actual length of sewer so encased. 726.14.6 Measurement for the removal of unsuitable material from trenches and excavations will be made per ton of backfill material required. This compensation will include excavation, placing of material, compaction of material, and disposal of waste excavation including any incidental items. 726.14.7 Measurement of rock excavation in trench will be made to the nearest cubic yard by measured dimensions or cross sections obtained by the engineer. The Contractor will notify the Engineer when the area of rock excavation is ready for measurement and will assist in determining them. The Contractor must provide adequate time for the engineer to obtain the required measurements. Failure to cooperate fully with the Engineer in acquiring the needed information will result in loss of pay for this item. 726.14.7.1 Unless established as a pay item, no direct measurement of shoring and bracing will be made. When a pay item, shoring and bracing will be computed per square yard.
9/1/2023 15
726-19
Rigid Pipe Culverts, Storm Drains and Sewers
726.14.8 When a pay item, stanking will be measured to the nearest linear foot along the geometrical centerline of the sewer. 726.14.9 When a bid item and not a portion of another bid item, Abandonment of Septic Tank and Field will be measured per each. 726.14.10 Pipe Sewer in Tunnel in Earth. Will be measured per linear foot. The length for payment will be the measured horizontal distance along the centerline of the sewer to the paylines of excavation for shafts or to the portal of the tunnel excavation. 726.14.11 Pipe Sewer in Bored Hole. Will be measured per linear foot. The length of sewer for which payment will be made will be the measured horizontal distance along the centerline of the pipe between the faces of the bore limited to the length required by the project plans and specifications unless such length has been ordered increased by the Director. 726.14.12 Pipe Sewer in Jacked Liner. Will be measured in accordance with the requirements of the original method for which it is an approved alternative. 726.14.13 Pipe Sewer Installed by Jacking. Will be measured per linear foot. The length of sewer for which payment will be made shall be the measured horizontal distance along the centerline of the pipe between the ends of the completed pipe sewer-jacked into final position, limited to the length of the distance between tunnel faces. 726.14.14 Grouting or Sand-Cement Backfill. When a bid item, will be computed to the nearest 1/10 cubic yard utilizing established volumes per linear foot filled. 726.15 Basis of Payment. 726.15.1 Sewer Pipe. The accepted quantity of each type of sewer pipe used, complete in place, including all fittings will be paid for at the contract unit bid price for the various items of construction. 726.15.2 Concrete for Encasement. Payment will be made for Class A concrete (MSD) encasements at the bid price per cubic yard for the class of concrete used. Such payment shall include the entire cost of furnishing and placing the encasement as shown in the Standard Drawings. It also shall include the costs of necessary excavation beyond paylines, and also the cost of supporting and securing the jointed pipe against movement during the placing of concrete. 726.15.3 Concrete for Cradle. Payment will be made for Class A concrete (MSD) in cradle at bid price per cubic yard for the class of concrete used. Such payment shall include the entire cost of furnishing and placing the concrete cradle as shown in the Standard Drawings. It also shall include the costs of necessary excavation beyond paylines, and also the cost of supporting and securing the jointed pipe against movement during the placing of concrete. 726.15.4 Payment for Shoring and Bracing. Will be per square yard, complete in place, at the contract unit bid price. 726.15.5 Payment for Stanking will be per linear foot at the contract unit bid price. 726.15.6 Abandonment of Septic Tank and Field will be paid per each at the contract unit 9/1/2023 15
726-20
Rigid Pipe Culverts, Storm Drains and Sewers
bid price. 726.15.7 Pipe Sewers in Tunnel in Earth. Payment will be made for the construction of completed pipe sewers in earth tunnels at the respective bid price for each size and type per linear foot for completed sewer in earth tunnel. The payment made shall include all costs of shafts, headings, liner plates, timbering, grouting, drainage, lighting, ventilation, all excavation, pipe in place, concrete, reinforcing masonry, bedding, cradling, or encasing, backfilling tunnel and any additional costs required to construct the completed pipe sewer in tunnel in earth. 726.15.8 Pipe Sewers in Bored Holes. Payment for completed pipe sewer in a bored hole, when required or permitted as an alternative to pipe sewer in tunnel, shall be made at the bid price for the construction method specified and for the length constructed in a bored hole. When permitted as an alternative to open-cut construction, payment will be as if the sewer has been constructed in an open cut. There will be no payment for the additional cost of the pipe and its encasement, and no allowance for lumber left in the trench. Permission to use construction involving a bored hole and reinforced concrete pipe with gasketed joint or ductile iron pipe instead of the construction originally specified, shall not entitle the Contractor to any compensation for costs of an unsuccessful or an incomplete attempt to use a bored hole. Payment for completed pipe in a bored hole where specified by the project plans and specifications, or were ordered by the Engineer, shall be made at the bid price per linear foot of completed specified sewer constructed in a bored hole. Such payment shall include all costs of labor, materials, equipment and tools to prepare the boring bit, bore the hole, install the linear pipe, lay and joint the ductile iron pipe or reinforced concrete pipe with gasketed joint, provide concrete collars at the junctions with other types of pipe, completely fill the annular space around the pipe, backfill the boring pit, and do all other things necessary or required for constructing the completed pipe sewer in a bored hole. 726.15.9 Pipe Sewers in Jacked Liners. Payment for completed pipe sewer in a jacked liner, where permitted by the project plans and specifications as an alternative to a pipe sewer in tunnel in earth, shall be made at the bid price for the construction method originally specified. Permission to use construction involving a jacked liner shall not entitle the contractor to any compensation for any additional expenses or for the costs of an unsuccessful or incomplete attempt to use jacking. When permitted as an alternative to open- cut construction, the method shall be approved by the Director.
9/1/2023 15
726-21
Rigid Pipe Culverts, Storm Drains and Sewers
726.15.10 Pipe Sewers Installed by Jacking. Payment for the construction of pipe sewers installed by jacking as an approved alternative to tunneling will be made at the bid price for the given size of specified pipe sewer in tunnel unless an agreed price has been established. Such payment shall include all costs of labor, materials, equipment, and tools for the jacking bit, guides, and jacks; drainage and excavation; furnishing, jointing, and jacking the pipe; and doing all things necessary to construct the completed pipe sewer by jacking. Permission to install a pipe sewer by jacking shall not entitle the Contractor to any compensation for any additional expenses or for the costs of an unsuccessful or incomplete attempt to use jacking. When such jacking is required by the contract, an unsuccessful or incomplete attempt will be measured and paid in accordance with the provisions of Section 104.3 or Section 109.4. 726.15.11 Grouting and Sand-Cement Backfill. Unless otherwise provided by the project plans, no separate payment will be made for grouting or sand-cement backfill. Any costs of furnishing and placing grout or sand-cement backfill as required by the specifications for any specific item shall be considered to be included in the payments from such item or items. When a bid item, grouting or sand-cement backfill will be paid as a computed quantity in place at the contract unit bid price. 726.15.12 The cost of any additional granular fill required beyond payline limits due to an unauthorized excavation beyond payline limits is to be borne by Contractor. No separate payment will be made for the placing of backfill either uncompacted or consolidated by jetting or supplemented due to settlement below the required elevation. Its cost shall be included in the bid prices for other items.
9/1/2023 15
726-22
Rigid Pipe Culverts, Storm Drains and Sewers
Section 727
Structural Plate Pipe, Structural Plate and Pipe-Arch Culverts
727.1 Description. This work shall consist of furnishing and installing built-up structural plate round pipe or built-up structural plate pipe-arch with a full metal bottom of galvanized corrugated metal plate curved sections bolted together to form the required shape shown on the plans. The thickness of the structural plate shall be as specified in the contract. 727.2 Materials. 727.2.1 All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Structural Plate Pipe and Pipe-Arches ...................................... 1023 Corrugated Aluminum Alloy Structural Plate ............................. 1024 727.2.2 The size and shape of the plates shall be such that the finished structure will have the dimensions shown on the plans. 727.3 Construction Requirements. 727.3.1 Handling. All pipe shall be handled with care to avoid damage. Pipe having damaged coating, any localized bends in excess of five percent of the specified pipe diameter or any dent in excess of ½ inch will be rejected at the site of the work, regardless of previous approvals. Rejected damaged pipe may be used, if repaired to the satisfaction of the engineer. 727.3.2 Laying Pipe. The structure shall be carefully laid true to lines and grades. Any structure that is not in true alignment or that shows undue settlement shall be taken up and relaid at the contractor's expense. If shown on the plans or directed by the engineer, camber shall be built into the structure to compensate for settlement from embankment loads. 727.3.3 Bedding and Backfill Material. The bed for structural plate pipe and pipe-arch culverts shall be formed in accordance with Section 725.3.3, except if rock is encountered, the trench shall be excavated to a minimum depth of 8 inches below the bottom of the pipe. 727.3.4 Backfilling. 727.3.4.1 Except where the backfill or embankment is to be formed of stone or rock fill, the material shall be placed in accordance with Section 725.3.4.5, except as modified herein. Layers of backfill or embankment shall be kept at approximately the same elevation on opposite sides of the structure at all times during the progress of the work in order to equalize the loading. This method of filling and compacting shall be continued until the top of the embankment is at an elevation level with the top of the structure.
5/1/2010
727-1
Structural Plate Pipe, Structural Plate, and Pipe-Arch Culverts
727.3.4.2 If the backfill or embankment over and around the structural plate pipe or pipearch is specified to be formed of stone or rock fill, a protective inner layer of backfill material, in accordance with AASHTO M 145, Classification A-1, A-2-4, A-2-5 or A-3, preferably mixed with earthy material, tamped into place in contact with the structure, and surrounded by a carefully placed outer layer of rock, shall be built up as the work proceeds around the perimeter of the structure above a specially prepared foundation. The protective layer shall be placed during the progress of the backfilling and placing of the embankment or rock fill in a manner and of sufficient thickness to protect the surface of the structure from injury to the coating. 727.3.5 Shop Elongation. The contractor shall maintain elongation during backfilling and embankment construction such that the vertical height of the opening after the embankment has been completed shall be no less than the diameter of the pipe or greater than the preelongated height. Steel and aluminum structural plate round pipe shop elongation, if required, shall be as shown on the plans. Pipe arches shall not be elongated. 727.3.6 Beveled End Sections. The plans will indicate where beveled end sections are required and the slope of the cutting line. On skewed round structures with beveled end sections, the end sections shall be rotated as required to better fit the adjacent roadway slope. Shop elongation shall be in accordance with Section 727.3.5. 727.4 Inspection and Replacement. Inspection and replacement of structural plate pipe and pipe-arch culverts shall be in accordance with Section 725.4, except deflection testing and maximum deflection allowed will not apply. 727.5 Method of Measurement. 727.5.1 Measurement of structural plate pipe, complete in place, will be made to the nearest foot along the geometrical center of the structure. 727.5.2 Measurement of structural plate pipe-arch, complete in place, will be made to the nearest foot along the center of the vertical dimension of the structure. 727.5.3 Excavation for placing structural plate pipe and pipe-arches will not be measured, except when the excavation for the installation is shown on the plans as Class 3 Excavation. 727.6 Basis of Payment. 727.6.1 The accepted quantities of structural plate pipe or structural plate pipe-arch culverts, complete in place, will be paid for at the contract unit price for each of the pay items included in the contract. 727.6.2 Unless specified otherwise, no direct payment will be made for the following: a) Beveling, skewing or for any additional work required in laying structural plate structures with beveled or skewed ends. b) Work involved in elongating. c) Backfilling, except as specified in Section 206.6.3.
5/1/2010
727-2
Structural Plate Pipe, Structural Plate, and Pipe-Arch Culverts
d) Construction of bedding or for bedding material. e) Trench excavation and backfilling, except when Class 3 Excavation is shown on the plans for a given pipe location. When shown on the plans, payment for Class 3 Excavation will be made in accordance with Section 206. f) Furnishing and installing plugs. g) Work or equipment to perform deflection testing.
5/1/2010
727-3
Structural Plate Pipe, Structural Plate, and Pipe-Arch Culverts
(This Page Intentionally Left Blank)
5/1/2010
727-4
Structural Plate Pipe, Structural Plate, and Pipe-Arch Culverts
Section 728
Corrugated Polyvinyl Chloride (PVC) Culvert Pipe
728.1 Description. This work shall consist of providing corrugated PVC pipe of the diameter designated, laid upon a firm bed and backfilled as specified. 728.1.1 The contract will specify either the type of pipe or the group of permissible types of pipe. If a group of permissible types is specified, the contractor shall use any of the types listed within the specified group as follows: Group A
Group B
Group C
Reinforced Concrete Pipe (RCP) Vitrified Clay Culvert and Sewer Pipe (VCP) Corrugated Metallic-Coated Steel Pipe (CMP)
Reinforced Concrete Pipe (RCP) Corrugated Metallic-Coated Steel Pipe (CMP) Corrugated Aluminum Alloy Pipe
Reinforced Concrete Pipe (RCP) Corrugated Metallic-Coated Steel Pipe (CMP) Corrugated Aluminum Alloy Pipe Corrugated Polyethylene Pipe
728.1.2 If the contract specifies corrugated PVC pipe or if the contract specifies pipe culverts by group and the contractor elects to furnish corrugated PVC pipe, the allowable overfill height shall be in accordance with the plans, unless specified otherwise. Minimum cover will be measured as shown on the plans. 728.1.3 If the contract specifies pipe culverts by group and the contractor elects to furnish metal pipe, the culvert shall be constructed in accordance with Section 725. If the contractor elects to furnish concrete or vitrified clay pipe, the pipe culvert shall be constructed in accordance with Section 726. If the contractor elects to furnish corrugated polyethylene pipe, the culvert shall be constructed in accordance with Section 730. 728.1.4 When Group B and Group C pipe are specified, two pipe diameters will be shown on the plans at those locations. The first dimension will indicate the diameter of pipe that shall be provided if the contractor elects to provide pipe for that location with a corrugated interior wall, and the second dimension provided in parenthesis will indicate the diameter of pipe that shall be provided if the contractor elects to provide pipe for that location with a smooth interior wall. The specified diameters may be the same or different and will be dependent upon the design features for that pipe location. Regardless of which diameter of pipe is selected for a given location, the pipe flow line shall be maintained at the elevations shown on the plans.
5/1/2010
728-1
Corrugated Polyvinyl Chloride (PVC) Culvert Pipe
728.1.5 If corrugated PVC pipe is specified in the contract or elected for use by the contractor, none of the corrugated PVC pipe shall be exposed to sunlight after installation. This will require the exposed portion of pipe and pipe end sections to be one of the other pipe material of the group of pipe specified, unless approved otherwise by the engineer. The minimum distance required to protect the corrugated PVC pipe from exposure to sunlight will be onehalf of the pipe diameter from the opening. This requirement will be waived when the corrugated PVC pipe is connected to drop inlets, manholes, box culverts or similar structures. 728.1.6 Pipe used for storm sewers may be any pipe listed under Group B pipe, with the following exceptions. All corrugated metal culvert pipes shall be Type IA or Type IR. Sewer pipe placed beneath the paved portion of roadways with average daily traffic greater than 3500 vehicles per day shall be Group A pipe. No other substitutions will be permitted, regardless of what type or group of pipe is specified for storm sewers outside of the paved portion for these roadways. 728.2 Materials. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Metallic-Coated Steel End Sections .......................................... 1020 Corrugated PVC Pipe ................................................................ 1028 Precast Concrete Flared End Sections ..................................... 1032 728.3 Construction Requirements. 728.3.1 Handling. All pipe shall be handled to avoid damage. Damaged pipe will be rejected regardless of previous approvals, and shall be replaced or repaired to the satisfaction of the engineer at the contractor’s expense. 728.3.2 Laying Pipe. 728.3.2.1 Pipe shall be laid true to lines and grades shown on the plans, with bell ends upstream and with the spigot end entered the full length into the adjacent section of pipe. Any pipe that is not in true alignment or that shows any undue settlement after laying but before the fill is placed, shall be taken up and re-laid at the contractor's expense. Camber shall be built into the pipe structure to allow for settlement from fill loads if shown on the plans or directed by the engineer. 728.3.2.2 Joints shall be soil-tight unless specified otherwise. Joints shall be installed such that the connection of pipe sections will form a continuous line free from appreciable irregularities in the flow line. Suitable field joints may be obtained with bell and spigot pipe ends with rubber gaskets meeting ASTM F 477, or double bell couplings.
5/1/2010
728-2
Corrugated Polyvinyl Chloride (PVC) Culvert Pipe
728.3.3 Bedding & Backfill Material. 728.3.3.1 Backfill material for corrugated PVC pipe shall consist of gravel, sand or sandy silt soil as shown on the plans. Backfill shall be free of organic material or frozen clumps. Backfill for pipe with diameters 15 inches or less shall have a maximum particle size of ¾ inch. Backfill for pipe with diameters greater than 15 inches shall have a maximum particle size of 1½ inches. 728.3.3.1.1 Gravel and sand shall consist of a well-graded mixture of stone fragments, gravel and sand and shall be in accordance with AASHTO M 145, Class Al or A3. 728.3.3.1.2 Sandy silt soil shall consist of non-plastic granular material with silt content higher than that of gravel or sand, and shall be in accordance with AASHTO M 145, Class A2-4 or A2-5. 728.3.3.2 Bedding material for pipe with diameters 15 inches or less shall have a maximum particle size of ¾ inch. Bedding material for pipe with diameters greater than 15 inches shall have a maximum particle size of 1¼ inches. 728.3.4 Installation. 728.3.4.1 Trench Requirements. The pipe shall be installed in a trench whether installed below grade or in an embankment. The construction sequence shall be as shown on the plans. When pipe is installed in an embankment, the embankment shall be placed and compacted to the required density to a minimum elevation of one foot above the top of pipe before a subtrench is excavated. The bedding shall be placed to the required thickness and grade, taking care to avoid compaction of the bedding under the middle one third of the pipe. The bedding outside the middle one third of the pipe shall be compacted to the required density shown on the plans before placing the pipe. The material under the haunches of the pipe shall be properly compacted. 728.3.4.2 Bedding in Unsuitable Material. If rock is encountered, the bedding depth shall be increased to 6 inches below the bottom of the pipe. If soft, spongy or unstable material is encountered, that material shall be removed and excavated to a minimum depth of 10 inches below the bottom of the pipe, and replaced with a suitable granular material. Payment for removal of unsuitable material and for backfilling will be made in accordance with Section 206.6.3, unless the unsuitable material is a result of the contractor's operations, in which case the removing and backfilling shall be at the contractor's expense. 728.3.4.3 Backfilling. Backfilling shall be completed as soon as practical. Suitable backfill material free from large lumps, clods or rocks shall be placed alongside the pipe and compacted as shown on the plans. The placement of the remainder of the backfill shall be conducted in such a manner as to prevent misalignment of the pipe, and in accordance with Section 203. Backfill shall be compacted to a minimum of 90 percent standard maximum density or otherwise specified embankment density. 728.3.4.4 Construction Loading. Before heavy construction equipment is operated over the pipe, the contractor shall provide adequate depth and width of compacted backfill or other cover to protect the pipe from damage or displacement. Any damage or displacement shall be repaired or corrected at the contractor's expense. 5/1/2010
728-3
Corrugated Polyvinyl Chloride (PVC) Culvert Pipe
728.3.4.5 Pipe Plugs. The ends of all pipe stubs for future connections at inlet and manhole structures and of all pipe installed as a portion of future sewers shall be sealed with suitable plugs. The plugs shall be installed in such a manner as to prevent infiltration of dirt into the pipe. 728.3.5 Inspection. The internal diameter of the barrel shall not be reduced by more than 7.5 percent of the pipe’s base inside diameter when measured no less than 30 days following completion of installation. After the roadway has been completed and before final acceptance of the project, the engineer will select at least 25 percent of the pipe for inspection for proper installation. A more extensive inspection will be conducted if pipe is found to be improperly installed. Any section of pipe found to be improperly installed shall be replaced or repaired by the contractor at the contractor’s expense to the satisfaction of the engineer. Repaired or replaced pipe will be retested as deemed necessary by the engineer. The contractor shall provide equipment and assistance as deemed necessary by the engineer to perform any testing. Pipe deflections will be determined by the engineer by having the contractor pushing or pulling a mandrel through the pipe, or verifying deflections by other methods approved by the engineer. Mandrels used for deflection testing may have either fixed or adjustable arms, but shall be approved by the engineer prior to use. The following will constitute improper installation: a) If alignment is in excess of 15 percent, will restrict flow or will cause excessive ponding within the pipe. b) Any section of pipe with deflections greater than 7.5 percent. c) If settlement is greater than one inch at five percent or more joints. d) The pipe shows evidence of being crushed or buckled at any location. e) The pipe shows evidence of joint separation. 728.4 Method of Measurement. Final measurement will not be made except for authorized changes during construction or where appreciable errors are found in the contract quantity. When two different diameters of pipe are shown on the plans for a given location for Group B or Group C pipe, the quantity of pipe installed will be based on the plan quantity for the larger diameter pipe and will not be considered an appreciable error in the contract quantity if the smaller allowed diameter pipe is used. Where required, measurement of corrugated PVC pipe, complete in place, will be made to the nearest foot along the geometrical center of the pipe. Measurement will include any other pipe used to protect the corrugated PVC pipe from exposure to sunlight. The revision or correction will be computed and added to or deducted from the contract quantity. 728.5 Basis of Payment. 728.5.1 The accepted quantities of pipe, complete in place, including all necessary tees, bends, wyes, cutting and joining new pipe to existing pipe, unless otherwise specified, will be paid for at the contract unit price for each of the pay items included in the contract. When two different diameters of pipe are shown on the plans for a given location for Group B or Group C pipe, the contract unit price for the larger diameter pipe will be used for payment purposes.
5/1/2010
728-4
Corrugated Polyvinyl Chloride (PVC) Culvert Pipe
728.5.2 Unless specified otherwise, no direct payment will be made for the following: a) Material or work required for placing couplings on exposed ends of the pipe. b) Any required backfilling, except as specified in Section 206.6.3. c) Construction of bedding or for bedding material. d) Trench excavation and backfilling, except when Class 3 Excavation is specified in the contract documents for a given pipe location. When specified, payment for Class 3 Excavation will be made in accordance with Section 206. e) Furnishing and installing plugs. f) Work or equipment to perform deflection testing.
5/1/2010
728-5
Corrugated Polyvinyl Chloride (PVC) Culvert Pipe
(This Page Intentionally Left Blank)
5/1/2010
728-6
Corrugated Polyvinyl Chloride (PVC) Culvert Pipe
Section 730
Thermoplastic Culvert Pipe
730.1 Description. This work shall consist of providing thermoplastic pipe of the diameter designated, placed and backfilled as specified in the contract documents or as directed by the Engineer. Pipe shall be in accordance with Section 724. 730.1.1 If the contract specifies thermoplastic pipe or if the contract specifies culvert pipe by group and the Contractor elects to furnish thermoplastic pipe, the allowable overfill height shall be in accordance with the plans, unless specified otherwise. Minimum cover will be measured as shown on the plans. 730.1.2 When furnishing thermoplastic pipe, the pipe shall meet the properties described in the appropriate section of this specification and be installed in accordance with the standard plans. When section properties or fill heights outside of the specification are required for use, a special design shall be prepared by the Contractor for approval by the Engineer. The special design shall include all relevant engineering data, stub compression values, and be stamped by a professional engineer registered in the State of Missouri. 730.2 Materials. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Metallic-Coated Steel End Sections (CMP) ............................... 1020 Corrugated Polyvinyl Chloride (PVC) Culvert Pipe .................... 1028 Precast Concrete Flared End Sections ..................................... 1032 Polypropylene (PP) Culvert Pipe ............................................... 1041 Corrugated Polyethylene (HDPE) Culvert Pipe ......................... 1047 730.3 Construction Requirements. 730.3.1 Handling. All pipe shall be handled to avoid damage. Damaged pipe will be rejected and shall be repaired or replaced at the Contractor's expense to the satisfaction of the Engineer. 730.3.2 Laying. 730.3.2.1 Flexible pipe shall be laid as shown on the plans, with bell ends upstream and with the spigot end entered the full length into the adjacent section of pipe. Any pipe that is not in true alignment or that shows any undue settlement after laying shall be taken up and re-laid at the Contractor's expense. Camber shall be built into the pipe structure to allow for settlement from fill loads if shown on the plans or directed by the Engineer. 730.3.2.2 Joints shall be soil tight and shall be installed such that the connection of pipe sections will form a continuous line free from appreciable irregularities in the flow line. Field joints may be corrugated bands, double bell couplings, bell and spigot pipe ends with a rubber O-ring gasket in accordance with ASTM F 477, or an alternative connection approved by the Engineer. All Joints shall comply with the soiltight joint performance criteria of AASHTO PP-63. 7/1/2016
730-1
Thermoplastic Culvert Pipe
730.3.3 Ultraviolet Protection. 703.3.3.1 Polyvinyl Chloride (PVC) Culvert Pipe. If PVC pipe is specified in the contract or elected for use by the Contractor, none of the PVC pipe shall be exposed to sunlight after installation. The minimum distance required to protect the exposed open end of a PVC pipe from sunlight will be one-half of the pipe diameter from the opening. The use of a different pipe material from the appropriate pipe group other than PVC is required in areas requiring ultraviolet protection. 730.3.4 Bedding and Backfill Material. Thermoplastic pipe bedding and backfill material shall consist of stone or crushed limestone that is sound, durable, and free from cracks and other structural defects that would cause it to deteriorate. It shall not contain any soapstone, shale, or other material easily disintegrated. Bedding and backfill materials shall be free of organic material or frozen clumps and shall conform to the "Standard Construction Specifications for Sewers and Drainage Facilities" of the Metropolitan St. Louis Sewer District (MSD), unless otherwise directed. 730.3.4.1 Bedding Material. A minimum of 4 inches (compacted) bedding material shall be provided prior to placement of the pipe unless otherwise specified. 730.3.4.1.1 MSD 1. Thermoplastic pipe diameters 18 inches or less. 730.3.4.1.2 MSD 3. Thermoplastic pipe with diameters greater than 18 inches. 730.3.4.2 Backfill Material. 730.3.4.2.1 MSD 1. Thermoplastic pipe diameters 18 inches or less. 730.3.4.2.2 MSD 3. Thermoplastic pipe with diameters greater than 18 inches. 730.3.5 Installation. 730.3.5.1 Trench Requirements. Thermoplastic pipe shall be installed in a trench, whether installed below grade or in an embankment. The construction sequence shall be as shown on the plans. When pipe is installed in an embankment, the embankment shall be placed and compacted to the required density to a minimum elevation of one-foot above the top of pipe before a sub-trench is excavated. The backfill shall be placed to the required thickness and grade taking care to avoid compaction of the backfill under the middle one third of the pipe. The backfill outside the middle one third of the pipe shall be compacted to the required density shown on the plans before placing the pipe. Compaction of backfill material under the haunches of the pipe shall be accomplished without disturbing the pipe alignment. 730.3.5.2 Bedding in Unsuitable Material. If rock is encountered, the bedding depth shall be increased to 6 inches below the bottom of the pipe. If soft, spongy, or unstable material is encountered, the material shall be removed and excavated to a minimum depth of 10 inches below the bottom of the pipe and replaced with MSD 4 granular material. Payment for removal of unsuitable material and for backfilling will be made in accordance with Section 206.6.3, unless the unsuitable material is a result of the Contractor's operations, in which case removing and backfilling shall be at the Contractor's expense. 7/1/2016
730-2
Thermoplastic Culvert Pipe
730.3.5.3 Backfill Construction. Backfilling shall be completed as soon as practical. Suitable backfill material free from large lumps, clods, or rocks shall be placed alongside the pipe and compacted as shown on the plans. The placement of the remainder of the backfill shall be conducted in a manner to prevent misalignment of the pipe and in accordance with Section 203. 730.3.5.3.1 Structural backfill shall be placed and compacted in layers not exceeding a loose lift thickness of 8 inches and brought up evenly and simultaneously on both sides of the pipe to an elevation not less than 1 foot above the top of the pipe. Structural backfill shall be worked into the haunch area and compacted by hand. All backfill shall be compacted to a minimum 90 percent standard density based upon standard proctor test. Special compaction means may be necessary in the haunch area. Ponding or jetting structural backfill to achieve compaction shall not be permitted without the permission of the Engineer. 730.3.5.4 Construction Loading. Before heavy construction equipment is operated over the pipe, the Contractor shall provide adequate depth and width of compacted backfill or other cover to protect the pipe from damage or displacement. Any damage or displacement shall be repaired or corrected at the Contractor's expense. 730.3.5.5 Pipe Plugs. The ends of all pipe stubs for future connections at inlet and manhole structures and of all pipe installed as a portion of future sewers shall be sealed with suitable plugs. Plugs shall be installed in a manner preventing infiltration of dirt into the pipe. No direct payment will be made for furnishing and installing plugs. 730.3.5.6 Skewed Ends. A pipe end may be cut to a maximum angle of 10 degrees to provide a skewed end. 730.3.6 Inspection. The internal diameter of the barrel shall not be reduced by more than 5 percent of the pipe’s nominal inside diameter when measured no less than 30 days following completion of installation. After the roadway has been completed and before final inspection of the project, the Engineer will inspect all pipe locations for proper installation. Any section of pipe found to be improperly installed, shall be replaced, or repaired by the Contractor at the Contractor’s expense and to the satisfaction of the Engineer. Repaired or replaced pipe will be re-inspected by the Engineer. The Contractor shall provide equipment and assistance as deemed necessary by the Engineer to perform any testing. Pipe deflections will be determined by the Engineer by having the Contractor either pushing or pulling a mandrel through the pipe, or verifying deflections by other methods approved by the Engineer. Mandrels used for deflection testing may have either fixed or adjustable arms, but shall be approved by the Engineer prior to use. The following will constitute improper installation: 1) If any horizontal or vertical alignment is in excess of 15 percent from plan alignment, will restrict flow or will cause excessive ponding within the pipe. 2) Any section of pipe with deflections greater than 5 percent, based upon the units of measurement used in fabricating the pipe. 3) If settlement is greater than one inch at 5 percent or more joints.
7/1/2016
730-3
Thermoplastic Culvert Pipe
4) The pipe shows evidence of being crushed or buckled at any location. 5) The pipe shows evidence of joint separation. 730.4 Method of Measurement. 730.4.1 Final measurement will not be made except for authorized changes during construction or where appreciable errors are found in the contract quantity. When two different diameters of pipe are shown on the plans for a given location for Group B or Group C pipe, the quantity of pipe installed will be based on the plan quantity for the larger diameter pipe and will not be considered an appreciable error in the contract quantity if the smaller allowed diameter pipe is used. Where required, measurement of flexible pipe, complete in place, will be made to the nearest foot along the geometrical center of the pipe. The revision or correction will be computed and added to or deducted from the contract quantity. 730.4.2 Excavation for placing pipe, pipe-arches, corrugated metal drop inlets and metal curtain walls will not be measured, except when excavation of the installation is shown on the plans. 730.5 Basis of Payment. 730.5.1 The accepted quantities of pipe, complete in place, including excavation, bedding, backfill, all necessary tees, bends, wyes, cutting and joining new pipe to existing pipe unless otherwise specified, will be paid for at the contract unit price for each of the pay items included in the contract. The accepted quantities of pipe by groups will be paid for in accordance with the item numbers, pay items and pay units listed. When two different diameters of pipe are shown on the plans for a given location for Group B or Group C pipe, the contract unit price for the larger diameter pipe will be used for payment purposes. 730.5.2 Unless specified otherwise, no direct payment will be made for the following: 1) Material or work required for placing couplings on exposed ends of pipe. 2) Any required backfilling, except as specified in Section 206.6.3. 3) Construction of bedding or bedding material. 4) Trench excavation and backfilling, except when Class 3 Excavation is shown on the plans for a given pipe location. When shown on the plans, payment for Class 3 Excavation will made in accordance with Section 206. 5) Furnishing and installing plugs. 6) Work or equipment to perform deflection testing.
7/1/2016
730-4
Thermoplastic Culvert Pipe
Section 731
Precast Reinforced Concrete Manholes and Drop Inlets
731.1 Description. This work shall consist of furnishing and installing precast concrete manholes and drop inlet sections on a poured-in-place concrete footing as shown on the plans. Precast reinforced concrete manholes and drop inlets may only be used on County-maintained right-of-way after approval is granted by the Director. 731.2 Materials. 731.2.1 All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Precast Reinforced Concrete Manhole and Drop Inlet Sections ................................... 1033 Concrete Curing Material............................................................................................... 1055 Plastic Joint Compound for Vitrified Clay and Concrete Pipe ........................................ 1057 Tubular Joint Seal.......................................................................................................... 1057 Mortar for Pipe Joints .................................................................................................... 1066 731.2.2 Concrete for footings shall be Class A (MSD). Air entrainment will not be required. Concrete shall be placed and float finished. After finishing, concrete shall be cured in the same manner as required for concrete pavement except that transparent membrane shall be used in lieu of pigmented membrane. Detailed shop drawings must be submitted and approved before this method may be used. 731.3 Construction Requirements. 731.3.1 Placement. Precast concrete manhole and drop inlet sections shall be carefully placed true to line and grade, and joints sealed in accordance with the applicable provisions of Section 726. 731.3.2 Footings. Footings shall be constructed to the size and shape shown on the plans. Forms will not be required. 731.4 Method of Measurement. 731.4.1 Measurement of precast concrete manholes and drop inlets, complete in place, will be made to the nearest foot as shown on the plans. The depth of the structure will be the vertical distance from the top of the uppermost precast section to the invert flowline. Final measurement will not be made except for authorized changes during construction, or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity.
5/1/2010
731-1
Precast Reinforced Concrete Manholes and Drop Inlets
731.4.2 Excavation will be measured and paid for in accordance with Section 206. Final measurement will not be made except for authorized changes during construction, or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. 731.5 Basis of Payment. 731.5.1 The accepted quantities of precast manholes and drop inlets, complete in place, including any necessary cutting or joining of new pipe or existing pipe to the structure, unless otherwise specified, will be paid for at the unit bid price for each of the pay items included in the contract. 731.5.2 No direct payment will be made for: a) Backfilling. b) Footing concrete. c) Steps. d) Weep holes, including excavation, permeable granular backfill, 4 inch drain tile with weep holes, or any other work incidental thereto.
5/1/2010
731-2
Precast Reinforced Concrete Manholes and Drop Inlets
Section 732
Flared End Sections
732.1 Description. This work shall consist of furnishing and installing precast concrete or metal flared end sections of the size and shape shown on the plans. 732.1.1 Precast concrete flared end sections shall be used with concrete or vitrified clay culvert pipe. 732.1.2 Metal flared end sections shall be used with metal culvert pipe. 732.1.3 End sections for HDPE and PVC pipe may be either precast concrete or metal flared end sections of the pipe group type specified for that application. 732.2 Materials. 732.2.1 All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Flared End Sections .......................................................................................... 1020 Precast Concrete Flared End Sections ............................................................. 1032 Plastic Joint Compound for Vitrified Clay and Concrete Pipe ............................ 1057 Tubular Joint Seal.............................................................................................. 1057 Mortar for Pipe Joints ........................................................................................ 1066 Safety Bars and Longitudinal Bars .......................................................... ASTM A 53 Bar Grate ............................................................................................... ASTM A 575 732.2.2 Headwalls and intake and outlet structures shall be constructed of Class B-1 airentrained concrete as required on the project plans meeting the requirements of Section 501. Materials proportioning, air-entraining, mixing, slump, and transporting of the portland cement concrete shall be in accordance with Section 501. Concrete shall be placed and cured in accordance with the applicable provisions of Section 703. When toe walls are precast, they may be constructed of any of the above specified concrete mixtures or they may be constructed of the same mixture used to fabricate the precast concrete flared end sections. Precast toe walls may be cured in accordance with Section 703 or in the same manner as the flared end sections. 732.3 Construction Requirements. 732.3.1 Flared end sections shall be joined to pipes or pipe-arches as shown on the plans. They shall be carefully placed to the line and grade of the structure on a uniformly firm soil foundation shaped to fit the lower part of the end section. Soft or unsuitable earth at the base of the structure shall be removed and replaced with crushed limestone in accordance with Section 726.3.11.6.
5/1/2010
732-1
Flared End Sections
732.3.1.1 Precast Concrete Flared End Sections. Reinforced concrete pipe flared end sections shall be precast and of the size shown on the project plans. They shall meet all applicable requirements of ASTM C 76. The joint material between the end section and the adjoining pipe shall be the same as that used for the pipe joints and shall be installed in the same manner. Toe walls shall be of the size and shape shown on the plans and may be precast or cast-in-place. Forming of cast-in-place toe walls will not be required. 732.3.1.1.1 Where shown on the project plans, outlets of storm water lines discharging into creeks and large unlined channels will be constructed as shown in the Standard Drawing using a single length of galvanized corrugated metal pipe. The concrete collar junction of the corrugated pipe and the storm sewer shall be of Class A (MSD) concrete as shown on the Standard Drawing C604.41. 732.3.1.2 Metal Flared End Sections. End sections shall be joined to the pipe or pipearch as shown on the plans. The toe plate, if specified, shall be set in a trench or driven to the proper elevation. Care shall be taken to avoid damage to the metal. 732.3.2 Safety Slope End Section. The safety slope end section shall consist of a metalflared end section, a safety bar system or a bar grate system, toe plate extension, if required in the contract, and any fasteners required for attachment to the culvert pipe. 732.3.2.1 Construction Requirements. Safety slope end sections shall be attached as shown on the plans and shall be placed to the line and grade of the structure on a uniformly firm soil foundation shaped to fit the lower part of the end section. 732.3.2.2 Toe Plate Extension. The toe plate extension, if required, shall be attached to the end section as shown on the plans. 732.3.2.3 Safety Bar System. Safety bars will be required on end sections of culvert pipes 24 inches in diameter or greater. The number, size and spacing of safety bars shall be as shown on the plans. 732.3.2.4 Bar Grate System. In lieu of the safety bar system, the bar grate system may be used. If used, the bar grate system shall be fabricated and installed as shown on the plans. 732.4 Method of Measurement. The in-place price for Flared End Sections shall include all costs for flared end section, concrete, toe walls, excavation, and bedding, and shall be paid per each at the contract unit bid price. 732.5 Basis of Payment. The unit prices bid for metal flared end sections will be considered to include the toeplate shown on the Standard Drawing included in the plans. Payment will be made for each completed headwall, or intake or outlet structure at the respective lump sum bid price for each completed structure. Each lump sum bid price shall include all costs of forms, concrete, reinforcing steel, preparing the end of pipes or conduits, general excavation for the structure, and all work as shown or specified for the completed structure.
5/1/2010
732-2
Flared End Sections
Section 733
Precast Concrete Box Culverts
733.1 Description. This work shall consist of furnishing and installing concrete box culverts. Where the construction of cast-in-place single or multi-cell reinforced concrete box culverts is specified, the contractor may be granted the option of constructing such culverts using precast reinforced concrete box sections and headwalls subject to the conditions specified in the contract. The Director will grant approval for the use of precast concrete box culvert sections on a case-bycase basis. 733.1.1 Precast concrete box culvert sections shall be constructed and installed in accordance with the "Standard Construction Specifications for Sewage and Drainage Facilities" published by the Metropolitan St. Louis Sewer District (MSD), when the drainage system is to be installed and maintained within the sewer district's jurisdiction. Precast box culverts under MSD's jurisdiction will be clearly marked as such on the project plans. For all other cases, additional criteria will govern the construction and installation of precast box culvert sections, as noted. 733.2 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Precast Box Culverts....................................................................................................... 1049 Plastic Joint Compound for Vitrified Clay and Concrete Pipe .................................. 1057 Tubular Joint Seal ................................................................................................................ 1057 Mortars and Grout ........................................................................................................... 1066 Waterproofing Materials ..................................................................................................... 1072 Filter Fabric ....................................................................................................................... 1074 733.3 Construction Requirements. 733.3.1 Subgrade Preparation and Bedding. Excavation and backfilling for precast box sections and end sections shall be in accordance with the requirements of Section 206, except that a layer of granular material at least 6 inches thick shall be placed immediately below the elevation of the bottom of box and end sections. Exception for 6” depth may be made if stable bedrock is encountered. In all cases, except placement on bedrock, a Class 1 geotextile fabric shall for permanent erosion control per AASHTO M288 be placed under the granular backfill base. The granular material shall meet the requirements of Section 1010 and shall be placed to extend at least 18 inches on each side of the structure. The bedding shall be compacted to provide uniform support for the bottom of the box and end sections. No direct payment will be made for furnishing, placing, or compacting the minimum 6 inches thick granular material and Geotextile Fabric unless noted in the plans. 733.3.2 Wall Backfill. Select Granular backfill shall be placed minimum 6” from the wall surface and encapsulated with Class 3 geotextile fabric for separation per AASHTO M288. No direct payment will be made for furnishing, placing, or compacting the minimum 6 inches thick granular material and Geotextile Fabric unless noted in the plans. 733.3.3 Placement. Individual box sections shall be set to lines and grade shown on the plans with the groove end upstream, and the spigot end extended full length into the adjacent 9/1/2023
733-1
Precast Concrete Box Culverts
downstream section of box. Joints. All joints between individual box sections shall be sealed with an approved joint system. Trowel grade compounds shall be applied to both mating surfaces. Rope or tape type plastic joint compound shall be applied in accordance with the manufacturer's recommendations. The joints shall be forced together with excess compound extruding both inside and outside the joint. Excess compound shall be removed from the interior surface. Joints between box sections shall be uniform for the full perimeter. External sealing bands shall be installed in accordance with the plans. 733.3.3.1 Lift Holes. Where lift holes as approved on the drawings have been used, the holes shall be filled with expansive mortar or tapered precast mortar plugs to provide a watertight section. The mortar shall be finished flush on the inside of the box and shall be properly cured on the outside. Tapered precast plugs shall be thoroughly sealed with plastic joint compound material. Lifting devices shall have sufficient bearing on the inside of the box section to avoid damage resulting from a concentration of stresses around the lift holes. 733.3.3.2 Multi-Cell Box Culvert. When multi-cell box culverts are used, a 2-inch minimum space shall be left between adjacent precast sections. Following the installation of the end sections, the 2-inch space between parallel sections shall be entirely filled with mortar or grout. After the mortar has attained sufficient strength, backfilling of the sections in accordance with Section 206 may begin. 733.3.3.3 Filter Fabric. Filter fabric shall encapsulate the outside surface of all connections when sand or granular fill is expected to come into contact with the structure. Fabric shall extend past each joint a minimum of 12 inches. 733.3.3.4 Waterproofing. In cases where the deck of the structure is intended to be overlaid with asphaltic concrete or driven on directly, a waterproofing system shall be applied in accordance with the plans. 733.4 Method of Measurement. 733.4.1 If the contractor, at his option, constructs alternate precast box culverts, measurement will be made as provided for cast-in-place structures for Class B concrete and reinforcing steel culverts. 733.4.2 If precast box culverts are specified in the contract, precast box culverts, complete in place including end sections, will be measured to the nearest foot along the geometrical center of culvert floors. Final measurement will not be made except for authorized changes during construction or where appreciable errors are found in the contract quantity. 733.5 Basis of Payment. 733.5.1 The accepted quantities for concrete box culverts, complete in place including end sections, will be paid for at the unit price for pay items included in the contract. No direct payment will be made for labor, material, and installation of select granular material and geotextiles noted in this section.
9/1/2023
733-2
Precast Concrete Box Culverts
Section 734
Installation of Pipe by Horizontal Boring Methods
734.1 Description. This work shall consist of furnishing and installing reinforced concrete pipe culvert (gasket-type) or steel pipe by horizontal boring methods underneath existing pavements at locations shown on the plans or as directed by the engineer. The minimum depth of installation shall be dependent upon the method used and the diameter of the pipe, and will require review and approval from the engineer before the start of this work. 734.2 Materials. The class of pipe specified in the contract item will be determined for vertical load only. Additional reinforcement or strength of pipe required to withstand jacking pressure shall be determined by the contractor and shall be furnished at the contractor's expense. If pipe ramming or auger boring is the horizontal boring method specified for use, steel casing pipe shall be used. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Reinforced Concrete Culvert, Storm Drain and Sewer Pipe.............................. 1026 Fiberglass-Reinforced Polymer Mortar Pipe...................................................... 1075 734.3 Construction Requirements. 734.3.1 The contractor shall protect the horizontal bore work area as shown on the plans. 734.3.2 Variations from theoretical alignment and grade for the completed pipe shall not exceed 6 inches for each 100 feet of pipe. Pavement or ground surface heave or settlement above the installation will not be permitted. To determine if heave or settlement is occurring, the contractor shall undertake surface monitoring measurements. 734.3.3 The excavated hole shall be no more than 1/10 foot greater than the outside diameter of the pipe. Sluicing and jetting with water as a primary means of soil cutting will not be permitted. When material tends to cave in from outside these limits, a metal shield shall be used ahead of the first section of pipe when pipe jacking, microtunneling or auger boring. 734.3.4 If the excavated hole is formed by Horizontal Directional Drilling (HDD), the boring equipment used to bore the hole shall be of proper type and in proper working order to ensure the work is performed to the satisfaction of the engineer. The size of installations by the directional drilling method shall be limited to those that can be accomplished by using a 24 inch maximum-sized reamer, unless approved by the engineer. 734.3.5 Holes bored by HDD shall be cleaned of excess material before pipe is jacked or pulled into place. Holes bored by the methods of auger boring, microtunneling or pipe jacking shall be cleaned as pipe is being jacked or pushed simultaneously into place. 734.3.6 Any areas resulting from caving or excavation outside the above specified limits shall be backfilled with a cellular concrete grout designed and produced in accordance with ASTM C 796, and with a method that will fill the voids. The excavated area around the pipe shall be sealed with grout for a minimum distance of 3 feet from the outside face of the fill or cut slope.
5/1/2010
734-1
Installation of Pipe by Horizontal Boring Methods
734.3.7 If steel casing pipe to be left in place is used with this installation method, the contractor may delete the gasket type joints for the limits of the jacked pipe. Steel casing pipe shall be welded by a certified welder or shall have a mechanical means of locking pipe joints into place. 734.3.8 Entry or exit pits or shafts shall be adequately sloped and shored prior to boring. 734.3.9 If the horizontal boring method chosen for use is pipe jacking or microtunneling, resilient joint cushioning material shall be used between individual pipe segments during the pipe jacking or microtunneling process. This material shall be ½ inch thick for pipe diameters up to 30 inches, and shall be ¾ inch thick for pipe diameters equal to or greater than 30 inches. 734.3.10 If the horizontal boring method chosen for use is auger boring or pipe ramming, an adequate steel leading edge band shall be used to protect the leading edge of the pipe from obstacles in the boring path. 734.4 Method of Measurement. Final measurement will not be made except for authorized changes during construction or where appreciable errors are found in the contract quantity. Where required, measurement of horizontal bore installed pipe, complete in place, will be made to the nearest foot along the geometrical center of the pipe. The revision or correction will be computed and added to or deducted from the contract quantity. The length of structure may be increased by no more than 3 feet as necessary to avoid cutting the pipe, but such increased length will not be included in the contract quantity for payment. 734.5 Basis of Payment. 734.5.1 All cost for work area protection will be paid for at the contract unit price for each of the pay items included in the contract. 734.5.2 The accepted quantities of horizontal bore installed pipe, complete in place, will be paid for at the contract unit price for each of the items included in the contract. Payment will be considered full compensation for excavation and backfilling of the jacking pits, disposal of excess excavation from boring operations, grout for filling voids, disposal of excess drilling fluids, video inspection or camera recording equipment, and any other incidental items or equipment necessary to complete the described work.
5/1/2010
734-2
Installation of Pipe by Horizontal Boring Methods
Section 736 Bridge Deck Sealer 736.1 Description. This work shall consist of furnishing and applying a sealing compound to the surface and exposed areas of bridge decks. The sealing compound shall be capable of penetrating the pore structure of the concrete to provide an effective subsurface barrier to inhibit moisture migration and corrosive chemical penetration. The compound shall not contain plasticizers, flexibilizers, oils, or diluents that remain unreactive in the resin or curing agent. 736.2 Materials. All materials shall conform to Division 1000, Materials Details, and specifically as follows: Item
Section
Penetrating Protective Sealer Material .............................................................. 1053 736.3 Construction Requirements. 736.3.1 A light brush sandblast shall be required on new concrete prior to application of sealer. The ambient temperature must be at least 40°F and rising on the day the sealer is applied. The deck concrete must be a minimum of twenty-eight (28) days old prior to application of the sealer. Traffic must not be allowed on the deck for at least twenty-four (24) hours after completing the application. 736.3.2 Sealing compound shall be applied to the entire deck surface including the top and front face of the barriers at the application rate recommended by the manufacturer. Sidewalks and the back face of the barriers shall not be sealed. 736.4 Method of Measurement. Final measurement of sealing will not be made except for authorized changes during construction or where appreciable errors are found in the contract quantity. The revision or correction will be computed and added to or deducted from the contract quantity. The area will be computed to the nearest square foot for the actual surface area over which sealing extends, including the portions of the faces of the barriers. 736.5 Basis of Payment. The accepted quantity of Bridge Deck Sealer will be paid for at the contract unit bid price.
9/1/2012
736-1
Bridge Deck Sealer
(This Page Intentionally Left Blank)
9/1/2012
736-2
Bridge Deck Sealer
Division 800
ROADSIDE DEVELOPMENT
2/1/2016
800-1
Roadside Development
(This Page Intentionally Left Blank)
2/1/2016
800-2
Roadside Development
Standard Specifications for Road and Bridge Construction Division 800 - Roadside Development Section
Description
Revision Date
800..... General Notes (Page 800-5)................................................................................ 6/6/2008 801..... Lime and Fertilizing ............................................................................................. 6/6/2008 802..... Mulching .............................................................................................................. 6/6/2008 803..... Sodding ............................................................................................................... 6/6/2008 804..... Topsoil................................................................................................................. 8/1/2012 805..... Seeding ............................................................................................................... 2/1/2016 806..... Pollution, Sediment and Erosion Control ............................................................. 2/1/2016 806.10 ...... Temporary Berms ............................................................................. 806-3 806.20 ...... Temporary Slope Drains ................................................................... 806-4 806.30 ...... Temporary Ditch and Inlet Checks .................................................... 806-4 806.40 ...... Sediment Basins ............................................................................... 806-6 806.50 ...... Temporary Seeding and Mulching .................................................... 806-7 806.70 ...... Silt Fence .......................................................................................... 806-7 806.80 ...... Temporary Pipe ................................................................................ 806-9 806.90 ...... Temporary Erosion Control Blankets................................................. 806-9 806.100 .... Temporary Stream Crossing ........................................................... 806-10 807..... Blank ................................................................................................................................. 808..... Planting Trees, Shrubs and Other Plants............................................................. 2/1/2016
2/1/2016
800-3
Division 800 - Index
(This Page Intentionally Left Blank)
2/1/2016
800-4
Division 800 - Index
Section 800
General Notes
800.1 No work shall proceed within streams channels or other bodies of water without required permits from the Corps of Engineers, Missouri Department of Natural Resources, or other agencies with jurisdiction. It shall be the contractor's responsibility to ensure that all permits are obtained prior to the start of any work. 800.2 All work in Division 800 shall conform to and be in compliance with the current "St. Louis County Sediment and Erosion Control Manual - Best Management Practice's (B.M.P.)", the St. Louis County Land Disturbance Code, and St. Louis County Land Disturbance Permit Number MO-R100008. In case of conflict, the more restrictive specification shall apply.
6/6/2008
800-5
General Notes
(This Page Intentionally Left Blank)
6/6/2008
800-6
General Notes
Section 801
Lime and Fertilizing
801.1 Description. This work shall consist of the application of agricultural lime and commercial fertilizer, and soil preparation for seeding and sodding on areas indicated on the plans, or designated by the Engineer. 801.2 Materials. 801.2.1 Material used for soil neutralization, unless otherwise specified, shall be agricultural lime with not less than 90 percent passing the No. 8 sieve and containing not less than 65 percent calcium carbonate equivalent. 801.2.2 Agricultural lime shall be furnished from a source that has been tested and certified in accordance with the Missouri Agricultural Liming Materials Act. The quantity of material required to provide the specified pounds of effective neutralizing material (E.N.M.) per acre, shall be as directed in the St. Louis County Sediment and Erosion Control Manual. If agricultural lime is furnished as a commercially bagged product, pelletized or otherwise, with a guaranteed product analysis shown on the bag listing the elemental properties and gradation, the E.N.M. shall be provided to the engineer. Material may be accepted on the basis of bag label analysis. 801.2.3 Fertilizer shall be a standard commercial product which, when applied at the proper rate, will supply the required quantity of total nitrogen (N), available phosphoric acid (P205) and soluble potash (K20). See the St. Louis County Sediment and Erosion Control Manual for proper application rate. Material may be accepted on the basis of bag label analysis or supplier's certification and shall comply with all applicable Missouri Fertilizer laws. 801.3 Equipment. Lime and commercial fertilizer shall be applied by mechanical equipment designed for this purpose. 801.4 Construction Requirements. 801.4.1 The area to be limed and fertilized will be the area designated within the limits of construction; shall have a uniform surface free from rills, washes, and depressions; and shall conform to the finished grade and cross section as shown on the plans. The soil, while in a tillable condition, shall be thoroughly broken up, worked, tilled, and loosened to a minimum depth of 2 inches. The seedbed or sodbed shall be prepared by loosening the existing soil on the slope, rather than by the addition of loose soil. 801.4.2 Lime and fertilizer shall be applied evenly at the rates designated in the contract, and only when the soil is in a tillable condition. After application, the lime and fertilizer shall be mixed into the soil by disking, harrowing, or raking to a minimum depth of 2 inches unless applied hydraulically on slopes steeper than 2:1 in accordance with Section 805.3.3.1. Lime and fertilizer shall be applied separately, but may be incorporated into the soil in one operation. Lime and fertilizer shall be applied not more than 48 hours before the seed is sown unless authorized by the Engineer.
6/6/2008
801-1
Lime and Fertilizing
801.5 Method of Measurement. Measurement of the area which has been limed and fertilized will be made to the nearest 1/10 acre. 801.6 Basis of Payment. The accepted quantity of liming and fertilizing will be paid for at the contract unit bid price. No direct payment will be made for liming and fertilizing areas for which seeding or sodding items are included in the contract.
6/6/2008
801-2
Lime and Fertilizing
Section 802
Mulching
802.1 Description. This work shall consist of the application of a mulch covering of the type specified in the contract. 802.2 Materials. 802.2.1 All materials used for mulching shall conform to the following: 802.2.1.1 Vegetative Mulch. The vegetative mulch shall be the prairie hay or straw from oats, rye, wheat, or barley. Prairie hay shall consist of any combination of any of the following plants: Big Bluestem, Little Bluestem, Indiangrass, Sideoats Grama and native wildflowers. The mulch shall be free of prohibited weed seed as stated in the Missouri Seed Law, and shall be relatively free of all other noxious and undesirable seeds. The mulch shall be clean and bright, relatively free of foreign material, and be dry enough to spread properly. 802.2.2 Mulch Overspray. Mulch overspray shall be either virgin wood cellulose fibers or recycled paper mulch. The mulch shall be produced by either the ground or cooked fiber process, shall not be water-soluble and shall have the following properties: Property
Requirement
Moisture Content, percent by weight (mass), max.
15
Organic Matter-Wood Fiber, percent by weight (mass), min.
80
pH
4.3-8.5
802.2.3 Certification. The contractor shall furnish a certification for mulch and a manufacturer's certification that the mulch overspray material is in accordance with these specifications. 802.3 Construction Requirements. 802.3.1 Application. Vegetative mulch shall be applied as directed in the St. Louis County Sediment and Erosion Control Manual. All mulch shall be distributed evenly within 24 hours following the seeding operation. Following the mulching operation, precautions shall be taken to prohibit foot or vehicular traffic over the mulched area. Any mulch that is displaced shall be replaced at once, but only after the work preceding the mulching which was damaged as a result of the displacement has been repaired to the satisfaction of the Engineer. The contractor may use erosion control blankets in lieu of mulch. 802.3.2 Stabilization. Vegetative mulch shall be secured from movement by either mulch overspray or embedment as indicated in the contract documents, or other methods as approved by the Engineer.
6/6/2008
802-1
Mulching
802.3.2.1 Mulch Overspray. Mulch overspray shall be applied over the vegetative mulch as a separate operation. Mulch overspray shall be applied in accordance with the manufacturer’s recommendations at a minimum rate of 750 pounds per acre. 802.3.2.2 Vegetative Mulch Embedment. Mulch shall be embedded in the soil a sufficient depth to prevent the loss of mulch by wind or water erosion and approximately parallel to the roadbed grade. 802.4 Method of Measurement. This item will not be measured for payment. 802.5 Basis of Payment. No direct payment will be made for providing and securing mulch. The accepted quantities of mulch will be considered completely covered by the contract unit price for seeding. 802.5.1 No direct payment will be made for maintaining mulch prior to acceptance for maintenance. On previously accepted mulched areas, the Engineer may authorize areas to be repaired in accordance with Section 104.3. 802.5.2 No additional payment will be made for erosion control blankets used in lieu of mulch at the contractor’s option.
6/6/2008
802-2
Mulching
Section 803
Sodding
803.1 Description. This work shall consist of furnishing and placing sod on shown on the plans or as designated by the Engineer. 803.2 Materials. Unless otherwise specified in the contract, the sod shall be Kentucky Bluegrass sods grown from a blend of at least three separate varieties, densely rooted and thrifty. The sod shall contain a growth of not more than 25 percent of other grasses and clovers, and be free of all weeds. The sod shall be cut in strips of uniform thickness with each strip containing at least ⅓ square yard and not more than one square yard. Sod shall be cut into strips, not less than 12 inches in width nor more than 9 feet in length. At the time of sod lifting, the top growth shall not exceed 3 inches in length. The thickness of the sod shall be determined by stacking ten pieces alternately with the soil of the first piece on the bottom. The height of the stack, without compression, shall exceed 11 inches and the thickness of the soil portion of each piece shall be not less than ¾ inch. All sod shall conform to the laws of Missouri and shall be obtained from sources meeting the approval of the Department of Agriculture, Plant Industries Division. 803.3 Construction Requirements. 803.3.1 Sod shall not be placed during a drought nor during the period from June 1 to September 1 unless authorized by the engineer, and shall not be placed on frozen ground. No dry or frozen sod shall be used. 803.3.2 The sodbed shall be prepared, limed, and fertilized in accordance with Section 801 and the St. Louis County Sediment and Control Manual. The bed shall be in a firm but uncompacted condition with a relatively fine texture at the time of sodding. The sod bed and sod shall be moist. All sod shall be placed to produce tight joints. Sod strips shall be laid along contour lines, by hand, commencing at the base of the area to be sodded and working upward. The transverse joints of sod strips shall be broken, and the sod carefully laid to produce tight joints. The sod shall be firmed, watered, and re-firmed immediately after it is placed. The firming shall be accomplished by use of a lawn roller or tamper. Sod placed on slopes 3:1 or steeper and in the flow line of ditches, shall be secured with metal clips or wooden pegs approximately ½ inch square by 12 inches in length, driven into the ground, leaving about ½ inch of the peg above sod, and spaced not more than 2 feet apart. Pegging of sod shall be done immediately after the sod has been firmed. When sodding is completed, the sodded areas shall be cleared of loose sod, excess soil, or other foreign material, and a thin application of topsoil shall be scattered over the sod as a top dressing, and the areas thoroughly moistened. 803.3.3 The contractor shall keep all sodded areas thoroughly moist for 21 days after laying. The sod shall be living at the time of acceptance. 803.4 Acceptance. No sodded areas will be accepted until the sod is fully rooted into the sod bed and thriving. Sod will not be accepted in the dormant state. 803.5 Method of Measurement. Measurement will be made to the nearest square yard of approved sodded surface area.
6/6/2008
803-1
Sodding
803.6 Basis of Payment. The accepted quantities of sodding will be paid for at the contract unit price. No direct payment will be made for sod bed preparation, liming or fertilizing sodded areas, or for the replacement of sodded areas not accepted by the Engineer.
6/6/2008
803-2
Sodding
Section 804
Topsoil
804.1 Description. This work shall consist of approved selected topsoil furnished and placed at the locations shown on the plans or as directed by the Engineer. 804.2 Materials. Topsoil shall be obtained from sources meeting ASTM D 5268 and approved by the Engineer. Topsoil shall be a fertile, friable, and loamy soil of uniform quality, without admixture of subsoil materials, and shall be free from materials such as hard clods, stiff clay, hardpan, partially disintegrated stone, pebbles larger than one inch in diameter, and any other similar impurities. Topsoil shall be relatively free from grass, roots, weeds, and other objectionable plant material or vegetable debris undesirable or harmful to plant life or which will prevent the formation of a suitable seedbed. A report shall be submitted by the supplier to the Engineer for review and approval that contains sample identification information, technician name and date tested and record as a minimum the following test information: 1) pH; and 2) Report the percentages by mass of the following: a) Deleterious materials; b) Organic material; c) Sand content; and d) Silt and Clay content. 804.3 Construction Requirements. 804.3.1 The Engineer shall be notified sufficiently in advance of the opening of any material source to permit the Engineer to prepare for necessary checking and measurement. Topsoil shall be secured from areas from which the topsoil has not been previously removed, either by erosion or mechanical methods. The soil shall not be removed in excess of the depth approved by the Engineer. Unless otherwise shown on the plans, the source of material and if needed, all required permits, shall be furnished by the contractor. During the period of removal of the topsoil material, the site shall be kept drained, and when all material has been removed, the site shall be left in a neat and presentable condition to the satisfaction of the Engineer. 804.3.2 The surface on which the topsoil is to be placed shall be free of all loose rock and foreign material greater in any dimension than one-half the depth of the topsoil to be added. The surface shall be raked or otherwise loosened just prior to being covered with topsoil. Topsoil shall be placed and spread over the designated areas to a depth sufficiently greater than shown on the plans so that after settling, the completed work will conform with the thickness shown on the plans. After spreading, all large clods and foreign material shall be removed by the contractor. 804.4 Method of Measurement. Topsoil will be measured to the nearest cubic yard of material in vehicles at the point of delivery. 804.5 Basis of Payment. The accepted quantity of topsoil will be paid for at the contract unit bid price, including hauling from any distance.
8/1/2012
804-1
Topsoil
(This Page Intentionally Left Blank)
8/1/2012
804-2
Topsoil
Section 805
Seeding
805.1 Description. This work shall consist of preparing, liming, and fertilizing a seedbed, and the furnishing and sowing of seeds as specified in the contract. All disturbed areas shall be seeded except: (1) sodded areas, (2) surfaced areas, (3) solid rock, and (4) slopes consisting primarily of broken rock. Disturbed areas outside of authorized construction limits shall be seeded at the contractor's expense. 805.2 Materials. 805.2.1 The seed shall be grown and processed in the United States or Canada and shall comply with the requirements of the Missouri Seed Law. Certain lots of seed may be desirable for the advancement of a local ecotype when specified, and will be the only seed permitted. The following percentages for purity and germination or pure live seed will be the minimum requirements in the acceptance of seed, unless otherwise permitted by the Engineer.
Bermuda Grass Smooth Brome Grass Kentucky Bluegrass Orchard Grass Annual Rye Grass Sudan Grass Reed Canary Grass Timothy Redtop Oat Grain Rye Grain Tall Fescue Red Fescue Korean Lespedeza Sericea Lespedeza Alsike Clover Red Clover Sweet Clover White Clover Hairy Vetch Crown Vetch Birdsfoot Trefoil Big Bluestream (Debearded) Blue Grama Buffalograss Indiangrass (Debearded) Little Bluestem (Debearded) Sand Lovegrass Sideoats Grama Switchgrass Weeping Lovegrass
Purity 95 85 85 85 98 98 97 98 92 98 98 97 97 98 98 98 98 98 98 97 98 98
Germination Including Hard Seed 80 80 80 80 85 85 75 85 85 85 80 85 85 85 85 85 85 85 85 80 70 80
(a)
2/1/2016
Pure Live Seed
42 64 72 54 40 69 67 62 83
(a)
Germination Excluding Hard Seed
55 55 55 55 55 55 50 40 50
Maximum Percent Weed Seed 1.00 2.00 1.00 2.00 1.00 1.00 1.00 1.00 2.00 1.00 1.00 2.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.30 0.10 0.30 0.30 1.00 0.30 0.20 0.20 0.20
Does not apply if unhulled or unscarified seed is specified.
805-1
Seeding
805.2.2 If the specified quantity is in pounds of seed, no reduction will be permitted in the specified quantity of seed if the purity or germination, or both, are higher than the minimum required by the specification. If the specified quantity is in pounds of pure live seed, the pure live seed quantity shall be determined from the actual percentage shown by the supplier for native grasses or by multiplying the actual percentages of purity times the actual percentage of germination including hard seed for other seed. 805.2.3 All leguminous seeds shall be inoculated or treated with the proper quantity of cultures approved for the particular legume to be sown. Leguminous seeds include Alsike Clover, Korean Lespedeza, Red Clover, Sericea Lespedeza, Sweet Clover, and White Clover. 805.2.3.1 The inoculant for treating leguminous seeds shall be a pure culture of nitrogen fixing bacteria. The containers of the inoculant shall be plainly marked with the expiration date for use and the manufacturer's directions for inoculating seed. 805.2.3.2 The process of inoculation shall be in accordance with the manufacturer's directions for the particular species of legume. The time lapse for sowing the seed following inoculation shall not exceed 24 hours. When hydraulic slurry seeding is used, an amount of inoculant equal to five times the normal rate required to inoculate only the legume seed shall be used. The inoculant shall be placed directly into the slurry and thoroughly mixed immediately before seeding. When other than the hydraulic slurry method is used, the legume seed may be inoculated at the normal rate if it is to be sown alone or if the legume seed is inoculated prior to mixing with other seed. A seed mixture which contains a legume that was not inoculated prior to mixing and is not to be seeded by the slurry method, shall be inoculated with sufficient inoculant to cover all seed. 805.2.3.3 Prohibited Weed Seeds. No tolerance will be applied to grass mixtures for prohibited weed seeds, namely: Field Bindweed (Convelvulus arvenis), Johnson Grass (Sorghum halerenge), and Canada Thistle (cirsium arvense). 805.3 Construction Requirements. 805.3.1 The seedbed shall be prepared, limed, and fertilized in accordance with Section 801. Seeding shall be done before the seedbed becomes eroded. Seed shall be uniformly applied at no less than the rates specified. Unless otherwise shown in the plans, the rate of application will be 210 pounds per acre consisting of 100 pounds of tall fescue, 100 pounds of perennial rye grass, and 10 pounds of Kentucky Bluegrass. 805.3.2 Disturbed areas outside of authorized construction limits shall be seeded at the contractor's expense. 805.3.3 During the months of December through May, August, and September, all lime, fertilizer, seed and mulch shall be applied to the finished slopes. During the months of June, July, October, and November, lime, fertilizer, seed, and mulch shall be applied at the following rates: Lime .......................................... 100 percent of the specified quantity Fertilizer ...................................... 75 percent of the specified quantity Seed ........................................... 50 percent of the specified quantity Mulch ........................................ 100 percent of the specified quantity
2/1/2016
805-2
Seeding
Alternate methods of seeding will be considered when submitted for approval but will not relieve the contractor of compliance with Section 805.7.1. Seeding shall be done before the proposed seedbed becomes eroded, crusted over, or dried out and shall not be done when the ground is in a frozen condition or covered with snow. When the partial application has been made during June, July, October, or November, the remainder of the fertilizer plus 75 percent of the specified quantity of seed shall be applied by overseeding during August, September, December, January, or February. Seeds shall be uniformly applied at the rates prescribed. Provisions shall be made by markers or other means to insure that the successive seeded strips will overlap or be separated by a space no greater than the space left between the rows planted by the equipment being used. If inspection during the seeding operations indicates that strips wider than the space between rows planted have been left unplanted, additional seed shall be planted on these areas. Hand seeding will be permitted in isolated areas with prior approval of the engineer. 805.3.3.1 Hydraulic Seeding and Fertilizing. In lieu of mechanical application of seed and fertilizer, hydraulic application may be used. Seed and fertilizer may be applied hydraulically provided the seed and fertilizer are applied separately. The seed and fertilizer shall be incorporated into the soil as specified in Sections 801.4.2 and 805.3.2.2, in separate operations except that raking will not be required when seeding a previously seeded and mulched area. On slopes steeper than 2:1, or when seeding is applied to a previously seeded and mulched area, seed and fertilizer may be applied hydraulically in a single operation, and incorporation into the soil will not be required. Seed and fertilizer, separately or in combination, shall be mixed with water and constantly agitated so that a uniform mixture can be applied hydraulically to the designated areas. The ratio of seed and fertilizer to water shall be calculated by determining the surface area covered by a given quantity of water. Seed shall not be added to the water more than 4 hours before application. 805.3.3.2 Dry Seeding. Dry seeding shall be done mechanically with equipment designed for even distribution of dry seed. The equipment may either be hand operated, such as knapsack seeder, or be tractor drawn, such as seed drill, except that tractor drawn equipment will not be permitted on a previously seeded and mulched area. After completing the seeding operation, if in the judgment of the engineer the seedbed is either too loose or contains clods which would reduce the germination of the seed, the contractor shall firm the area by rolling. When rolling is required, a lawn type roller shall be used and care shall be taken to avoid over compacting the soil. 805.4 Sediment and Erosion Control Requirements. If seeding is being applied to satisfy a sediment and erosion control permit requirement, follow the seeding specifications in the St. Louis County Sediment and Erosion Control Manual. The application shall be determined by the Engineer. 805.5 Acceptance. The performance standard shall be met before acceptance of the work. At least two random counts per acre in representative areas of the project will be conducted. All erodible seeded areas shall provide a minimum of 20 living plants, uniformly spaced, of the specified type per square foot. For areas with a large percentage of rock, the number of living plants shall be proportional to the percentage of erodible surface, as determined by the Engineer. Inspection for acceptance will be made within 60 days after seeding, excluding seeding dates that fall between September 30 and March 1. Seeding dates that fall between September 30 and March 1 will be counted no earlier than May 1. 2/1/2016
805-3
Seeding
805.5.1 Final payment for seeding will be contingent upon project acceptance. Seed must have germinated and produced a green and growing ground cover, regardless of method used to apply seed, before acceptance will be made. 805.6 Corrective Action. Inadequate stands shall be reworked and reseeded within the time period agreed upon at the contractor’s expense. On previously accepted seeded areas, the Engineer may authorize eroded areas to be repaired in accordance with Section 104.3. 805.7 Method of Measurement. Measurement will be made of the area seeded to the nearest 1/10 acre. 805.8 Basis of Payment. The accepted quantity of seeding will be paid for at the contract unit price. No direct payment will be made for liming, fertilizing or seedbed preparation. No direct payment will be made for additional work and seed required when seeding during the months of June, July, October, and November.
2/1/2016
805-4
Seeding
Section 806
Pollution, Sediment and Erosion Control
806.1 Description. This work shall consist of furnishing, installing, maintaining and removing temporary pollution, erosion and sediment control measures; furnishing and placing permanent erosion control features; or a combination of both as shown on the plans, on the SWPPP, or as directed by the Engineer. For additional information see the St. Louis County "Sediment and Erosion Control Manual", located on the "Department of Transportation - Publications & Manuals" Internet website at: www.stlouisco.com/YourGovernment/CountyDepartments/ HighwaysandTraffic/HighwayPublicationsManuals. 806.2 Schedule of Work. Prior to the preconstruction conference and the start of construction, the contractor shall submit schedules for the implementation of temporary pollution control and temporary and permanent erosion control work, as applicable, for construction operations. The contractor's schedule shall address specifically the pollution and erosion control measures planned at all streams or other bodies of water. No work shall start until the pollution and erosion control schedules and methods of operations have been approved by the engineer. Any delay of the work resulting from failure to submit acceptable pollution and erosion control schedules and methods of operations will be considered non-excusable. 806.3 Material. All material shall be in accordance with Division 1000, Material Details, and specifically as follows: Item
Section
Lime and Fertilizing
801
Mulching
802
Seeding
805
Geotextile Fabric
1011
806.4 Construction Requirements. The engineer will limit the surface area of erodible earth material exposed by clearing and grubbing or by excavation, borrow and fill operations in accordance with the following. The engineer may direct the contractor to provide immediate permanent or temporary pollution control measures to prevent contamination of adjacent streams or other bodies of water. Such work may involve the construction of temporary berms, dikes, dams, sediment basins and slope drains, and use of temporary mulches, seeding or other control devices or methods as necessary to control erosion and pollution. 806.4.1 If the Engineer determines ditch checks, as shown on the plans, are not suitable due to site conditions, a combination of ditch checks and erosion control blankets or rock blankets shall be designed to effectively reduce flow velocities. 806.4.2 The contractor shall exercise effective management practices throughout the life of the project to control pollution. Pollutants such as chemicals, fuels, lubricants, bitumen, raw sewage or other harmful material shall not be discharged on or from the project. Temporary pollution control measures, such as storage and handling of petroleum products and other pollutants, shall be coordinated with temporary and permanent erosion control features specified in the contract to ensure economical, effective and continuous erosion and
2/1/2016
806-1
Pollution, Sediment and Erosion Control
pollution control. These requirements will also apply to work within easements designated by the Director. 806.4.3 The contractor shall incorporate all permanent erosion and pollution control features into the project at the earliest practical time. Temporary measures shall be used to correct conditions that develop during construction which were not foreseen during the design stage, that are needed prior to installation of permanent pollution control features, or that are needed temporarily to control erosion that develops during normal construction practices, but are not associated with permanent control features on the project. 806.4.4 Clearing and grubbing operations shall be scheduled and performed such that grading operations and erosion control features will follow immediately thereafter. The surface area of erodible earth material exposed at one time by clearing and grubbing, excavating fill or borrow shall not exceed 435,000 square feet within any individual drainage area without installation of erosion controls for that drainage area. The total erodible surface area exposed at one time for an entire project shall not exceed 750,000 square feet without specific, written approval from the Engineer. 806.4.5 The Engineer will limit the additional amount of erodible surface areas exposed by clearing and grubbing, excavation, borrow and fill operations with the amount of fill area in which the finished grading, mulching, seeding and other such permanent erosion control measures are completed and properly maintained. If seasonal limitations make such operations impractical, temporary erosion control measures shall be taken immediately. 806.4.6 Unless otherwise provided or approved in writing by the Engineer, construction operations in streams or other bodies of water shall be restricted to those areas that must be entered for the construction of temporary or permanent structures. Streams or other bodies of water shall be promptly cleared of all false work, piling, debris or other obstructions placed therein or caused by construction operations. 806.4.7 Fording of streams or other bodies of water with construction equipment will not be permitted, except as allowed by the engineer. Temporary bridges or other structures shall be used wherever an appreciable number of stream or other bodies of water crossings are necessary. Unless otherwise approved in writing by the Engineer, mechanized equipment shall not be operated in streams or other bodies of water except as may be required to construct channel changes and temporary or permanent structures. If a Corps of Engineer Section 404 or Department of Natural Resources Section 401 permit is applicable for a project, the permit requirements and conditions will prevail. 806.4.8 The location of all material pits, other than commercially operated sources, and all excess material sites will be subject to approval from the engineer. Erosion from construction operations and pollution control measures shall not cause water pollution. 806.4.9 In the event of conflict between these requirements and the pollution control laws, rules or regulations of other federal, state or local agencies, the more restrictive laws, rules or regulations will apply. 806.4.10 Unless otherwise specified, or directed by the Engineer, all temporary erosion control measures shall be removed by the contractor after permanent erosion control measures are established.
2/1/2016
806-2
Pollution, Sediment and Erosion Control
Section 806.10 Temporary Berms 806.10.1 Description. This work shall consist of constructing and maintaining temporary berms of rock or compacted soil at the top of fill slopes or transverse to the centerline of fills. 806.10.2 Material. Temporary berms shall consist of graded material from within the project limits or any other suitable material approved by the Engineer. 806.10.3 Construction Requirements. Temporary berms shall be constructed to the approximate dimensions shown on the plans. 806.10.3.1 Type A Berms. Type A berms shall be machine compacted with a minimum of one pass over the entire width of the berm. 806.10.3.2 Type B Berms. Type B berms shall be machine compacted with a minimum of three passes over the entire width of the berm. Material removed from Type B berms shall be incorporated in the embankment when possible. The contractor shall remove and dispose of any excess or unsuitable material to a location approved by the Engineer. 806.10.3.3 Type A and Type B Berms. Temporary berms shall drain to a compacted outlet at a slope drain. On transverse berms, the top width of the berms may be wider and the side slopes flatter to allow equipment to pass over these berms with minimal disruption. 806.10.3.4 Type C Berms. Type C berms shall be constructed of rock base material in accordance with Section 303.2 or other material as approved by the Engineer. A vegetative mulch or an equivalent erosion control blanket shall be placed on the upslope side of the Type C berm. The vegetative mulch shall be placed in such a manner that the final compacted thickness is 2 inches. The material for the vegetative mulch shall be in accordance with Section 802. The straw layer or equivalent erosion control blanket shall be removed and replaced as directed by the Engineer. 806.10.4 Method of Measurement. 806.10.4.1 Quantities for Type A berms will be included in Class A or Unclassified Excavation quantities listed in the contract. Final measurement will not be made for Type A berms, except in accordance with Section 203.8.1.1. 806.10.4.2 Measurement of Type B and C berms will be made to the nearest linear foot. 806.10.5 Basis of Payment. 806.10.5.1 Payment for Type A berms will be made at the contract unit price for Class A or Unclassified Excavation and will be considered full compensation for all labor, equipment and material to construct, maintain and remove Type A berms.
2/1/2016
806-3
Pollution, Sediment and Erosion Control
806.10.5.2 The accepted quantities of Type B and C berms will be paid for at the contract unit price and will be considered full compensation for berm installation, maintenance, removal and any other work noted on the plans. No additional payment will be made for any costs associated with the straw layer or equivalent erosion control blanket on the Type C berm. 806.10.5.3 Any handwork at slope drain inlets will be considered part of the contract unit price for slope drains.
2/1/2016
806-4
Pollution, Sediment and Erosion Control
Section 806.20 Temporary Slope Drains 806.20.1 Description. This work shall consist of constructing and maintaining temporary slope drains to carry water down slopes and to reduce erosion. The method selected shall be approved by the Engineer prior to construction. See the St. Louis County Sediment and Erosion Control Manual for additional information. 806.20.2 Construction Requirements. The contractor shall provide temporary, impermeable slope drains to carry water or water with suspended solids down fill slopes until permanent erosion control measures are established. The contractor shall provide temporary slope drains on fill slopes at approximately 500-foot intervals or as directed by the engineer. All temporary slope drains shall be adequately anchored to the slope to prevent disruption of flow. Inlet ends shall be properly constructed to channel water into the temporary slope drain. Outlet ends shall have some means of dissipating the energy of the water to reduce erosion downstream. The contractor shall restore the site of the slope drains to the satisfaction of the Engineer. 806.20.3 Method of Measurement. Measurement of temporary slope drains will be made to the nearest linear foot. 806.20.4 Basis of Payment. The accepted quantities of temporary slope drains will be paid for at the contract unit price.
2/1/2016
806-5
Pollution, Sediment and Erosion Control
Section 806.30 Temporary Ditch and Inlet Checks 806.30.1 Description. This work shall consist of constructing and maintaining temporary ditch and inlet checks, removing sediment deposits from these checks and disposing of the sediment at a location approved by the Engineer. See the St. Louis County Sediment and Erosion Control Manual for additional information. 806.30.2 Material. All material shall be in accordance with Section 806.3 and the following: 806.30.2.1 Posts. Wood, steel or synthetic posts may be used. Posts shall be of sufficient length, but no less than 4 feet, to ensure adequate embedment while fully supporting the silt fence and shall have sufficient strength to resist damage during installation and to support applied loads while in service. 806.30.2.2 Support Fence. All geotextile silt fences shall be supported either externally by wire or other approved mesh to a height of at least 24 inches or by a suitably designed support system capable of keeping the material erect. Either method shall be strong enough to withstand applied loads. 806.30.3 Construction Requirements. 806.30.3.1 Ditch Checks. Ditch checks shall be constructed of rock, sand bags, rock bags or an approved alternative erosion control measure as specified in the contract. Ditch checks shall not be used where drainage areas exceed 2 acres or where ditch slopes exceed 2 percent. Approved alternate ditch checks shall be installed and maintained according to the manufacturer's recommendations. 806.30.3.1.1 Rock Ditch Checks. Rock ditch checks shall be constructed with clean rock. A minimum of 50 percent of the rock shall have a diameter of 6 inches or greater, with a maximum size of 9 inches. Silt fence or an equivalent filter fabric shall be placed beneath the rock ditch check as shown on the plans. 806.30.3.1.2 Sand Bag Ditch Checks. Sand or rock for sand bags shall be a uniform granulation with a maximum aggregate size of 2 inches, shall be clean to allow percolation of water through the sand bag and shall meet the approval of the Engineer. Sand bags shall be of tightly woven burlap or other material that is sufficiently durable to remain intact for the time intended. Sand bags shall be filled approximately three-fourths full, shall weigh approximately 55 pounds and shall be securely closed. The sand bags shall be laid in horizontal courses, and successive courses shall break joints with preceding ones. The bags shall be packed against each other and tamped to provide a uniform surface. 806.30.3.1.3 Drop Inlet Checks. Drop inlet checks shall be constructed adjacent to the drop inlet as shown on the plans or as directed by the engineer, as necessary to prevent sediment from entering the inlet. Material shall be in accordance with the requirements of the ditch checks or as approved by the Engineer.
2/1/2016
806-6
Pollution, Sediment and Erosion Control
806.30.3.1.4 Maintenance. The contractor shall replace checks as directed by the Engineer. Periodic sediment removal shall include removal and disposal of sediment to a location where sediment will not erode into construction areas, streams or other bodies of water. The contractor shall inspect the ditch checks for sediment accumulation after each storm event and shall remove the sediment when deposits reach approximately one-half the original height of the check. Alternate temporary erosion control methods shall be maintained in accordance with the manufacturer and as directed by the Engineer. 806.30.3.1.5 Method of Measurement. Measurement of sediment removal will be made to the nearest cubic yard. 806.30.4 Basis of Payment. The accepted quantities of temporary checks will be paid for at the contract unit price for each pay item included in the contract. This shall include constructing, maintaining, repairing and removing and disposing of the check after completion of the work. The contractor will be compensated at the contract unit price if the engineer determines unusual conditions warrant repair or replacement of a check.
2/1/2016
806-7
Pollution, Sediment and Erosion Control
Section 806.40 Sediment Basins 806.40.1 Description. This work shall consist of constructing sediment basins as shown on the plans or as directed by the Engineer to detain sediment. This work shall also include disposal of excavated material, sediment and basin removal and site restoration. See the St. Louis County "Sediment and Erosion Control Manual" for additional information. 806.40.2 Construction Requirements. The area where a sediment basin is to be constructed shall be cleared of vegetation to enable sediment removal. The sediment basin shall be an excavated or dammed storage area with defined side slopes. Inlet and outlet areas shall be lined with rock riprap. 806.40.2.1 The inlet of a sediment basin shall be constructed with a wide cross-section and a minimum grade to prevent turbulence and to allow deposition of soil particles. When the depth of sediment reaches one-half the original depth of the sediment basin in any part of the pool, all accumulation shall be removed. 806.40.2.2 The contractor shall dispose of accumulated sediment and excavated material removed during the construction of the sediment basin in locations where the material will not erode into the construction areas, streams or other bodies of water. 806.40.2.3 Sediment basins shall remain in service until all disturbed areas draining into the structure have been satisfactorily stabilized. When use of a temporary sediment basin is to be discontinued, the contractor shall remove any sediment and backfill, properly compact all excavations, restore the area to the existing ground’s natural or intended condition, and seed and mulch in accordance with Sections 802 and 805. 806.40.3 Method of Measurement. 806.40.3.1 Measurement of sediment basin excavation and sediment removal will be made to the nearest cubic yard. 806.40.3.2 Measurement of all seeding required after the sediment basin is built, after removal of the sediment basin and for site restoration will be in accordance with Section 805. 806.40.4 Basis of Payment. 806.40.4.1 The accepted quantities for constructing a sediment basin and for sediment removal will be paid for at the contract unit price. 806.40.4.2 Payment for all seeding and mulching required after the sediment basin is built, after removal of the sediment basin and for site restoration, will be in accordance with Section 805. 806.40.4.3 If additional clearing and grubbing is necessary for construction of a sediment basin, payment will be included in the contract unit price for sediment basin.
2/1/2016
806-8
Pollution, Sediment and Erosion Control
Section 806.50 Temporary Seeding and Mulching 806.50.1 Description. This work shall consist of furnishing and applying fertilizer, seed, vegetative mulch or other acceptable cover authorized by the Engineer. This work shall produce a quick ground cover to reduce erosion in disturbed areas expected to be redisturbed at a later date. Finish grading of areas will not be required. Hydraulic seeding and fertilizing in accordance with Section 805 will be permitted. 806.50.2 Construction Requirements. Seeding and mulching shall be a continuous operation on all cut and fill slopes, excess material sites and borrow pits during the construction process. All disturbed areas shall be seeded and mulched as necessary to eliminate erosion. 806.50.2.1 The contractor shall provide permanent seeding and mulching as shown on the plans following temporary seeding. 806.50.2.2 Temporary seeding mixtures of cereal grains shall be applied as directed in the St. Louis County "Sediment and Erosion Control Manual". All erodible seeded areas shall provide a minimum of 20 plants of the species planted per square foot on at least two random counts per acre in representative areas of the field. For areas with a large percentage of rock, the number of living plants shall be proportional to the percentage of erodible surface, as determined by the Engineer. The counts will be conducted 60 days after the species is planted. 806.50.2.3 Mulch placed over temporary seed mixtures shall be applied in accordance with Section 802. 806.50.2.4 Fertilizer shall be applied as directed in the St. Louis County "Sediment and Erosion Control Manual". 806.50.2.5 Lime shall be applied as directed in the St. Louis County "Sediment and Erosion Control Manual". 806.50.3 Method of Measurement. Measurement of all temporary seed mixtures and accompanying mulch will be made to the nearest 1/10 acre. 806.50.4 Basis of Payment. The accepted quantities of all temporary seed mixtures and the accompanying mulch will be paid for at the contract unit price per acre.
2/1/2016
806-9
Pollution, Sediment and Erosion Control
Section 806.70 Silt Fence 806.70.1 Description. This work shall consist of furnishing, installing, maintaining, removing and disposing of a silt fence designed to remove suspended particles from sheet flow passing through the fence and to prevent sediment from polluting nearby streams or other bodies of water. The quantities of silt fence shown on the plans may be increased or decreased at the direction of the engineer. At the Engineer's discretion, the location may be modified to fit field conditions. Such variations in quantity will not be considered as a change in work. See the St. Louis County "Sediment and Erosion Control Manual" for additional information. 806.70.2 Material. All material shall be in accordance with Section 806.3. 806.70.2.1 Posts. Posts shall be in accordance with Section 806.30.2.1. 806.70.2.2 Support Fence. 806.30.2.2.
Support fences shall be in accordance with Section
806.70.2.3 Prefabricated Fence. Prefabricated fence systems may be used if the systems meet all of the above material requirements. 806.70.3 Construction Requirements. 806.70.3.1 Fabric Fence. The contractor shall install silt fence as shown on the plans and at other locations directed by the Engineer. Fence construction shall be adequate to handle the stress from hydraulic and sediment loading. Fabric at the bottom of the fence shall be buried a minimum of 6 inches to prevent flow under the barrier. The trench shall be backfilled, and the soil compacted over the fabric. Fabric splices with a minimum 2foot overlay shall be located only at a support post. Any installation method acceptable to the Engineer will be allowed as long as the effectiveness and intent of the silt fence is achieved. All geotextile construction shall be in accordance with Sections 624 and 1011. 806.70.3.1.1 Post spacing shall not exceed 5 feet. Posts shall be driven a sufficient depth into the ground or placed on closer spacing as necessary to ensure adequate resistance to applied loads. 806.70.3.1.2 The silt fence shall be fastened securely to the upslope side of the post. When wire support fence is used, the wire shall extend into the trench a minimum of 2 inches. 806.70.3.2 Maintenance. The contractor shall maintain the integrity of silt fences as long as the fences are necessary to contain sediment runoff. The contractor shall inspect all silt fences immediately after each rainfall and at least daily during prolonged rainfalls. Any deficiencies shall be immediately corrected by the contractor. In addition, the contractor shall make a daily review of the silt fences in areas where construction activities have changed the natural contour and drainage runoff to ensure the silt fences are properly located for effectiveness. Where deficiencies exist, additional silt fences shall be installed as approved or directed by the Engineer.
2/1/2016
806-10
Pollution, Sediment and Erosion Control
806.70.3.3 Sediment. The contractor shall remove and dispose of sediment when accumulations reach approximately one-half the fence height, or sooner when directed by the Engineer. If required by heavy sediment loading, a second silt fence shall be installed as directed by the Engineer. 806.70.3.4 Removal. The silt fence shall remain in place until removal is directed by the Engineer. Upon removal, the contractor shall remove and dispose of any excess silt accumulation, grade and dress the area to the satisfaction of the engineer, and establish vegetation on all bare areas in accordance with the contract requirements. The fence material shall remain the property of the contractor. 806.70.4 Method of Measurement. Silt fence will be measured to the nearest linear foot from end to end of each separate installation. 806.70.5 Basis of Payment. The accepted quantities of silt fence will be paid for at the contract unit price.
2/1/2016
806-11
Pollution, Sediment and Erosion Control
Section 806.80 Temporary Pipe 806.80.1 Description. This work shall consist of installing and removing temporary pipe utilized to carry water under temporary roadways, silt fences, berms or other locations determined by the Engineer and to prevent the contractor's equipment from coming in direct contact with water when crossing an active stream, intermittent streams created during heavy rainfalls or other bodies of water. 806.80.2 Material. Any pipe approved by the Engineer may be used. 806.80.3 Construction Requirements. Installation of temporary pipe shall be in accordance with the specifications for permanent pipe and shall prevent water from causing erosion around the pipe. All backfill material for pipes shall be placed in 6-inch lifts and mechanically compacted. Compaction tests will not be required. Temporary pipe placed in intermittent or active streams shall be backfilled with clean rock. 806.80.4 Method of Measurement. Measurement of temporary pipe will be made to the nearest linear foot. 806.80.5 Basis of Payment. The accepted quantities of temporary pipe will be paid for at the contract unit price. Unless provided as a pay item in the contract documents, no direct payment will be made for the placement and removal of the backfill material or rock.
2/1/2016
806-12
Pollution, Sediment and Erosion Control
Section 806.90 Temporary Erosion Control Blankets 806.90.1 Description. This work shall consist of furnishing and placing erosion control blankets on slopes or ditches for short-term or long-term protection of seeded areas at locations shown on the plans or as directed by the Engineer. See the St. Louis County "Sediment and Erosion Control Manual" for additional information. 806.90.2 Material. Erosion control blankets shall be used as designated in the contract or as approved by the Engineer. The contractor shall provide prequalified erosion control blankets of the class and type specified in the contract documents or as approved by the engineer. A manufacturer's certification for each type of blanket used stating that the blankets are in accordance with Section 1011.3.6, shall be provided to the Engineer. 806.90.3 Construction Requirements. Erosion control blankets shall be installed and maintained according to the manufacturer's recommendations. 806.90.4 Method of Measurement. Measurement of erosion control blankets will be made to the nearest square yard of surface area covered by the completed mat. 806.90.5 Basis of Payment. The accepted quantity of blanket will be paid for at the contract unit price for each of the pay items included in the contract. If blanket is used in lieu of other erosion control measures, payment will be made at the contract unit price for the pay items in the contract for the respective items that the blanket replaces.
2/1/2016
806-13
Pollution, Sediment and Erosion Control
Section 806.100 Temporary Stream Crossing 806.100.1 Description. This work shall consist of constructing a temporary stream crossing to facilitate the movement of equipment across a stream. See the St. Louis County "Sediment and Erosion Control Manual" for additional information. 806.100.2 Material. Rock furnished for temporary stream crossings shall be in accordance with Section 303.2. 806.100.3 Construction Requirements. The contractor shall be responsible for the design, installation, maintenance and removal of the temporary stream crossing and any structures installed for the construction of the temporary stream crossing. Appropriate measures shall be taken to maintain near normal downstream flows and to minimize flooding upstream. The temporary stream crossing shall be constructed to permit the free movement of the stream’s aquatic life. 806.100.3.1 Prior to construction of the temporary stream crossing, all information shall be submitted to the Engineer as needed for the issuance or modification of the Army Corps of Engineers permit. The contractor shall not begin construction on any temporary stream crossing without written permission from the Engineer. 806.100.3.2 All approaches to the temporary stream crossing shall be maintained such that all storm water runoff is diverted to retention devices. 806.100.3.3 When the temporary stream crossing is no longer needed, the crossing shall be removed as soon as possible and the area shall be restored to pre-project conditions or to the satisfaction of the Engineer. 806.100.4 Basis of Payment. No direct payment will be made for the design, installation, maintenance or removal of temporary stream crossings. The contractor shall be responsible for all costs, including damage and penalties.
2/1/2016
806-14
Pollution, Sediment and Erosion Control
Section 808
Planting Trees, Shrubs and Other Plants
808.1 Description. This work shall consist of furnishing and planting materials in the locations designated on the plans or established by the engineer. 808.1.1 Shrubs designated to be removed and relocated shall be protected as required for new stock during the temporary removal interim, and then be replanted as hereinafter specified. 808.2 Materials. 808.2.1 Plants. 808.2.1.1 Unless otherwise specified or permitted by the engineer, trees, shrubs, and other plants shall be nursery stock and shall be true to type and name in accordance with the current edition of Standardized Plant Names published by the American Joint Committee on Horticultural Nomenclature. A nursery is defined as a place where trees and plants are grown in established rows for the purpose of replanting at a new location. The nursery stock shall have well developed branch systems and vigorous healthy root systems. All stock shall be well formed and the trunks of trees shall be uniform. All plants shall have a normal habit of growth and shall be sound, healthy, and vigorous. They shall be free from insects, disease, and defects such as knots, sun-scald, injuries, serious abrasions of the bark, or objectionable disfigurements. Thin weak plants will not be accepted. All nursery stock shall qualify under the AAN Horticultural Standards of the current American Standard for Nursery Stock, ANSI Z 60.1. Substitution of plant stock of other materials will not be permitted except by approval of the engineer. 808.2.1.2 All measurements for height, spread, branching, diameter, and root spread or ball size shall be as specified in the current AAN American Standard for Nursery Stock, ANSI Z 60.1. Acceptance of plant material will be made only at the planting site following the completion of the planting work, except that acceptance for height, spread and number of branches will be made before pruning the plant. Each shipment shall be accompanied by an invoice showing sizes and varieties of material and ANSI Z 60.1 certification. 808.2.1.3 All plant stock shall be certified free of insects and disease by the Missouri Department of Agriculture. 808.2.1.4 Inspection of nursery stock may be made at the nursery by the Engineer. Approval of material on such inspection shall not be construed as an acceptance. Inspection and acceptance of plant materials will be made only at the planting site following the completion of the planting work with the exception that acceptance for height, spread, and number of branches will be made before pruning the plant. Each shipment shall be accompanied by an invoice showing sizes and varieties of materials included. 808.2.1.5 Invoices showing size and grade of materials shipped, plus all necessary state, federal, and other inspection certificates, showing the source of origin and the health of the plant materials shall be presented to the Director prior to final acceptance.
2/1/2016
808-1
Planting Trees, Shrubs and Other Plants
808.2.1.6 All stock shall be dug and packed with special care to avoid unnecessary injury to or removal of roots. Each variety shall be packed in separate bundles, clearly and accurately labeled. Roots shall be carefully protected with wet straw, moss, or other material so that the plants arrive with roots in a moist and healthy condition. All stock shall have been grown within a 150-mile radius of St. Louis. 808.2.1.7 Plants indicated by ball diameter shall be balled and burlapped and shall be lifted from the ground so as to retain as many roots as possible. Such plants shall be so dug and transported as to provide and retain a firm ball of the original soil. The ball shall be wrapped with burlap and securely tied to keep the ball firm and intact. Balls shall be adequately protected from rain or sudden changes in weather. Trees or other plants will not be accepted if the balls of earth are loosened or broken. 808.2.1.8 Plants specified as container grown shall have grown in that container sufficiently long for new fibrous roots to have developed such that the root mass will retain its shape and hold together when removed from the containers; however the root mass shall not have grown in container long enough to have become pot bound. The container shall be sufficiently rigid to hold the ball shape protecting the root mass during shipping. The containers of all container-grown plants shall be removed just prior to planting. 808.2.1.9 It is the intention of the County to allow the property owners to voice an opinion in the types of trees to be planted in specific areas. Accordingly, a percentage not more than 15 percent of the below listed trees may be requested for planting. Exact numbers of specific tree types will be determined after consultation with the property owners and representatives of the Department. Tree types not shown on this listing may be ordered to meet special requirements of an area or project as directed by the Director.
Types of Trees, Bushes and Shrubs Deciduous Trees Baldcypress ........................................................................... (Taxodium distichum) Cleveland Select Pear .................................. (Pyrus calleryana, 'Cleveland Select') Flowering Cherry (Kwanzan) ....................................(Prunus serrulata, 'Kwanzan') Flowering Dogwood ........................................................................ (Cornus florida) Northern Red Oak ........................................................................... (Quercus rubra) Norway Maple ............................................................................. (Acer platanoides) Redbud ...................................................................................... (Cercis canadensis) Red Maple (Scarlet Maple) ................................................................ (Acer rubrum) Pin Oak (True Pin Oak).............................................................. (Quercus palustris) Tuliptree ...............................................................................(Liriodendron tulipifera)
2/1/2016
808-2
Planting Trees, Shrubs and Other Plants
Evergreen Trees Austrian Pine ....................................................................................... (Pinus nigra) Eastern White Pine .......................................................................... (Pinus strobus) Norway Spruce ....................................................................................(Picea abies) Deciduous Bushes / Shrubs Burning Bush (Winged Euonymus) ..........................................(Euonymus alatus) Forsythia ..........................................................................................(Forsythia spp.) Gold Flame Spirea ............................................. (Spiraea x bumalda, 'Gold Flame') Miss Kim Dwarf Korean Lilac (or Miss Kim Dwarf Manchurian Lilac) ................. (Syringa patula, 'Miss Kim') Purpleleaf Sand Cherry ...............................................................(Prunus x cistena) Red Twig Dogwood ..............................................................(Cornus alba 'Sibirica') Evergreen and Semi-Evergreen Bushes / Shrubs Dense Spreading Japanese Yew ................................................ (taxus cuspidata) Scarlet Firethorn .................................................................. (Pyracanthia coccinea) Sea Green Juniper ............................................. (Juniperus chinensis, 'Sea Green') 808.2.2 Mulching Material. The mulching material shall be wood chips substantially free of foreign material. 808.2.3 Tree Wrapping Paper and Binder Twine. Wrapping paper for trees shall be a waterproofed tree wrapping paper of good commercial quality furnished in 4 inch width. Twine for tying paper shall be any approved commercially available binder twine. 808.2.4 Supporting Stakes for Trees. Supporting stakes for trees shall be an approved 2 inch x 2 inch x 6 foot posts of sound wood and free from knots that would affect the serviceability of the posts. 808.2.5 Peat Moss. Peat moss shall be a natural domestic product consisting of partially decomposed stems and leaves of any variety of sphagnum mosses and shall be substantially free of woody substances and mineral matter such as sulphur and iron. Peat moss shall be granulated and used in an air-dry, loose condition. 808.3 Construction Requirements. 808.3.1 Planting Dates. Planting shall be performed during either the fall phase or the spring phase or both, as designated in the contract. The beginning dates established in the contract for the respective phases will be considered to be the effective date of the Notice to Proceed.
2/1/2016
808-3
Planting Trees, Shrubs and Other Plants
808.3.2 On roadways open to traffic, the contractor shall avoid crossing the pavement with men, equipment, or materials. 808.3.3 Care of Plants Before and During Planting. Immediately following delivery and inspection at the job site, all bare root plants shall be "heeled in" in a manner satisfactory to the Engineer. All "heeled in", balled and burlapped, and container grown plants shall be protected and their roots kept moist until planted. While bare root plants are being transported to and from "heeling in" grounds, distributed in planting beds, or awaiting planting after distribution, their roots shall be protected from drying out by means of wet canvas, burlap, or straw, except as specified in Section 808.3.6.6. The trunks and branches of all trees shall be carefully protected from injury of any kind during all operations. Any injured tree may be rejected. 808.3.4 Location and Spacing of Plants. The general location of each individual tree or shrub and the areas for ground cover plants will be shown on the plans. To facilitate the staking operations, the contractor shall notify the engineer in writing at least 2 weeks in advance of the date on which he intends to begin planting. Stakes indicating plant locations shall be set for the contractor by representatives of the St. Louis County Department of Transportation within 48 hours from the time the contractor requests such stakes. Stakes for indicating plant locations shall be furnished by the contractor in accordance with the provisions of Section 105.8. 808.3.5 Pruning Roots. A maximum of root growth shall be preserved and no root pruning will be permitted except as noted herein. Any large or fleshy roots that have been broken, crushed, or badly bruised shall be cleanly cut back to sound wood. Interfering roots shall be pruned if directed by the engineer. 808.3.6 Planting. 808.3.6.1 The planting of all plants shall be subject to the inspection of the Engineer. Any rock, rubble, or other underground obstructions shall be removed to the required depth. If underground obstructions, not feasible to move are encountered in the planting areas, then other locations may be selected by the Engineer. The contractor shall notify the Director at least 24 hours before proceeding with planting operations. 808.3.6.2 Preparation of Holes. Holes for trees shall be not less than 18 inches larger in diameter than the ball diameter, container, or root spread. Holes for shrubs shall not be less than 12 inches larger than the ball diameter, container, or root spread. Holes for vines and seedlings shall be not less than 9 inches in diameter. The holes shall be of such depth to set the plants at the same height at which they grew in the nursery. If the holes are dug too deep, it shall be necessary to add enough backfill material to the bottom of the hole to allow for settling. Depth of holes for vines and seedlings shall be sufficient to allow for proper spreading of roots. 808.3.6.3 Backfill Material. In general, backfill material for planting shall consist of the existing excavated soil broken into less than one-inch clods and thoroughly mixed with peat moss as required. Plants with a ball diameter, container, or root spread of 15 inches or less require one bushel of peat moss. Plants with a ball diameter, container, or root spread of over 15 inches require 2 bushels of peat moss. Peat moss will not be required for vines or seedlings.
2/1/2016
808-4
Planting Trees, Shrubs and Other Plants
808.3.6.4 Bare Root Trees and Shrubs. Plants with bare roots shall be held firmly in the proper position with the roots spread out during backfilling. Backfill material shall be worked and puddled around the roots and thoroughly firmed during backfilling. Sufficient water shall be used to insure thorough saturation of the backfill material around the plant roots. 808.3.6.5 Balled and Burlapped and Container Grown Stock. Plants which are balled and burlapped or container grown shall be set to proper position and grade. The backfill material shall be carefully worked and puddled around the ball. Sufficient water shall be used to insure thorough saturation of the backfill material. 808.3.6.6 Vines and Seedlings. Vines and seedlings shall be planted on 3-foot centers and 3 foot staggered rows within designated areas. When a bundle of plants is opened, all plants in that bundle shall immediately be placed in a container of water and each plant planted from the container. Plants placed in the holes shall be backfilled immediately. Backfill material shall be thoroughly firmed, and all plants shall be watered the same day of planting. 808.3.6.7 Preparation of Plant Beds. Prior to planting in areas designated on the plans as plant beds, the existing sod shall be removed by stripping with a sod cutter set for a 1 inch depth of cut. The sod so removed shall be disposed of by the contractor outside the limits of the right-of-way or as directed by the Engineer. 808.3.6.8 Mulching. Individual plants except for vines and seedlings shall be mulched with a 4-inch layer of wood chips over the backfill or as shown on the plans. All areas shown on the plans as plant beds shall be mulched with a 4-inch thick layer of wood chips in a continuous bed over the entire area. Mulch will not be required for vines or seedlings. 808.3.6.9 Fertilizing. A 10-8-6 inorganic commercial fertilizer shall be applied to all plant materials at the time of planting. The fertilizer shall be delivered to the site in unopened containers bearing the manufacturer's statement of analysis. Apply fertilizer at the rate of ¼ pound to ½ pound per inch of caliber for trees, and 2 pounds per 100 square feet of planting bed. 808.3.7 Pruning Branches or Stems. 808.3.7.1 Deciduous trees shall be pruned to balance the loss of roots. Pruning shall retain the natural form of the plant type. Only thinning cuts will be permitted on trees. A single trunk shall be preserved on all shade trees. All dead, broken, and interfering branches shall be removed. When branches are removed, they shall be cut off flush with the parent branch. All cut surfaces over 1 inch in diameter shall be painted with tree paint or tar. 808.3.7.2 Deciduous shrubs shall be pruned by removing all dead wood and broken branches and by removing or heading approximately ⅓ to ½ of the branches. 808.3.7.3 Evergreens shall be pruned only to the extent of removing dead or damaged portions of the branches, except as permitted by the Engineer. 808.3.7.4 Vines shall be pruned to the extent necessary to retain approximately 6 inches of runner above the ground surface. 2/1/2016
808-5
Planting Trees, Shrubs and Other Plants
808.3.8 Wrapping Trees. The trunks of all deciduous trees, and the lower part of the largest branches of trees of more than 5-inch caliber, shall be carefully wrapped with tree wrapping paper immediately after planting. The wrapping shall begin at the ground line and extend upward in a spiral to the lowest major branch. The spiral paper shall overlap not less than 1 inch. Multiple stemmed trees shall have each stem separately wrapped to the lowest major branch. Suckers and small twigs shall be removed to permit proper wrapping. The wrapping paper shall be held in place with binder twine. 808.3.9 Supporting Methods for Trees. Trees 2 inches or more in caliber, or as determined by the Director, shall be properly supported using 3 guy wires securely anchored to approved stakes not less than 5 feet from the trunk and at a height as indicated on the plans. The trunk shall be adequately protected from the guy wires. The guy wires are to be Number 12 gage wire. The supports shall be installed within 2 days of planting. 808.3.10 Finishing. Waste material, including sod, subsoil, rock, branches, twigs, packing material, and other debris shall be disposed of by the contractor outside the limits of the rightof-way or as directed by the Engineer. All roadway shoulders and other areas damaged by the contractor's operations shall be restored to a satisfactory condition as directed by the Engineer. Finishing in accordance with this section shall be performed following the completion of each planting phase when fall and spring planting phases are required. 808.4 Care and Replacement. 808.4.1 Starting with the first day of planting for each phase and continuing through a period of 45 days following the last day of planting within the respective phase, the contractor shall keep all plants watered sufficiently to maintain moist soil in the root zone. The Engineer may direct watering as necessary to maintain moist soil and may halt further planting within the respective phases until sufficient water is applied to those plants in place. In addition to watering, the contractor shall perform such weeding, adjusting tree supporting posts, pruning, chemical spraying for insect and disease control, and keep all bedded areas substantially clear of weeds and grass to insure healthy plants. The contractor, at no cost to the county, will be permitted to apply commercial wilt-proofing compound or liquid fertilizer on plants during the planting or the watering period of the contract. 808.4.1.1 In addition to the 10 percent retained percentage specified in Section 808.6, there will be withheld an amount equal to 15 percent of the price bid for plants until satisfactory completion of the watering requirements specified for each phase of planting, at which time the 15 percent will be released. 808.4.2 The contractor shall be responsible for the proper care of all plants until final inspection and acceptance of the plants has been made by the Engineer. 808.4.2.1 Any plant, which in the judgment of the Engineer, is not in a healthy growing condition at the time of final plant inspection shall be replaced by the contractor in accordance with the original specifications except that additional peat moss will not be required for the backfill material, and except that the specified 45 day watering period will not be required. No maintenance will be required for those plants replaced under this replacement specification.
2/1/2016
808-6
Planting Trees, Shrubs and Other Plants
808.4.3 Final Plant Inspection. For those contracts requiring fall phase planting only, the final inspection of plants will be made as soon as practicable after May 15. For those contracts requiring spring phase planting only, or requiring both fall and spring phase planting, the final plant inspection will be made as soon as practicable following either the specified spring watering period or May 15 whichever comes last. Plants not accepted at the time of final plant inspection will be marked and shall be replaced in the fall in accordance with the dates established in the contract. The contractor will be relieved of all further responsibility for plants that are accepted at the time of final plant inspection. 808.5 Liquidated Damages. Liquidated damages will be charged in accordance with Section 108.7 except that liquidated damages will be charged against the contractor only for those days which would qualify as working days. The designated amount will be charged separately for each phase of planting and for the plant replacement period. Liquidated damages will not be charged during required watering periods. 808.6 Method of Payment. Trees will be planted and, upon planting, the contractor shall be paid 90 percent of the bid price within 30 days of receipt of invoice for the planting. The contractor will receive the final 10 percent payment following the first successful leafing out of the trees, within 60 days of the first following growing season when leafing out occurs. The replacement of unsuccessful planting material shall be the responsibility of the contractor at no cost to the County. Replacement shall be made at the direction of the Director or his authorized representative. 808.7 Basis of Payment. The accepted quantities of plants will be paid for at the contract unit bid price for each plant of the types, species, and sizes required, complete in place. No direct payment will be made for any incidental items such as supporting posts, mulch, edging, and water necessary for this work.
2/1/2016
808-7
Planting Trees, Shrubs and Other Plants
(This Page Intentionally Left Blank)
2/1/2016
808-8
Planting Trees, Shrubs and Other Plants
Division 900
TRAFFIC CONTROL FACILITIES
9/1/2023
900-1
Traffic Control Facilities
(This Page Intentionally Left Blank)
9/1/2023
900-2
Traffic Control Facilities
Standard Specifications for Road and Bridge Construction Division 900 - Traffic Control Facilities Section
Description
Revision Date
902..... Roadway Striping ................................................................................................ 7/1/2016 903..... Roadway Signing ................................................................................................ 7/1/2016 904..... St. Louis County Traffic Signals ........................................................................... 9/1/2023 Index ........................................................................................................... 904-1 St. Louis County Traffic Signals ................................................................ 904-9
9/1/2023
900-3
Division 900 - Index
(This Page Intentionally Left Blank)
9/1/2023
900-4
Division 900 - Index
Section 902
Roadway Striping
902.1 All striping materials shall be manufactured in accordance with Section 1048. 902.2 All striping for temporary striping or permanent striping shall be installed in accordance with the current Manual of Uniform Traffic Control Devices (MUTCD) published by the Federal Highway Administration (FHWA). 902.2.1 Striping installations and removals shall be performed in accordance with Sections 620, 621 and 622.
7/1/2016
902-1
Roadway Striping
(This Page Intentionally Left Blank)
7/1/2016
902-2
Roadway Striping
Section 903
Roadway Signing
903.1 All permanent regulatory, warning, and guide signs along County roads will be furnished and installed by the St. Louis County Department of Transportation, unless otherwise indicated. 903.2 All existing regulatory, warning, and guide signs along County roads will be removed or relocated by the St. Louis County Department of Transportation as required, unless otherwise indicated. 903.3 For all temporary construction signing see Section 612, "Traffic Control Devices". 903.4 The contractor shall notify the Engineer one day in advance of any required signing modifications.
7/1/2016
903-1
Roadway Signing
(This Page Intentionally Left Blank)
7/1/2016
903-2
Roadway Signing
Section 904
Saint Louis County Traffic Signals Index
Section Number and Description Index
904
Page Number
.....................................................................................................................904-1
Saint Louis County Traffic Signals ............................................................................904-7
904.1 Description ...............................................................................................................904-8
904.2 General Requirements for Materials and Equipment. ................................................904-8
904.3 Materials. ..................................................................................................................904-8 904.3.1 Conduit. ............................................................................................................904-8 904.3.1.1 Polyvinyl Chloride Conduit. ......................................................................904-9 904.3.1.2 Polyethylene Duct. ...................................................................................904-9 904.3.1.3 Steel Conduit. .........................................................................................904-9 904.3.1.3.1 Steel Conduit Within Railroad Right of Way ...................................904-9 904.3.1.3.2 Steel Conduit Attached to a Bridge Structure. ...............................904-9 904.3.2 Conductor Cable and Wire. ..............................................................................904-9 904.3.2.1 Power Cable. ...........................................................................................904-9 904.3.2.2 Multi-Conductor Signal Cable. .............................................................. .904-10 904.3.2.3 Ground Wire. ......................................................................................... 904-10 904.3.2.4 Detector Loop Cable. ............................................................................. 904-10 904.3.2.5 Push Button and Detector Loop Lead-In Cable. ..................................... 904-10 904.3.2.6 Communication Cable for Accessible Pedestrian Signal Equipment ...... 904-11 904.3.2.7 Communication Cable for Traffic Signal Interconnect............................. 904-11 904.3.2.7.1.Fiber Optic Cable. .......................................................................... 904-11 904.3.3 Preformed Pull Box and Cover. ...................................................................... 904-13 904.3.4 Concrete Pull Box Frame, Cover, Cable Hooks, and Ground Rods. ............... 904-13 904.3.5 Detector Loop Sealant. ................................................................................... 904-14 904.3.6 Concrete. ........................................................................................................ 904-14 9/1/2023
904-1
Traffic Control Facilities
Section Number and Description
Page Number
904.3.7 Reinforcing Steel. ........................................................................................... 904-14 904.3.8 Signs and Striping. ......................................................................................... 904-14 904.4 Equipment. .............................................................................................................. 904-15 904.4.1 Signal Head Assemblies. ................................................................................ 904-15 904.4.1.1 General Requirements. .......................................................................... 904-15 904.4.1.2 Signal Head Hardware. .......................................................................... 904-15 904.4.1.3 Signal Face Types. ................................................................................ 904-16 904.4.1.3.1 Conventional Vehicle Signal Face. ................................................ 904-16 904.4.1.3.1.1 Basic Construction and Mounting. ........................................ 904-16 904.4.1.3.1.2 Optical Unit Features. ........................................................... 904-17 904.4.1.3.1.3 Visors and Backplates. ......................................................... 904-18 904.4.1.3.2 Optically Limiting Vehicle Signal Face. .......................................... 904-18 904.4.1.3.2.1 Basic Construction and Mounting. ........................................ 904-19 904.4.1.3.2.2 Optical Unit Features. ........................................................... 904-19 904.4.1.3.2.3 Visors and Backplates. ......................................................... 904-20 904.4.1.3.3 Pedestrian Signal Face. ................................................................ 904-21 904.4.1.3.3.1 Basic Construction and Mounting. ........................................ 904-21 904.4.1.3.3.2 Optical Unit Features. ........................................................... 904-21 904.4.1.3.3.3 Visors. .................................................................................. 904-23 904.4.2 Aluminum Post with Square Pedestal Base Assembly. ................................... 904-23 904.4.2.1 Assembly on Type C Concrete Base. .................................................... 904-23 904.4.2.1 Assembly on Type P Concrete Base...................................................... 904-24 904.4.3 Steel Cantilever Mast Arm Assembly. ............................................................. 904-25 904.4.4 Wood Poles, Guys and Span Wire Assembly. ................................................ 904-28 904.4.5 Power Supply Assemblies. ............................................................................ 904-29 904.4.5.1 Type Mounted on Wood Pole................................................................. 904-29 904.4.5.2 Type Mounted on Steel Post with Concrete Embedment. ...................... 904-29 904.4.6 Traffic Actuated Controller. ............................................................................. 904-29 904.4.6.1 Controller Cabinet. ................................................................................. 904-30 904.4.6.1.1 Basic Construction. ....................................................................... 904-30 904.4.6.1.2 Size and Mounting. ....................................................................... 904-31 904.4.6.1.3 Ventilation. .................................................................................... 904-31 904.4.6.1.4 Special Switches, Sockets, Outlets, and Lights. ............................ 904-32 9/1/2023
904-2
Traffic Control Facilities
Section Number and Description
Page Number
904.4.6.2 Panel Wiring, Circuit Breakers and Relays............................................. 904-33 904.4.6.3 Controller Phase Requirements. ............................................................ 904-35 904.4.6.4 Actuated Controller Unit Features. ......................................................... 904-36 904.4.6.4.1 Controller Unit Functional Standards. ............................................ 904-36 904.4.6.4.2 Controller Unit Connector Pin Designations. ................................. 904-37 904.4.6.4.3 Controller Unit Assembly Requirements. ....................................... 904-37 904.4.6.4.4 Coordination.................................................................................. 904-38 904.4.6.4.5 Time Base Programming............................................................... 904-39 904.4.6.4.6 Preemption.................................................................................... 904-40 904.4.6.5 Malfunction Management Unit. .............................................................. 904-41 904.4.6.6 Solid State Load Switches. .................................................................... 904-42 904.4.6.7 Flash Operation. .................................................................................... 904-42 904.4.6.8 Solid State Flasher Unit. ........................................................................ 904-43 904.4.6.9 Traffic Signal Battery Backup System. ................................................... 904-43 904.4.6.9.1 Approval of Battery Backup Systems. .......................................... 904-44 904.4.6.10 Unmanaged Ethernet Switch. .............................................................. 904-45 904.4.6.10.1 Basic Requirements ..................................................................... 904-45 904.4.6.10.2 Port Configuration ........................................................................ 904-45 904.4.6.10.3 Power Supply .............................................................................. 904-45 904.4.6.10.4 Installation .................................................................................... 904-45 904.4.6.10.5 Warranty ..................................................................................... 904-45 904.4.6.11 Singlemode Fiber Optic Patchcord....................................................... 904-45 904.4.6.12 Electronic Door Locking Mechanism. .................................................. 904-46 904.4.6.12.1 Lock Control Unit. ...................................................................... 904-46 904.4.6.12.1.1 Basic Construction and Mounting. ..................................... 904-46 904.4.6.12.1.2 Operational and Security Features. .................................. 904-46 904.4.6.12.2 Card Reader with Keypad ........................................................... 904-47 904.4.6.12.2.1 Basic Construction and Mounting. ..................................... 904-47 904.4.6.12.2.2 Operational and Security Features. .................................. 904-47 904.4.6.12.3 Power Supply. ............................................................................ 904-48 904.4.6.12.4 Auxiliary Power Input ................................................................... 904-48 904.4.6.12.5 Electric Solenoid .......................................................................... 904-48 904.4.6.12.6 Documentation. ..........................................................................904-48 9/1/2023
904-3
Traffic Control Facilities
Section Number and Description
Page Number
904.4.6.13 Power Strip. ........................................................................................904-48 904.4.6.13.1 Basic Requirements. .................................................................. 904-48 904.4.6.13.2 Security Features ........................................................................ 904-49 904.4.6.13.3 Installation. ................................................................................. 904-49 904.4.6.14 Approval of Controller Equipment. ....................................................... 904-49 904.4.7 Detectors. ....................................................................................................... 904-49 904.4.7.1 Pedestrian Push Button Detector. .......................................................... 904-49 904.4.7.1.1 Basic Construction and Mounting .................................................904-50 904.4.7.1.1.1 Control Module ..................................................................... 904-50 904.4.7.1.2 Accessible Pedestrian Signal (APS) Features. ............................ 904-50 904.4.7.1.3 Maintenance and Operational Features. ..................................... 904-51 904.4.7.1.4 Pedestrian Push Button Detector Extension Assembly. ............... 904-51 904.4.7.1.4.1 Installation, Assembly, and Mounting. ................................ 904-51 904.4.7.1.5 Approval of Pedestrian Push Button Detector.
........................... 904-51
904.4.7.2 Vehicle Inductive Loop Detection Systems. ........................................... 904-52 904.4.7.2.1 Card Rack Mounted Type. .......................................................... 904-52 904.4.7.3 Overhead Vehicle Video Detection System. ........................................... 904-53 904.4.7.3.1 Camera System with Internal Processor. ..................................... 904-53 904.4.8 Fiber Optic Termination Housing.…………………….. ..................................... 904-55 904.4.9 Vehicle Video Detection Camera Mounts..…………………….. ....................... 904-55 904.4.9.1 Camera Mount on Luminaire Arm.…...................................................... 904-55 904.4.9. 2 Camera Mount on Post Extension......................................................... 904-55 904.4.9.3 Camera Mount on Mast Arm. ................................................................. 904-55 904.4.10 Pan Tilt Zoom (PTZ) Internet Protocol Video Surveillance Camera ............... 904-55 904.4.10.1 PTZ Surveillance Camera ..................................................................... 904-55 904.4.10.2 PTZ Camera Mount on Post Extension ................................................. 904-56 904.4.10.3 Special Cables and Connections Needed For PTZ Camera.................. 904-56 904.4.10.3.1 Twisted Pair Video Communication Cable ................................... 904-56 904.4.10.3.2 RJ45 Connectors ........................................................................ 904-57 904.4.10.4 Managed Ethernet Switch ..................................................................... 904-57 904.4.10.4.1 Basic Requirements ..................................................................... 904-57 904.4.10.4.2 Port Configuration ........................................................................ 904-57 904.4.10.4.3 Power Supply ............................................................................... 904-58 9/1/2023
904-4
Traffic Control Facilities
Section Number and Description
Page Number
904.4.10.4.4 Installation .................................................................................... 904-58 904.4.10.4.5 Warranty ...................................................................................... 904-58 904.4.11 Fiber Optic Cable Termination Cabinet .......................................................... 904-58 904.4.11.1 Basic Construction ................................................................................ 904-58 904.4.11.2 Size and Mounting ................................................................................ 904-60 904.4.11.3 Ventilation ............................................................................................. 904-60 904.4.12 School Zone Beacon Wireless Communication Equipment. ........................ 904-60 904.4.12.1 Wireless Radio Communication Equipment .......................................... 904-60 904.4.12.2 Antenna Assembly ................................................................................ 904-61 904.4.12.2 Delivery of Equipment ........................................................................... 904-61 904.4.13 Rapid Rectangular Flashing Beacon Assembly. .......................................... 904-61 904.4.13.1 Beacon Assembly ............................................................................... 904-61 904.4.13.1.1 General Requirements ............................................................... 904-61 904.4.13.1.2 Size and Mounting. ...................................................................... 904-62 904.4.13.2 Beacon Control Unit Cabinet ............................................................... 904-62 904.4.13.2.1 General Requirements ................................................................. 904-62 904.4.13.2.2 Basic Construction. ..................................................................... 904-63 904.4.13.2.3 Size and Mounting. ...................................................................... 904-63 904.4.13.2.4 Ventilation. ................................................................................... 904-63 904.4.13.3 Solar Panel ........................................................................................... 904-63 904.4.13.4 Pedestrian Push Button Detector ......................................................... 904-64 904.4.13.4.1 Push Button Cable ....................................................................... 904-64 904.4.13.5 Luminaire Arm with Light Fixture .......................................................... 904-64 904.4.13.5.1 Luminaire Arm ............................................................................ 904-64 904.4.13.5.2 Light Fixture ............................................................................... 904-64
904.5 Construction Requirements. .................................................................................... 904-65 904.5.1 Location of Existing Underground Facilities, Structures and Utilities. .............. 904-65 904.5.2 Location of New Concrete Bases, Pull Boxes and Detector Loops. ................ 904-65 904.5.3 Traffic Signal Construction in Solid Rock. ....................................................... 904-65 904.5.4 Construction of Concrete Bases. .................................................................... 904-65 904.5.5 Construction of Concrete Pads. ...................................................................... 904-66
9/1/2023
904-5
Traffic Control Facilities
Section Number and Description
Page Number
904.5.6 Installation of Preformed Pull Boxes. .............................................................. 904-66 904.5.7 Construction of Concrete Pull Boxes. ............................................................. 904-66 904.5.8 Adjustment of Existing Concrete Pull Boxes. .................................................. 904-67 904.5.9 Installation of Conduit. .................................................................................... 904-67 904.5.9.1 Conduit in Trench. ................................................................................. 904-67 904.5.9.2 Pushed Conduit. .................................................................................... 904-68 904.5.9.3 Directional Boring. ................................................................................. 904-68 904.5.9.4 Conduit in Doweled-On Concrete Median. ............................................. 904-69 904.5.9.5 Conduit on Wood Pole. .......................................................................... 904-69 904.5.9.6 Conduit Repair. ...................................................................................... 904-69 904.5.10 Connecting Conduit to Existing Concrete Pull Boxes. ................................... 904-69 904.5.11 Installation of Signal Posts and Mast Arm Assemblies. ................................. 904-69 904.5.12 Installation of Wood Poles, Guys and Span Wire Assemblies. ...................... 904-70 904.5.13 Installation of Power Supply Assemblies. ..................................................... 904-71 904.5.13.1 Type Mounted on Utility Pole. .............................................................. 904-71 904.5.13.2 Type Mounted on Steel Post with Concrete Embedment. .................... 904-71 904.5.14 Installation of Signal Heads. ......................................................................... 904-71 904.5.15 Installation of Controller Cabinets. ................................................................ 904-72 904.5.16 Installation of Detector Loops. ...................................................................... 904-72 904.5.17 Installation of Wiring. .................................................................................... 904-73 904.5.18 Fiber Optic Cable. ........................................................................................ 904-75 904.5.18.1 Installation of Fiber Optic Cable. .......................................................... 904-75 904.5.18.2 Fiber Optic Cable Terminations............................................................ 904-76 904.5.18.3 Testing of Fiber Optic Cable and Terminations. ................................... 904-76 904.5.18.3.1 Optical Time Domain Reflectometer. ........................................... 904-77 904.5.18.3.2 Documentation. ........................................................................... 904-77 904.5.19 Removal of Existing Concrete Pull Boxes. .................................................... 904-77 904.5.20 Removal of Existing Concrete Bases. ........................................................... 904-77 904.5.21 Removal of Existing Reinforced Polymer Concrete Pull Boxes ..................... 904-77 904.5.22 Relocation or Removal of Existing Signal Equipment. .................................. 904-77 904.5.23 Modification of Existing Traffic Signals. ......................................................... 904-78 904.5.24 Signal Maintenance During Construction. ..................................................... 904-79 904.5.24.1 Daily Cleanup During Construction. ................................................... 904-79 9/1/2023
904-6
Traffic Control Facilities
Section Number and Description
Page Number
904.5.24.2 Traffic Handling During Construction. ................................................. 904-79 904.5.24.3 Maintenance of Interconnect Facilities During Construction .................. 904-79 904.5.24.4 Maintenance of Vehicle Detection Systems During Construction .......... 904-80 904.5.25 Restoration. ................................................................................................ 904-81 904.5.26 Final Clean Up. ............................................................................................. 904-81
904.6 Temporary Traffic Signals. ...................................................................................... 904-81
904.7 Signal Acceptance Procedures. .............................................................................. 904-82 904.7.1 Signal Inspection. ........................................................................................... 904-82 904.7.2 Signal Test Period. ......................................................................................... 904-82 904.7.3 Signal Maintenance Information. .................................................................... 904-82 904.7.4 Final Acceptance. ........................................................................................... 904-83
904.8 Method of Measurement. ........................................................................................ 904-83
904.9 Basis of Payment. .................................................................................................. 904-83
904.10 Guarantee. ............................................................................................................ 904-83
9/1/2023
904-7
Traffic Control Facilities
904 Saint Louis County Traffic Signals 904.1 Description. This work shall consist of furnishing and installing traffic signal materials and equipment as shown on the drawings and/or as specified in the contract. 904.2 General Requirements for Materials and Equipment. 1) Materials and equipment shall be new stock unless the contract or plans provides for relocation of existing equipment or use of equipment furnished by others. New materials and equipment shall be the product of reputable manufacturers; shall conform to current requirements of IPCEA, NEMA, RETMA, NEC, IMSA, NESC, ITE, AASHTO, ASTM and regulations of the National Board of Fire Underwriters, as applicable; shall be in accordance with the County's current specifications; and shall meet the approval of the Engineer. Special approval of manufacturers' controller equipment, including panel wiring, is required, and may be obtained by fulfilling the requirements as specified in Section 904.4.6.14. 2) Each Bidder shall indicate on his proposal the major manufacturers of the traffic signal materials and equipment to be installed and the time required for their delivery. 3) If all signal materials and equipment for which a bid is submitted are not in exact accordance with these specifications, the Bidder shall attach to his proposal a detailed list wherein all deviations from these specifications shall be expressly listed. 4) Upon request by the Engineer, the Contractor shall produce manufacturers' letters of certification or certified test reports to show that traffic signal materials and equipment are in compliance with the specifications. 5) Six (6) sets of catalog cuts (or a pdf file if approved by the Engineer) identifying the project name and the manufacturers' model numbers of traffic signal equipment shall be submitted by the Contractor to the Engineer for approval before signal construction commences. Approval of these catalog cuts does not relieve the Contractor of responsibility for satisfactory performance of this equipment. Catalog cuts shall be submitted at least two (2) weeks in advance of the Contractor's need for approval. This time requirement for approval does not relieve the Contractor of his responsibility for delivery of signal materials and equipment within the time specified on the bid forms. 6) If new mast arms are specified in the contract, or shown on plans, six (6) sets of shop drawings (or a pdf file if approved by the Engineer) shall be submitted by the Contractor to the Engineer for approval prior to fabrication, as specified in Section 904.4.3(13).
904.3 Materials. All materials shall conform to Division 1000, Materials Details. 904.3.1 Conduit. The size of conduit to be installed shall be as specified in the contract or noted on the plans. The type of conduit to all power supplies and span wire poles shall be polyvinyl chloride (PVC) conduit. The type of conduit to all other structures and facilities shall be either PVC or polyethylene duct (PE), as chosen by the contractor, unless otherwise specified in the contract or noted on the plans.
9/1/2023
904-8
Traffic Control Facilities
904.3.1.1 Polyvinyl Chloride Conduit. Polyvinyl chloride (PVC) conduit and fittings shall be Schedule 40, heavy-wall type, and conform to the requirements of the current Underwriters Laboratories Standard for Rigid Nonmetallic Conduit, UL 651, as specified in Section 1060. 904.3.1.2 Polyethylene Duct. Polyethylene (PE) duct should be smoothwall duct and conform to ASTM D3035 SDR 11. Conventional PVC couplings shall not be attached to PE duct. All couplings used with PE duct shall be approved by the Engineer. 904.3.1.3 Steel Conduit. Steel conduit shall only be used under the following conditions. 904.3.1.3.1 Steel Conduit Within Railroad Right of Way. Steel conduit shall: 1) Be used only when requested by the Railroad. 2) Be allowed only within the Railroad’s right-of-way. 3) Be connected to PVC or PE duct by means approved by the Engineer. The size, thickness, and structural specifications of the steel conduit to be installed shall be as specified in the contract or noted on the plans. 904.3.1.3.2 Steel Conduit Attached to a Bridge Structure. Steel conduit shall: 1) Be used only when an interconnect conduit is attached directly to a bridge structure. PVC or PE duct shall be used if the conduit is bored under a bridge structure. 2) Be connected to the bridge structure as specified in the contract or noted on the plans. 3) Be connected to PVC or PE duct by means approved by the Engineer. The size, thickness, and structural specifications of the steel conduit to be installed shall be as specified in the contract or noted on the plans. 904.3.2 Conductor Cable and Wire. 904.3.2.1 Power Cable. All power cable shall be 600-volt, single conductor cable, with type THHN-THWN polyvinyl chloride insulation. The single conductor shall be soft drawn, Class B, 19 strand, copper wire conforming to the current requirements of IPCEA S-61402, Part 2. All power cable shall be plainly marked on the outside of the insulation with the manufacturer's name and identification of the type of cable. 1) Polyvinyl chloride insulation shall be Type THHN-THWN and shall conform to the current requirements of IPCEA S-61-402, Paragraph 3.8, or Underwriters Laboratories Standard UL 83. The insulation shall be applied directly to and shall tightly fit the surface of the conductor. 2) The polyvinyl chloride insulation shall be color coded so that the AC(+) cable is black and the neutral cable is white. 9/1/2023
904-9
Traffic Control Facilities
3) The average thickness of insulation shall be as specified in Table I, with a minimum thickness of 90 percent thereof for insulation. Conductor sizes and thickness of insulation may be increased if approved by the Engineer.
TABLE I SINGLE CONDUCTOR POWER CABLE - TYPE THHN-THWN Conductor Size (AWG No.)
Insulation Thickness (Inch)
Maximum Outside Diameter (Inch)
6
.0625
0.33
4
.0625
0.38
3
.0625
0.41
2
.0625
0.44
904.3.2.2 Multi-Conductor Signal Cable. All signal cable shall be 600-volt, multiconductor cable, meeting the requirements of the current IMSA Specification 19-1. The conductors shall be No. 14 AWG, stranded copper wire, with color coded polyethylene insulation. The signal cable shall have a black polyvinyl chloride outer jacket and shall be plainly marked on the outside with the manufacturer's name and identification of the type of cable. 904.3.2.3 Ground Wire. A ground wire shall be used to ground each signal post, mast arm assembly and controller cabinet to a ground rod inside the nearest concrete pull box and shall be No. 6 AWG, 7 strand, soft drawn bare copper wire. The ground wire shall be mechanically connected to the ground rod. 904.3.2.4 Detector Loop Cable. Detector loop cable shall be installed in sawed slots as shown on the plans. The cable shall be 600-volt, single conductor, meeting the requirements of the current IMSA Specification 51-5. The conductor shall be No. 14 AWG, stranded copper wire, with Type THHN polyvinyl chloride thermoplastic insulation and a gasoline and oil resistant nylon jacket. The detector loop cable shall be furnished in a flexible polyethylene tube jacket for the full length of the cable. The tube jacket shall have a nominal 1/4 inch outside diameter and a minimum 30 mil wall thickness. The tube jacket shall have a smooth bore, resist abrasion and resist deterioration from oils and solvents. The detector loop cable shall have the manufacturer's name and identification of the type of cable plainly marked on the outside of the tube jacket. 904.3.2.5 Push Button and Detector Loop Lead-In Cable. This type of cable shall be 600-volt, two conductor shielded cable and twisted two to three turns per foot, meeting the requirements of the current IMSA Specification 50-2. The conductors shall be No. 18 AWG, stranded tinned copper wire with a color-coded polyethylene insulation. The cable
9/1/2023
904-10
Traffic Control Facilities
shall also be provided with a mylar-backed aluminum foil shield, a stranded tinned copper un-insulated drain wire over the twisted pair, and a polyethylene outer jacket. 904.3.2.6 Communication Cable for Accessible Pedestrian Signal Equipment This type of cable shall be 300 volts and have four (4) conductors. The conductors shall be No. 18 AWG, stranded thin copper wire, with polyvinyl chloride insulation (0.017 inch thick) color and/or number coded with a nylon overcoat. The communication cable shall have a black polyvinyl chloride outer jacket (0042 inch thick) and be plainly marked on the outside with the manufacturer’s name and identification of the type of cable. This communication cable shall be rated for outdoor use. The nominal outside diameter of the cable shall be approximately 0.309 inches. This communication cable is only to be used to connect the pedestrian push button detector to the control module in the pedestrian signal indication assembly. 904.3.2.7 Communication Cable for Traffic Signal Interconnect. 904.3.2.7.1 Fiber Optic Cable. The cable shall meet all requirements stated within. It shall be new, unused and of current design and manufacture. The fiber optic cable shall meet all requirements of ANCI/ICEA Standard for fiber optic outside plant communication cable S-87-640-2006, GR-20-CORE and the United States Department of Agriculture Rural Utilities Service (RUS) 7 CFR 1755 900 (PE-90). The cable shall be equivalent to Corning 036XU4-XXXXXD20 (30 single-mode, 6 multimode) with the first tube being 12 single-mode, followed by one (1) tube of 12 single-mode, followed by one (1) tube of 6 single-mode, followed by one (1) tube of 6 multimode, or as approved by the Engineer. All fibers in the cable must be usable fibers and meet the following specifications. 1) Multimode Fiber: The multimode fiber shall meet EIA/TIA-492AAAA-A-1997. “Detail Specification for 62.5 µm Core Diameter/ 125 µm cladding diameter graded-index multimode optical fibers. Core diameter: ........................................................................ 62.5 µm Cladding diameter: .................................................................. 125 µm Core to cladding concentricity: ................................................ ≤1.5 µm Coating diameter: ..................................................................... 250 µm Fiber type: ....................................................................... Graded Index Operating temperature: ......................-40 degrees C to +70 degrees C Attenuation @ 850 nm: ...................................................... ≤ 3.4 db/km @ 1300 nm: ........................................................≤1 db/km 2) Single-mode Fiber: The single-mode fiber utilized in the optical cable shall meet ITU G.652 (Tables A, B, C, & D), IEC Specification 60793-2-50 Type B1.3, EIA/TIA 492-CAAB and Telcordia Generic Requirements GR-20-CORE.
9/1/2023
904-11
Traffic Control Facilities
Typical core diameter: ............................................................... 8.2 µm Cladding diameter: .......................................................... 125 ± 0.7 µm Core to cladding concentricity: ................................................ ≤0.5 µm Coating diameter: ............................................................... 242 ± 5 µm Operating temperature: ......................-40 degrees C to +70 degrees C Attenuation uniformity:....... No point discontinuity greater than 0.05 dB at either 1310 nm or 1550 nm 3) The coating shall be a dual layered, UV cured acrylate applied by the fiber manufacturer. The coating shall be mechanically or chemically removable without damaging the fiber. 4) Optical fibers shall be placed inside a loose buffer tube. The nominal outer diameter of the buffer tube shall be 2.5 mm. The buffer tube shall be of polypropylene construction and contain up to 12-fibers. The fibers shall be colored with ultraviolet (UV) curable inks. Fillers may be included in the cable core to lend symmetry to the cable cross-section where needed. 5) The central anti-buckling member shall consist of a glass reinforced plastic rod. The purpose of the central member is to provide tensile strength and prevent buckling of the cable. The central anti-buckling member shall be coated with a thermoplastic material when required to achieve dimensional sizing to accommodate buffer tubes/fillers. 6) Each buffer tube shall contain a water-swellable yarn or water blocking element for water-blocking protection. The water-swellable yarn or water blocking element shall be non-nutritive to fungus, electrically non-conductive, and homogeneous. It shall also be free from dirt or foreign matter.
7) Buffer tubes shall be stranded around a central member using the reverse oscillation stranding process. Water-swellable yarn or water blocking element shall be applied longitudinally along the central member during stranding. Water blocking elements shall be applied uniformly throughout the buffer tube. 8) For single layer cables, a water-swellable tape shall be applied longitudinally around the outside of the stranded tubes/fillers. The water-swellable tape shall be non-nutritive to fungus, electrically non-conductive and homogenous. It shall also be free from dirt and foreign matter. 9) All dielectric cables (with no armoring) shall be sheathed with medium density polyethylene. The minimum nominal jacket thickness shall be 1.3 mm. Jacket material shall be applied directly over the tensile strength members and waterswellable tape. 10) The jacket or sheath shall be marked with the manufacturer’s name, the words “Optical Cable”, the year of manufacture, and sequential feet or meter marks. The markings shall be repeated every two feet. The marking shall be in a 9/1/2023
904-12
Traffic Control Facilities
contrasting color to the cable jacket. The height of the marking shall be approximately 2.5 mm. 11) The maximum tensile load for installation shall be 2700 N (608 lbf). 12) All optical fibers shall be proof-tested by the fiber manufacturer at a minimum load of 100 kpsi. All optical fibers shall be 100% attenuation tested. The attenuation test results of each fiber shall be provided with each cable reel. 904.3.3 Preformed Pull Box and Cover. 1) Each preformed pull box and cover shall be of gray color and be manufactured from reinforced polymer concrete materials. These materials shall consist of sand and gravel aggregates, bound together with a polymer and reinforced with continuous woven glass strands. 2) Each preformed pull box shall have a bolt down cover fastened by two (2) recessed, stainless steel hex head bolts. These bolts shall be aligned with two (2) stainless steel inserts set in the opposite corners of the pull box. 3) Each preformed pull box cover shall have a skid resistant surface with a recessed pull slot for removing the pull box cover. 4) Each preformed pull box shall have the words ST. LOUIS CO. TRAFFIC engraved in the cover. 5) The size of the preformed pull box to be installed shall be as specified in the contract or noted on the plans. The design of each size preformed pull box and cover shall be based upon the minimum load rating of the pull box and cover as specified on the following table. Size of Preformed Pull Box (Nominal Dimensions)
Min. Load Rating Over 10” Sq. Area
12”W x 12”L x 12”H ................................................................................. 8000 lbs. 13”W x 24”L x 18”H ............................................................................... 12000 lbs. 17”W x 30”L x 26”H (Minimum) .............................................................. 12000 lbs. 904.3.4 Concrete Pull Box Frame, Cover, Cable Hooks and Ground Rods. 1) Each concrete pull box frame and cover shall be cast iron conforming to the requirements of ASTM A 48, Class 30, and of the dimensions shown on the standard detail drawings. The weight of the cover shall range from 65 pounds to 85 pounds. The cover shall be scoriated, web reinforced and have the words TRAFFIC SIGNAL cast on the cover. A 3/4 inch diameter lift hole shall be provided in the cover. Each frame and cover shall be given one coat of a good quality commercially available selfetching primer followed by two coats of a quality commercially available rust preventative paint. The paint shall be black with a flat finish. 9/1/2023
904-13
Traffic Control Facilities
2) Cable hooks shall be galvanized steel and have a minimum diameter of 3/8 inch and a minimum length of six inches. The cable hooks provided shall be either pole steps or carriage bolts. 3) Each ground rod shall be copper clad, have a 5/8-inch diameter and be 10 feet in length (minimum). 904.3.5 Detector Loop Sealant. The detector loop sealant shall be a waterproof, polyester system with excellent adhesion to both concrete and asphalt substrate, whether damp or dry. The sealant shall be a self-leveling polyester system that flows easily into the sawed slots and blends into the surface of the pavement. Once applied, it shall cure to a durable, flexible compound protecting the detector loop against road abuse and seasonal thermal changes. The sealant shall cure at low temperatures and not be affected by freeze-thaw cycles, deicing salts, gasoline, or oil. Unless otherwise approved by the Engineer, the loop sealant shall be in conformance with the specific values described below: 1) The loop sealant shall be a polyester compound with excellent adhesion to both concrete and asphalt substrate. The sealant shall be pourable, self-leveling and capable of total encapsulation of detector loop wires. 2) The loop sealant shall have the following characteristics: Property
Specific Value
Shore D Hardness .................................................................................. 60 ±5 Tensile Elongation ............................................................................... 15-25% Tensile Strength ................................................................ 350 p.s.i. Minimum Compressive Yield Strength (Ultimate) ................................... 2000-3000 p.s.i. Salt Water Absorption (3% Solution) ...................................... 0.20% Maximum Oil Absorption ........................................................................ 0.02% Maximum Gasoline Absorption .............................................................. 0.80% Maximum Water Absorption ................................................................... 0.20% Maximum Freeze-Thaw Resistance ................................................................... Excellent 904.3.6 Concrete. Unless otherwise approved by the Engineer, materials, proportioning, mixing, slump, and transporting of portland cement concrete shall be in accordance with the applicable provisions of Section 501 for Class B concrete. 904.3.7 Reinforcing Steel. Reinforcing steel for concrete shall be deformed bars in accordance with the applicable provisions of Section 1036. 904.3.8 Signs and Striping. Permanent signing and striping materials for each signal installation shall be furnished and installed by Saint Louis County, unless otherwise noted on the drawings or specified in the contract.
9/1/2023
904-14
Traffic Control Facilities
904.4 Equipment. 904.4.1 Signal Head Assemblies. Each signal head shall be composed of one or more signal faces with each signal face composed of one or more signal sections. All signal head assemblies shall meet the following general requirements. 904.4.1.1 General Requirements. 1) Each signal section shall be a self-contained assembly consisting of a section housing, optical unit, terminal block, and all necessary gaskets to ensure a weatherproof unit. 2) If new signal sections are to be combined with existing sections, the new signal sections shall be adaptable to the existing. 3) Each signal face's horizontal alignment, arrangement, and location shall be as shown on the drawings. 4) Each signal head shall be assembled in a configuration and mounted in a manner which is in conformance with the standard detail drawings. All doors shall open to a 180 degree position to allow unobstructed access. 904.4.1.2 Signal Head Hardware. 1) Unless otherwise approved by the Engineer, all pipe and nipples used for assembling and mounting signal faces shall be Schedule 40 extruded aluminum pipe with a 1-1/2 inch nominal pipe size. The pipe and nipples shall be equal to aluminum alloy 6061-T6 and have a natural aluminum finish. Painting of pipe and nipples will not be permitted. 2) Unless otherwise approved by the Engineer, all terminal compartment housings and fittings, including elbows, tees, crosses, and hub plates, used for assembling and mounting signal faces, shall be aluminum and have a nominal pipe size of 11/2 inches. These fittings and terminal compartment housings shall be equal to either permanent mold castings of aluminum alloy 319.0-F, 356.0-T6, or Almag 35, conforming to the requirements of ASTM B 108, or sand castings of aluminum alloy 319.0-F, 356.0-T6, or Almag 35, conforming to the requirements of ASTM B 26. All fittings and terminal compartment housings shall be free from imperfections and have a natural aluminum finish. Painting of these items will not be permitted. 3) Unless otherwise approved by the Engineer, all pipe, nipples, elbows, tees, crosses, hub plates and terminal compartments shall have straight threads. One (1) stainless steel square or hex head set screw shall be furnished at each connection point in all elbows, tees, crosses, hub plates, terminal compartments and post top mountings to ensure rigid mounting. 4) Fittings which attach to the signal housing shall have either integral serrations or a serrated locking ring, both of which must be compatible with the 72 serrations on the signal housing. Serrated fittings shall be secured to the signal housing by a threaded collared nipple or by a threaded nipple with a hex nut. Upon request, the
9/1/2023
904-15
Traffic Control Facilities
signal head manufacturer shall submit a sample of their serrated locking ring to the Engineer for his approval. 5) Terminal compartments shall contain a double row barrier type terminal block with not less than twelve (12) points using No. 8-32 NC screws. The door to each terminal compartment shall be either aluminum or aluminum color impregnated plastic and held in place using two (2) stainless steel screws. 6) Each signal head installed on a mast arm shall be mounted using an astro-bracket with an in-line terminal compartment. The astro-bracket shall be banded or cabled onto the mast arm. The Contractor shall provide to the County the type of astrobracket and mounting hardware to be used prior to the installation of any signal heads for the County’s review and approval. The County has the sole right to approve, modify, or reject the astro-bracket proposed by the Contractor. a) Banded Astro-Bracket. The astro-bracket shall be equivalent to Pelco Standard Astro-Brac AB-3004-L. The astro-bracket shall be banded onto the mast arm using a 5/8 inch by 0.30-inch stainless steel banding and stainless steel mounting hardware. b) Cabled Astro-Bracket. The astro-bracket shall be equivalent to Pelco Standard Astro-Brac AB-3009-L. The astro-bracket shall be cabled onto the mast arm using a galvanized cable and stainless steel mounting hardware. 904.4.1.3 Signal Face Types. Each signal face shall be of the type designated in the contract or shown on the drawings. 904.4.1.3.1 Conventional Vehicle Signal Face. 904.4.1.3.1.1 Basic Construction and Mounting. Each 12-inch section housing shall be fabricated from ultraviolet stabilized color impregnated polycarbonate resin having back, sides, top and bottom integrally cast to form a single unit. It shall be clean, smooth, and free from imperfections. The signal housing and the lens door shall be black. Painting of signal sections will not be permitted. 1) The top and bottom ends of each signal section shall be of a ribbed construction so as to produce the strongest possible assembly consistent with light weight. 2) The top and bottom of each housing shall have an opening to accommodate standard 1-1/2 inch pipe fittings and brackets. Each opening shall have 72 integrally cast radial serrations to ensure positive locking of the sections. The connection between signal housings shall be weatherproof and capable of being directed at any angle in the horizontal plane in 5-degree increments. Housings shall be rigidly fastened together by a three-bolt assembly or other connectors approved by the Engineer. 3) A square housing door shall be suitably hinged and held securely to the body of the housing by corrosion resistant locking devices. Latching of the door shall be achieved without the use of special tools. All door hardware shall be of corrosion resistant material. Gaskets which will exclude dust 9/1/2023
904-16
Traffic Control Facilities
and moisture shall be used between the lens and the door. Either a gasket or an integral hood recess shall be used between the body of the housing and the lens door. 4) A minimum of two internal bosses shall be provided in each signal section for the mounting of a terminal block. 5) The mounting shall be as specified on the County's Standard Detail Drawing C904.10 and C94.20 904.4.1.3.1.2 Optical Unit Features. The signal indication module shall consist of a Light Emitting Diode (LED) unit. Installation into existing traffic signal housings built to the Institute of Transportation Engineers (ITE) Vehicle Traffic Signal Head standards shall be without modification to the housing and shall not require special tools. 1) The LED signal module shall have a smooth outside lens surface. The lens shall be uniformly tinted to enhance ON/OFF contrasts in a manner not to affect luminous intensity or chromaticity. The module shall be easily replaceable in the field without the need of any special tools. The module shall be marked to assure proper orientation to the housing. The lens material shall be ultraviolet (UV) stabilized polycarbonate to withstand direct sunlight exposure for a minimum of 5 years without evidence of deterioration. In no instance shall individual LED’s be visible in the field of vision when the signal section is energized. 2) The LED signal module shall be rated for continuous use in the ambient temperature range of -40 degrees C to +74 degrees C and be protected against dust and moisture intrusion. 3) The LEDs shall be indium based AllnGaP technology for red and yellow, and GaN for green. The LED signal module shall conform to ASTM specifications where applicable. Enclosure and lens shall have a minimum UL94-VO grade flame retardant material. Lens shall be made of UV stabilized material. 4) The LED signal module shall meet the minimum initial intensity requirements as defined in the latest edition and revision of the ITE Standards for Adjustable Face Vehicle Traffic Control Signal Heads. 5) The LED signal module shall conform to the chromaticity requirements of the latest edition and revision of the ITE Standard for Adjustable Face Vehicle Traffic Control Signal Heads. 6) Each LED signal module shall be provided with color coded No. 18 AWG stranded copper wire with insulation rated at 104 degrees C. The wiring shall be of sufficient length to extend, without splicing, to the terminal block located within each signal face with the module in a fully open position. The wiring leads shall be terminated with a spade tongue connectors for ease of connection to the terminal block.
9/1/2023
904-17
Traffic Control Facilities
7) The LED signal module shall operate from 80V to 135V at 100 Hz without perceptible flicker. 8) Transient voltage protection and fusing shall be provided to withstand high repetition noise transients and low repetition high energy transients per NEMA TS-2 specifications. 9) The LED drive circuitry shall be wired such that a failure of one LED will not result in the loss of more than 20% of the total LED signal illumination. The module shall be designed to sense a loss of light output due to LED failure of between 25% to 40%, upon which the unit shall present an impedance of 500 Kohms to the AC line. The LED signal shall be operationally compatible with traffic controller assemblies meeting the NEMA TS-2 Standards with the exception of dimming. 10) The LED on board circuitry must meet FCC regulations concerning the emission of electronic noise. 11) The warranty period shall be for 60 months of field operation for failure due to workmanship or material defects and minimum of 36 months for loss of more than 40% of the initial rated luminous intensity. Each LED signal module shall be identified on the backside with the manufacturer’s name and serial number. 904.4.1.3.1.3 Visors and Backplates. 1) A round tunnel visor shall be supplied with each signal section unless otherwise specified. Tunnel visors shall be polycarbonate, not less than 0.060 inches thick. The visors shall be a removable type held in place by either four snap-on tabs or by four fastening screws. The visors shall fit tightly against the door thereby not permitting any perceptible filtration of light between them and the housing doors. Visors shall be at least 10 inches long for all 12-inch signal sections. Visors shall angle downward not less than 3 degrees nor more than 7-1/2 degrees. Visors shall be black and color impregnated, with the underside flat black. 2) Backplates shall be provided for all signal heads as shown on the drawings or as specified in the contract. Backplates shall be black, color impregnated, weather resistant, and ABS type thermoplastic. They shall be one piece, 0.125 inch thick, vacuum formed with a 5/8-inch flange on all sides for rigidity and structural integrity and designed to fit each manufacture’s signal head precisely. Backplates shall be rigidly secured to each signal face with non-corrodible fasteners, as directed by the manufacturer. 904.4.1.3.2 Optically Limiting Vehicle Signal Face. An optically limiting vehicle signal face shall provide an indication to the selected field of view through the use of an electronic steerable beam providing a visibility zone of red, yellow, and green, without requiring louvers or other external blocking devices to achieve the end result. No indication shall result from external illumination, nor shall one section illuminate another. 9/1/2023
904-18
Traffic Control Facilities
904.4.1.3.2.1 Basic Construction and Mounting. Each 12-inch signal section housing shall be one-piece molded and manufactured from Ultra-Violet stabilized Makrolon 9417 or equivalent. It shall be clean, smooth, and free from imperfections. 1) Housings containing electronic components shall be made of ULV94VO flame retardant materials. The housings shall be a minimum of .090 inch thick and have a 5-inch square maximum opening in the rear. The opening shall accommodate a thermal transfer device that shall dissipate heat to the outside of the housing and physically connected to the LED’s within. The housing shall utilize ribbing to enhance the structural strength while reducing weight. The top and bottom exterior of the housing shall be parallel to ensure alignment of assembled section and shall have a common vertical centerline. The top and bottom of the housing shall have an opening to permit the entrance of 1-1/2 inch N.P.T fittings and standard traffic signal mounting hardware. The top and bottom opening of each housing section shall have 72 integrally cast radial serrations to allow proper joining of stacked sections to insure positive locking of the sections. 2) The door shall be a single molded piece with an integrated dome that eliminates the need for a lens/door gasket and shall be manufactured from Ultra-Violet stabilized new polymer resin. The door shall have two evenly spaced latch slots and shall pivot from the left side on stainless steel hinge pins. The door shall latch at the right side using stainless steel hardware and shall have four stainless steel threaded inserts for retaining the visor. The door shall be fitted with a gasket that will form a dust and moisture resistant seal between the door and housing. 3) Each section housing shall be predrilled for backplates. Each three, four, or five section signal head assembly shall be provided with a terminal block in the yellow indication compartment to provide a connection point for external wiring. The terminal block shall be barrier type, capable of accommodating up to 10 AWG wire on each terminal. The terminal block hardware shall be #8-32 x 5/16 (.3125) inch long binder head stainless steel screws. 4) External color of the housing shall be black, and completely impregnated in the resin material so that scratches will not expose uncolored material. 5) The individual LED light sources shall be wired so that a catastrophic failure of one LED light source will result in the loss of not more than 10 percent of the signal light output. 6) The mounting shall be as specified on the County's Standard Detail Drawing C904.10 and C94.20 904.4.1.3.2.2 Optical Unit Features. The optical unit for each 12-inch signal section shall consist of an objective lens, lamp, lamp collar, and optical limiterdiffuser. The optical unit shall be designed in conjunction with the visor to eliminate the return of outside rays entering the unit from above the horizontal. 9/1/2023
904-19
Traffic Control Facilities
1) The integrated dome shall be clear, circular, convex, scratch resistant, hard coated, and UV stabilized. The 12-inch dome shall have a diameter between 11-15/16 (11.9375) inches and 12 1/32 (12.03125) inches. The lens shall diffuse the light emanating from the LED’s to provide light disbursement across the outer dome. In no instance shall individual LED’s be visible in the field of vision when the signal section is energized. The optically limiting signal face shall be designed to allow the light output through the lens to be directed or steered into a specific viewing zone. Steering shall be accomplished electronically. The use of mechanical devices, tape, or masking to limit visibility shall not be allowed. The design of the optically limiting signal shall accommodate light output steering in both the vertical and horizontal direction. 2) Ambient light adjustment shall be provided and shall be designed to adjust the intensity of the light output in response to ambient light levels. Adjustments shall be accomplished in a smooth manner in response to ambient light levels and corresponding to two internal levels described as Day and Night. 3) Each signal section shall be installed, and optically aligned in accordance with manufacturer's instructions. 4) Manufacturer shall warrant the Optical Limiting Signal, to be free from defects in material and workmanship for a minimum of seven (7) years from date of shipment from the manufacturer. 904.4.1.3.2.3 Visors and Backplates. 1) A round tunnel visor shall be supplied with each signal section unless otherwise specified. Tunnel visors shall be polycarbonate, not less than 0.060 inches thick. The visors shall be a removable type held in place by either four snap-on tabs or by four fastening screws. The visors shall fit tightly against the door thereby prohibiting filtration of light between the visor and the housing doors. Visors shall be at least 10 inches long for all 12-inch signal sections. Visors shall angle downward not less than 3 degrees or more than 7-1/2 degrees. Visors shall be black and color impregnated, with the underside flat black. 2) Backplates shall be provided for all signal heads as shown on the drawings or as specified in the contract. Backplates shall be black, color impregnated, weather resistant, and ABS type thermoplastic. They shall be one piece, 0.125 inch thick, vacuum formed with a 5/8-inch flange on all sides for rigidity and structural integrity, and designed to fit each manufacture’s signal head precisely. Backplates shall be rigidly secured to each signal face with non-corrodible fasteners, as directed by the manufacturer.
9/1/2023
904-20
Traffic Control Facilities
904.4.1.3.3 Pedestrian Signal Face. 904.4.1.3.3.1 Basic Construction and Mounting. In order to facilitate installation and maintenance, the signal housing shall be designed so that all components are readily accessible from the front by merely opening the signal door. 1) Unless otherwise approved by the Engineer, the signal housing shall be fabricated from ultraviolet stabilized color impregnated polycarbonate resin having back, sides, top and bottom integrally cast to form a single unit. It shall be clean, smooth, and free from imperfections. The outside dimensions of the case shall be approximately 16 inches high x 18 inches wide x 9 inches deep. The signal housing, the lens door, and visor shall be black. Painting of the signal head will not be permitted. 2) The signal head shall be suitable for either post top or side mounting. The top and bottom of each housing shall have an opening to accommodate standard 1-1/2 inch pipe fittings and brackets. Each opening shall have 72 integrally cast radial serrations to ensure positive locking of the sections. Two corresponding serrated locking ring fittings shall be furnished with each signal case and shall be subject to the approval of the Engineer as specified in Section 904.4.1.2(4). The connection between signal housings shall be weatherproof and capable of being directed at any angle in the horizontal plane in 5-degree increments. Two caps shall be furnished to seal the openings on the top and bottom of each signal housing. 3) The signal housing shall be constructed in a manner that will also allow either right or left side mounting. Whenever side mounting is required, a side bracket shall be fastened to the housing with a watertight seal. Watertight seals shall also be provided on the side(s) of the head not used for mounting purposes. The side bracket shall have a natural aluminum finish and be designed for banding to either a signal post or a mast arm pole. A barrier type terminal block, furnished with not less than 5 points, shall be installed inside the side bracket on two bosses integrally cast in the bracket. The side bracket shall be designed to protect the terminal block from dust and moisture. 4) The rectangular signal door shall be fabricated from ultraviolet stabilized black color impregnated polycarbonate resin. The door shall be complete with hinge lugs and latch slots. All door hardware shall be of corrosion resistant material. Either a gasket or an integral hood recess shall be used to prevent dust and moisture from entering the signal housing. 5) Internal bosses shall be provided in the signal housing for the mounting of a terminal block and other internal components. 904.4.1.3.3.2 Optical Unit Features. The signal indication module shall consist of a Light Emitting Diode (LED) unit. Installation into existing traffic signal pedestrian housings shall be without modification to the housing and shall not require special tools.
9/1/2023
904-21
Traffic Control Facilities
1) The LED signal module shall have a smooth outside lens surface. The lens shall be uniformly tinted to enhance ON/OFF contrasts in a manner not to affect luminous intensity or chromaticity. The lens material shall be ultraviolet (UV) stabilized polycarbonate to withstand direct sunlight exposure for a minimum of 5 years without evidence of deterioration. In no instance shall individual LED’s be visible in the field of vision when the signal section is energized. 2) The LED signal module shall have a pedestrian interval countdown display to inform pedestrians of the number of seconds remaining in the pedestrian change interval. Countdown displays shall not be used during the Walk interval nor during the Yellow change interval of a concurrent vehicular phase. 3) The left half of the signal module shall have a Lunar white LED filled Walking Person symbol overlaid on a Portland orange LED filled Upraised Hand symbol, all on a black opaque background. The right half of the signal module shall have 9-inch high countdown numbers filled with Portland orange LEDs, all on a black opaque background. 4) The timing for the countdown pedestrian change interval shall be provided by the timing programmed in the traffic controller. Only two conductors (with ground), from the traffic controller back panel to the pedestrian signal head, shall be required to transmit countdown display timing. No separate timing device, independent of the timing programmed in the traffic controller, shall be required. 5) The LED signal module shall have a fuse and transient suppressor incorporated for line and load protection. 6) The LED signal module shall not have more than 20% harmonic distortion. 7) The LED signal module shall meet FCC Title 47, Subpar B Section 15 Regulations for Electric Noise. 8) The LED signal module shall conform to NEMA moisture resistance STD 250-1991 for Type 4 enclosures (ITE 6.4.6.2 Moisture Resistance) 9) The LED signal module shall be rated for continuous use in the ambient temperature range of -40 degrees C to +74 degrees C and be protected against dust and moisture intrusion. 10) The LED signal module shall operate between 80V to 135V. 11) The warranty period shall be for 60 months of field operation for failure due to workmanship or material defects and minimum of 36 months for loss of more than 40% of the initial rated luminous intensity. Each LED signal module shall be identified on the backside with the manufacturer’s name and serial number.
9/1/2023
904-22
Traffic Control Facilities
904.4.1.3.3.3 Visors. Each signal face shall be provided with a rectangular crate type visor designed to eliminate sun phantom. The material used in construction of the crate visor shall be ultraviolet stabilized black color impregnated polycarbonate plastic. The visor assembly may be either mounted to the signal door or be molded as an integral part of the signal door into a one piece assembly. 904.4.2 Aluminum Post with Square Pedestal Base Assembly Types. Aluminum post with square pedestal base assemblies shall be installed on either a Type C or Type P concrete base. 904.4.2.1 Aluminum Post with Square Pedestal Base Assembly on Type C Concrete Base. This type of assembly shall be used when a combination of vehicle signal heads, pedestrian signal heads, signage and pedestrian push buttons are design features. The assembly shall meet the following specifications: 1) The aluminum post shall be straight continuous Schedule 80 extruded aluminum pipe with a 4-l/2 inch nominal outside diameter. The post shall be equal to aluminum alloy 6061-T6 and have a spun finish. The post shall have tapered threads on one end to form a threaded connection with an aluminum base. A removable aluminum post cap, with stainless steel set screws, shall be provided when specified in the contract or noted on the plans. 2) The aluminum square pedestal base shall be free from imperfections and equal to either a permanent mold casting of alloy 319.0-F, conforming to the requirements of ASTM B 108, or a sand casting of alloy 319.0-F, conforming to the requirements of ASTM B 26. The pedestal base shall be approximately 15 inches high x 13-1/2 inches square and weigh a minimum of 20 pounds. The pedestal base shall have a natural aluminum finish. The handhole shall have a minimum 8-inch x 8-inch cover and be either cast aluminum or aluminum colored plastic. Painting of the pedestal base and handhole cover will not be permitted. The pedestal base shall have a 12-3/4 inch diameter bolt circle with the handhole designed to provide easy access to all wiring and anchor bolt nuts. A 1/4-inch x 3/4 inch - 20 NC stainless steel hex head bolt shall be used to fasten the handhole cover to the pedestal base. The top opening of the pedestal base shall be chamfered and have tapered threads to form a threaded connection with a Schedule 80, 4-1/2 inch nominal outside diameter post. 3) A post to base collar assembly shall be provided and designed to reinforce a pedestal post at the point where the threads enter the pedestal base. The reinforcing collar shall be a two or three-piece cast aluminum unit that clamps around the top of a pedestal base with socket head bolts. The reinforcing collar shall be supplied with a roll pin for holding the collar securely in place. The collar shall have an opening to be used for drilling a pilot hole for the roll pin. Welded connections shall not be allowed between the pedestal base and the post. 4) Anchor bolts shall conform to ASTM A-307 and have minimum yield strength of 36,000 psi. The bolts shall have a diameter of either 5/8 inches or 3/4 inches and be 18 inches long, plus a right angle hook having a minimum length of 2 inches. Minimum top four inches of each bolt shall be threaded. Each bolt shall be
9/1/2023
904-23
Traffic Control Facilities
furnished with a hex nut and washer. All anchor bolts, nuts and washers shall be hot dipped galvanized and meet the requirements of ASTM A-153. 5) Anchor bolts shall also include an additional aluminum alloy 6061-T6 washer, that shall be a four sided isosceles trapezoid with the following dimensions/characteristics: a) The washer shall be 5/16 inch thick. b) The upper base length shall be 1.5 inches. c) The lower base length shall be 5 inches. d) The base angle shall be 45 degrees. e) The height (perpendicular distance between the upper base and the lower base) shall be 2 inches. f) The corners of the base angle shall have a 3/16-inch radius. g) The geometric center of this washer shall have a 1-1/8 inch hole. 904.4.2.2 Aluminum Post with Square Pedestal Base Assembly on Type P Concrete Base. This type of assembly shall be used when pedestrian push button(s) and informational signage accompanying the push button(s) are the only design features. Vehicle signal heads, pedestrian signal heads or other types of signage will not be allowed on an assembly mounted on a Type P concrete base. The assembly shall meet the following specifications:
9/1/2023
1)
The aluminum post shall be straight continuous Schedule 40 extruded aluminum pipe with a 4-l/2 inch nominal outside diameter. The post shall be equal to aluminum alloy 6061-T6 and have a spun finish. The post shall have tapered threads on one end to form a threaded connection with an aluminum base. A removable aluminum post cap, with stainless steel set screws, shall be provided.
2)
The aluminum post with square pedestal base assembly shall be no greater than seven feet total height.
3)
The aluminum square pedestal base shall be free from imperfections and equal to either a permanent mold casting of alloy 319.0-F, conforming to the requirements of ASTM B 108, or a sand casting of alloy 319.0-F, conforming to the requirements of ASTM B 26. The pedestal base shall be approximately 10 inches high x 6-3/4 inches square and weigh a minimum of 7 pounds. The pedestal base shall have a natural aluminum finish. The handhole shall have a minimum 3-3/4 inch x 5-3/4 inch cover and be either cast aluminum or aluminum colored plastic. Painting of the pedestal base and handhole cover will not be permitted. The pedestal base shall have a 6-inch diameter bolt circle with the handhole designed to provide easy access to all wiring and anchor bolt nuts. A 1/4-inch x 3/4 inch - 20 NC stainless steel bolt and lock washer shall be used to fasten the handhole cover to the pedestal base. The top opening of the pedestal base shall be chamfered and have tapered threads to form a threaded connection with a Schedule 40, 4-1/2 inch nominal outside diameter post.
904-24
Traffic Control Facilities
4)
The post shall be secured to the base by means of a 5/16-inch x 3/4 inch x 7 inch long bolt with lock washer and nut. Set screws may be used in addition to the bolt but will not be an acceptable equivalent of the bolt. Welded connections shall not be allowed between the pedestal base and the post.
5)
A tether cable shall be attached to the bolt securing the post to the base and to one of the four anchor bolts. The tether cable shall be 18 inches total in length with loops on both ends large enough to slip over the anchor bolt but not the nut that secures the anchor bolt. The loops shall be securely fastened by cable clamps. A 5/8-inch flat washer shall be installed on top of the anchor bolt nut before the tether cable is attached. A second 5/8-inch flat washer shall be installed on top of the tether cable loop before the assembly is secured with a jam nut. All bolts, nuts and washers shall be hot dipped galvanized and meet the requirements of ASTM A-153
6)
The square pedestal base shall be equipped with a secure grounding lug.
7)
Anchor bolts shall conform to ASTM A-307 and have a minimum yield strength of 36,000 psi. The bolts shall have a diameter of 5/8 inches and be 18 inches long, plus a right angle hook having a minimum length of 2 inches. Minimum top four inches of each bolt shall be threaded. Each bolt shall be furnished with a hex nut and washer. All anchor bolts, nuts and washers shall be hot dipped galvanized and meet the requirements of ASTM A-153.
904.4.3 Steel Cantilever Mast Arm Assembly. 1) Each steel cantilever mast arm assembly shall consist of a pole and a cantilever mast arm with various accessory items, such as plates, fasteners, end caps, anchor bolts, and a handhole with removable cover. The assembly shall be designed to support rigidly mounted signals and signs without the use of tie rods, guy wires or other supports. 2) The pole shall have a round cross section. Each pole shall be made from not more than two sections of minimum seven (7) gauge, hot rolled steel, with a minimum yield strength of 50,000 psi. Not more than two longitudinal welds and no circumferential welds shall be permitted in the pole's shaft. All poles after being formed and welded shall be "cold worked" to insure roundness and straightness of the shaft. Unless otherwise approved by the Engineer, each pole shall be uniformly tapered from the bottom to top with a maximum taper of one inch in diameter for each seven feet in length (0.14 inches per foot). Unless otherwise indicated on the drawings or specified in the contract, the total height of each standard pole shall be 19 feet and the total height of each extended height pole shall be 28 feet. A removable corrosion resistant metal pole cap shall be provided on the top of each pole. A minimum four inch by sixinch handhole reinforcing frame shall be welded into each pole, complete with a removable corrosion resistant metal cover to facilitate entry. The center of the handhole shall be located approximately 18 inches above the pole's base and at either 90 degrees or 180 degrees with respect to the traffic signal mast arm. The extended height pole shall have an additional, similar sized handhole reinforcing frame welded into each pole at the same height as and at 180 degrees with respect to the traffic signal mast arm, complete with a removable corrosion resistant metal cover attached to the pole by a chain, to facilitate entry. A grounding lug or connector shall be 9/1/2023
904-25
Traffic Control Facilities
provided inside each pole at a location easily accessible from the lower handhole. The pole assembly shall be galvanized inside and outside and shall meet the requirements of ASTM A-123. 3) The cantilever mast arm shall have the same cross-sectional shape as the supporting pole. Each mast arm shall be made from one section of minimum seven (7) gauge, hot rolled steel, with a minimum yield strength of 50,000 psi. Only one longitudinal weld and no circumferential welds shall be permitted in the mast arm's shaft. All mast arms after being formed and welded shall be "cold worked" to ensure roundness and straightness of the shaft. Unless otherwise approved by the Engineer, each mast arm shall be uniformly tapered from the butt to the outer end with a maximum taper of one inch in diameter for each seven feet in length (0.14 inches per foot). Mast arm lengths shall be specified in 2 foot even increments as shown on the drawings or as specified in the contract. Mast arms 10 feet to 40 feet in length shall be one (1) piece arms. Mast arms 42 feet to 44 feet in length may be fabricated as two (2) piece arms, joined by a bolted telescopic connection. The bolted telescopic connection shall be shown in detail on the manufacturer's approved shop drawing. A removable corrosion resistant metal arm cap shall be provided on the outer end of each mast arm. The mast arm assembly shall be galvanized inside and outside and shall meet the requirements of ASTM A-123. 4) The seam welds on the supporting pole and mast arm shall be ultra high frequency resistant or of the submerged arc process. The welds shall insure 60 percent penetration and be rated at not less than 100 per cent of the yield strength of the steel. Each seam weld shall be smooth, straight and centered on its longitudinal axis. 5) The base, pole, arm and gusset plates shall be of adequate thickness, conform to ASTM designation A-36, and have a bolt spacing as specified on the County's Standard Detail Drawing C904.30, "Steel Mast Arm Assembly." The pole plate shall be tapped. All plates shall be galvanized and meet the requirements of ASTM A-123. The distance between the center of the mast arm connection and the top of the supporting pole shall be 12 inches. 6) Pole shaft, base plate, anchor bolts, mast arm, and structural connecting hardware, shall be designed in accordance with loading and allowable stress requirements of the 1994 AASHTO "Standard Specifications for Structural Supports for Highway Signs, Luminaires and Traffic Signals." Loading shall be based on an isotach wind velocity of 80 mph. Calculations and standard detail drawing shall be submitted by the manufacturer for verification of compliance to these specifications and to the dimensions and design criteria specified on the County's Standard Detail Drawing C904.30, "Steel Mast Arm Assembly." All calculations for mast arms 10 feet to 36 feet in length shall be made with a projected area of 24 square feet and a load of 175 pounds at the end of the arm. All calculations for mast arms 38 feet to 44 feet in length shall be made with a projected area of 24 square feet and a load of 160 pounds at the end of the arm. 7) Projection of the mast arm longitudinal center line, at the outer end of the mast arm, shall not deflect below the horizontal plane. This criteria shall be met when the structure is fully loaded, i.e., 175 pounds at the end of the arm for arms 10 feet to 36 feet in length, and 160 pounds at the end of the arm for arms 38 feet to 44 feet in
9/1/2023
904-26
Traffic Control Facilities
length. In no case shall the mast arm rise be more than 0.50 inches per foot in an unloaded condition. 8) A luminaire arm of a specified length shall be provided when indicated on the drawings or specified in the contract. The luminaire arm shall be a galvanized steel cantilever arm, with a plastic end cap bushing, and a steel bolted clamp assembly for attachment to an extended height mast arm pole. 9) Anchor bolts shall be fabricated from high strength steel having a minimum yield strength of 55,000 psi. The anchor bolts for mast arms 10 feet to 36 feet in length shall be 1-1/4 inches in diameter and 48 inches long, including a six-inch right-angle hook. The anchor bolts for mast arms 38 feet to 44 feet in length shall be 1-1/2 inches in diameter and 60 inches long, including a six-inch right-angle hook. Minimum top six inches of each bolt shall be threaded. Each bolt shall be furnished with two (2) hex nuts and two (2) washers. A minimum of one foot of the threaded end of each anchor bolt and all nuts and washers shall be hot dipped galvanized and meet the requirements of ASTM A-153. All anchor bolts shall be covered with corrosion resistant metal nut covers or acorn nuts. A 1/4-inch-thick steel template ring or welded cross member shall be furnished with each mast arm assembly. The template ring or cross member shall have a bolt circle of the same size as the bolt circle for the anchor bolts and it shall rest upon the right-angle hooks of the anchor bolts when permanently installed in the mast arm's concrete base. The use of a solid disc or plate as a template for the installation of anchor bolts will not be permitted. 10) Excluding anchor bolts, all fasteners with a bolt diameter of 1/2 inch or greater shall conform in material to ASTM A-325 and be hot dipped galvanized and meet the requirements of ASTM A-153. All fasteners with a bolt diameter less than 1/2 inch shall conform in material to ASTM A-307 and be electro zinc plated or conform in material to AISI 300 series and be stainless steel. 11) The cantilever mast arm assembly shall be handled in a manner to avoid damage to the galvanized surfaces. Any galvanized material on which the coating has been damaged shall be rejected or may, with the approval of the Engineer, be repaired in accordance with Section 712.14. 12) Manufacturers proposing to supply St. Louis County with steel cantilever mast arm assemblies are required to have on file with the County previously approved shop drawings for all assemblies with mast arms 10 feet to 44 feet in length, in 2-foot increments. Assemblies with mast arm lengths greater than 44 feet shall be fabricated in accordance with Missouri Department of Transportation (MoDOT) standards and specifications and the shop drawings shall be listed on MoDOT’s approved product list. 13) Prior to fabrication, the Contractor shall submit to the Engineer six (6) copies of the manufacturer’s steel mast arm assembly shop drawings. The shop drawings submitted by the Contractor shall be either the previously approved shop drawings on file with the County or listed on MoDOT’s approved product list as stated in Section 904.4.3(12). The shop drawings shall indicate the project name and the quantity and size of the mast arm assemblies being submitted for approval. Such approval shall 9/1/2023
904-27
Traffic Control Facilities
not relieve the Contractor of his responsibility under the contract or permit for successful completion of the work in accordance with the specifications. The copies of the shop drawings shall be submitted at least two weeks in advance of the Contractor’s need for approval. This time requirement for approval does not relieve the Contractor of his responsibility for delivery of each mast arm assembly within the time specified on the bid forms or with the permit. 14) St. Louis County’s previously approved shop drawings ensure that all mast arm assemblies with arms 10 feet to 44 feet in length be fabricated to provide interchangeability when an assembly is damaged or knocked down. The County will inspect all mast arm assemblies with arms 10 feet to 44 feet in length for interchangeability at the time of installation. If the assemblies are not deemed interchangeable in accordance with the County’s previously approved shop drawings, the arms and/or poles will be rejected in the field. 904.4.4 Wood Poles, Guys and Span Wire Assembly. 1) Wooden poles, as specified in Section 1050, shall be Class II wood poles or better. The length of wood poles shall be as shown on the plans. Guy wires, clamps, guards, stand off pipe, fittings, anchors, rods, concrete embedment, and other items used for the installation and support of wood poles shall be included as part of the installation of Class IV wood poles. a) Guy wire shall be 3/8-inch, high strength, 7 strand, double galvanized wire conforming to the requirements of ASTM A 475. b) Stand off guys, when specified, shall include a 2-1/2 inch diameter galvanized pipe with galvanized end fittings. The pipe shall be of sufficient length to allow positioning of the guy anchor at the location shown on the plans or at the location spotted in the field by the Engineer. c) Plastic guy wire guards shall meet the current requirements of the National Electrical Safety Code, Article 282, Paragraph E. Guy wire guards shall be yellow and made of high-density polyethylene or polyvinyl chloride (PVC) material. The material shall have excellent color retention, be ultraviolet stabilized, and have non-brittle properties. Guy wire guards shall be 8 feet long and be a full round design to cover the guy wire all around (360 degrees). The plastic guards shall be designed to resist upward movement when installed. If clamps are utilized to resist movement, they shall be hot dipped galvanized. d) Guy wire anchors in soil shall be 4-way, 10-inch diameter, expanding anchors with 3/4-inch galvanized thimble eye anchor rods which extend a minimum of 5 feet into the soil. Guy wire anchors in rock shall be 1-3/4 inch expanding anchors with 3/4-inch galvanized thimble eye anchor rods which extend a minimum of 2-1/2 feet into rock. 2)
9/1/2023
Each span wire assembly shall include a 3/8-inch steel span wire from which signal heads and cable are to be suspended and a l/4-inch steel tether wire for restraining bottom movement of signal heads. Also included shall be all clamps,
904-28
Traffic Control Facilities
cable straps, insulators and other items used for a span wire assembly installation, as shown on the standard detail drawings. The span wire and tether wire shall be high strength, 7 strand, double galvanized wire conforming to the requirements of ASTM A 475. All clamps shall be fabricated from low alloy steel. 904.4.5 Power Supply Assemblies. Each type of power supply assembly shall consist of a rainproof circuit breaker cabinet/panel, meter socket and all other necessary appurtenances except those furnished by the utility company or those separately listed in the contract or shown on the plans. Each assembly shall meet the approval of Ameren Missouri and the electrical code of the Saint Louis County Department of Public Works. All bi-metal connections shall be covered with a non-curing silicon paste used for sealing, lubricating, protecting, and insulating against water infiltration and arcing. 904.4.5.1 Type Mounted on Wood Pole. The wood pole type power supply assembly shall consist of a circuit breaker cabinet mounted below a meter socket on the side of a wood utility pole or wood span wire pole as shown on the plans or as specified in the contract. The circuit breaker cabinet shall be a 70 ampere minimum, a single phase, three (3) wire, 120/240 volt enclosure, with two (2) single pole 50 ampere circuit breakers. The circuit breaker cabinet shall be a suitably finished type 3R rainproof metal enclosure. The meter socket shall be aluminum, a 120/240 volt, ringless, five (5) terminal, five (5) jaw, 100 ampere minimum, overhead socket with a clamped jaw manual by-pass. The bottom of the meter socket glass shall be a maximum of 5-1/2 feet above finish grade, except over walkways where the bottom of the meter socket shall be 6-1/2 feet above the walkway. The power supply assembly shall also include the 2-inch PVC conduit, with an expansion fitting, mounted on the wood pole below the circuit breaker cabinet, ground rod, bare No. 6 AWG ground wire in 3/4 inch PVC, No. 6 AWG aluminum service entrance cable of sufficient length to reach utility company secondary and form a drip loop, and all power supply hardware. 904.4.5.2 Type Mounted on Steel Post with Concrete Embedment. The steel post type power supply assembly shall consist of a circuit breaker cabinet mounted opposite a meter socket on the web side of a W6x9 galvanized steel post embedded in concrete. The circuit breaker cabinet shall be a 70 ampere minimum, single phase, three (3) wire, 120/240 volt enclosure, with two (2) single pole 50 ampere circuit breakers. The circuit breaker cabinet shall be a suitably finished type 3R rainproof metal enclosure. The meter socket shall be aluminum, a 120/240 volt, ringless, five (5) terminal, five (5) jaw, 100 ampere minimum, overhead socket with a clamped jaw manual by-pass. The bottom of the meter socket glass shall be a maximum of 5-1/2 feet above finish grade, except over walkways where the bottom of the meter socket shall be 6-1/2 feet above the walkway. The power supply assembly shall also include the 2-inch PVC conduits mounted on the W6x9 galvanized steel post, concrete embedment with ground rod and bare No. 6 AWG ground wire, and all power supply hardware. 904.4.6 Traffic Actuated Controller. A traffic actuated controller is defined as the complete assembly of all required equipment and components for actuated control of traffic signal indications for all approaches to an intersection.
9/1/2023
904-29
Traffic Control Facilities
904.4.6.1 Controller Cabinet. Each controller cabinet shall be a weatherproof cabinet conforming to the following requirements. 904.4.6.1.1 Basic Construction. 1) Controller cabinets shall be 1/8-inch reinforced sheet aluminum alloy (5052H32). All controller cabinets shall be neat in appearance and sufficiently rugged to withstand normal usage. 2) All controller cabinets shall have all exterior and interior surfaces solvent cleaned. 3) A hinged main door shall provide complete access to the interior of the cabinet. A raintight gasket shall provide a tight fit between the door and the cabinet. (Foam Rubber Gaskets will not be accepted). The door shall be provided with a No. 2 cabinet lock that works in conjunction with the electronic door locking mechanism outlined in section 904.4.6.12. An auxiliary door, positioned on the main cabinet door, equipped with a raintight gasket, shall allow access to a switch panel, keypad, card reader and auxiliary power receptacle and shall be equipped with a lock whose key will not unlock the main door. Two keys shall be provided for each type of lock used. 4) The door hinges and pins shall be of corrosion resistant metal. Each pin shall be a solid rod, at least 1/8 inch in diameter. If continuous hinges are furnished, the pins shall be continuous the full length of the hinges and shall not be less than 1/16-inch diameter. Each door hinge shall be rigidly fastened to both the cabinet and the door. Fastening of hinges with sheet metal screws shall not be acceptable. 5) The main cabinet door shall be equipped with at least a two position stop and catch arrangement to hold the door open at positions of 90 degrees and 180 degrees, plus or minus 10 degrees. 6) The controller cabinet shall contain a minimum of three (3) strong reinforced mounting shelves to adequately accommodate the mounting and weight of the controller unit and all necessary ancillary equipment. The mounting facilities shall permit the controller unit and/or ancillary equipment to be withdrawn from the cabinet for inspection or maintenance without breaking any electrical connections or disrupting operation of the intersection. Screws used for mounting shelves or other mounting purposes (i.e., panels, wiring terminals, etc.) shall not protrude beyond the outside wall of the cabinet. 7) The controller cabinet shall contain one (1) pull out drawer assembly. The drawer shall be made of aluminum and be reinforced to adequately accommodate a notebook computer. The drawer shall have a lid that is hinged at the rear to gain access to the entire storage area. The drawer slides shall be of full extension ball bearing type. The drawer assembly shall be mounted on the left side of the cabinet, between the second and third shelves. The installation of the pull-out drawer assembly shall not block any terminal facilities. The drawer dimensions shall be 18 inches wide by 12 inches deep by 2 inches high. The mounting facilities shall permit the controller unit and/or 9/1/2023
904-30
Traffic Control Facilities
ancillary equipment to be withdrawn from the cabinet for inspection or maintenance without breaking any electrical connections or disrupting operation of the intersection. Screws used for mounting the drawer or other mounting purposes (i.e., panels, wiring terminals, etc.) shall not protrude beyond the outside wall of the cabinet. 904.4.6.1.2 Size and Mounting. 1) The controller cabinet shall provide space for housing all equipment and components. The size of the controller cabinet shall be as shown on the plans or as specified in the contract. 2) The controller cabinet shall be ground mounted. a) Mounting flanges for bolting each ground mount cabinet to a Type D concrete base shall be located inside the cabinet along the bottom perimeter. Mounting flanges located outside a ground mount cabinet shall not be acceptable. b) Anchor bolts for ground mount cabinets shall conform to ASTM A-307 and have a minimum yield strength of 36,000 psi. The bolts shall have a diameter of either 5/8 inches or 3/4 inches and be 18 inches long, plus a right angle hook having a minimum length of 2 inches. The bolts shall extend a maximum of 2-1/2 inches above the cabinet base and be threaded. Each bolt shall be furnished with a hex nut and washer. All anchor bolts, nuts and washers shall be hot dipped galvanized and meet the requirements of ASTM A-153. c) Anchor bolts shall also include an additional aluminum alloy 6061-T6 washer, that shall be a four sided isosceles trapezoid with the following dimensions/characteristics: • • • • • • •
The washer shall be 5/16 inch thick. The upper base length shall be 1.5 inches. The lower base length shall be 5 inches. The base angle shall be 45 degrees. The height (perpendicular distance between the upper base and the lower base) shall be 2 inches. The corners of the base angle shall have a 3/16-inch radius. The geometric center of this washer shall have a 1 1/8-inch hole.
904.4.6.1.3 Ventilation. 1) Each controller cabinet shall have an adjustable thermostatically controlled ventilating fan installed in the top of the cabinet. The fan shall have an exhausting capability, in an enclosure, of at least 100 cubic feet per minute. A 1/4 inch mesh screen shall be installed inside the cabinet as a guard covering the vent fan blades. The thermostat controlling the fan shall be manually adjustable to turn on between 90 degrees F (32 degrees C) to 150 degrees F (66 degrees C) with a differential of not more than 10 degrees F (5.5 degrees 9/1/2023
904-31
Traffic Control Facilities
C) between automatic turn-on and turn-off. calibrated in degrees shall be provided.
An easy to read dial setting
2) Each controller cabinet shall be supplied with a replaceable furnace type fiberglass filter mounted behind louvers and in the lower one fourth of the cabinet door or sides. The acceptable standard size filter to be provided shall depend upon the type of controller cabinet mounting and be as described below: a) In a ground mount controller cabinet, a 12-inch x 16-inch x 1-inch replaceable furnace type fiberglass filter shall be provided. 904.4.6.1.4 Special Switches, Sockets, Outlets, and Lights. All switches shall be permanently marked so that their identity and operation shall be readily apparent. 1) Each controller cabinet shall have only a two (2) position SIGNAL - FLASH switch mounted on the switch panel behind the auxiliary door to the main cabinet door. The switch shall be labeled as SIGNAL and FLASH. The two (2) positions of the switch and their functions are described below: a) SIGNAL - Power is supplied to the signal lights and their operation is controlled by the controller unit. b) FLASH - Signal lights are controlled by the flasher unit. The controller unit is operating with stop timing introduced. This stop timing shall be removed by either setting this switch back in the SIGNAL position or as specified below in 904.4.6.1.4(2). An input shall be put into the controller unit through the “D” harness, to show a local flash alarm. 2) Each controller cabinet shall have a switch provided inside the cabinet to put the signal lights into flashing operation with the controller unit remaining in operation without stop timing being introduced. Access to this switch shall be attainable only by opening the main cabinet door. This switch shall remove stop timing if it was previously introduced by the FLASH switch behind the auxiliary door. 3) Each controller cabinet shall have a switch provided inside the cabinet in an unobstructed area to remove power from the controller unit and malfunction management unit only without interrupting power to other controller features. Access to this switch shall be attainable only by opening the main cabinet door. 4) Separate push button momentary switches, with normally open contacts, shall be provided inside the cabinet in an unobstructed area to put calls into the controller unit for each actuated vehicle and pedestrian phase. If preemption phasing is shown on the plans or purchase order, then a push button shall be provided for each preemption sequence. The test push buttons shall feed a logic ground to the controller unit. 5) Each controller cabinet shall have a ground fault circuit interrupter (GFCI) duplex outlet in an unobstructed area inside the cabinet.
9/1/2023
904-32
Traffic Control Facilities
6) Each controller cabinet shall have two (2) Relume (or equivalent) traffic control box LED light panels. One panel shall be mounted inside the front of the cabinet above the door. The second panel shall be mounted on the bottom of the fiber termination housing using magnetic strips to allow removal of the fiber termination housing without the removal of the light panel. The two panels shall be powered by one 80 watt power supply. The power supply shall be provided and mounted in an unobstructed area inside the cabinet with a switch mounted so that the lights will be turned off when the door is closed. 7) Two (2) heat lamp sockets controlled by a thermostat which turns the lamps on at 40 degrees F (4 degrees C) and off at 60 degrees F (16 degrees C) shall be provided. A lamp rated at 150 watts, 120 volts shall be supplied with each socket. 904.4.6.2 Panel Wiring, Circuit Breakers and Relays. 1)
All wiring inside the controller cabinet shall be stranded and shall be neatly bundled and secured with plastic cable ties. Copper barrel lugs shall be provided for all field connections inside the controller cabinet. Insulated crimped-on connectors, one per wire, of an approved type shall be used for all other panel connections. The outgoing signal circuits shall be the same polarity as the line side of the power supply, and the common return of the signal circuits shall be the same polarity as the ground side of the power supply. The power supplied shall be provided through two single conductor cables unless otherwise indicated. The ground side of the power supply shall be carried throughout the controller in a continuous circuit and shall be secured to a ground bus bar in an approved manner. Sufficient terminals shall also be provided on the ground bus bar for the common return of all field and panel connections.
2)
Each controller cabinet shall be furnished with easily accessible wiring panel(s) of all metal construction sufficiently rugged to withstand normal usage. Unless otherwise approved by the Engineer, the back panel shall be so constructed, mounted, and wired so as to allow the panel to be swung forward and down to facilitate access to back wiring, without removing equipment or shelves. The backpanel shall be mounted a minimum of 4 inches from the bottom of the cabinet. As a minimum, the following barrier type terminal strips shall be provided on the panel(s): a) Terminals for all incoming power lines. b) Terminals and bases for signal load switches and outgoing field circuits. The following minimum number of load switch bases with sufficient terminals shall be provided: Size by Phase Designation
Min. No. of Load Switch Bases
Four Phase................................................................................... 8 Eight Phase ................................................................................ 16
9/1/2023
904-33
Traffic Control Facilities
c) Terminals and bases for all flash transfer relay(s) and outgoing signal field circuits. d) Terminals for all sensor and detector cables. e) Terminals for all special circuits which may be required to provide the operation shown on the signal plans. 3) All terminals shall be permanently marked so that their identity may be readily apparent. 4)
A surge arrestor shall be provided to block high speed transients and remove high energy surges from the incoming AC lines. The arrestor shall be designed for a peak current of 58.5 KA and a clamping voltage not to exceed 395 volts during surge. The arrestor shall provide protection from main neutral to ground as well as main line to ground. The surge arrestor shall be equal to EDCO #SHP 30010.
5)
A minimum 30 ampere line filter shall be installed on the incoming power line after the 30-ampere circuit breaker.
6)
The following minimum number of flashing field circuits complete with flash transfer relays shall be provided:
Size by Phase Designation
Min. No. of Flashing Field Circuits
Four Phase................................................................................... 6 Eight Phase .................................................................................. 8 All indications that are to be flashed on any single approach shall flash simultaneously. The load shall be equally distributed between the two outputs of the flasher whenever feasible. An unbalanced flashing load shall be subject to the approval of the Engineer.
9/1/2023
7)
The transfer relays that control the switching operation between the control mechanism and the flasher unit shall be designed to carry 10 amperes (tungsten filament load) per contact set. The socket for each flash transfer relay shall be equal to BEAU 5400 Series socket or TRW Cinch 2400 Series socket. All wiring must be soldered to sockets; push on terminal lugs are not allowed.
8)
The signal bus shall be connected to the incoming AC+ through a signal bus mercury contactor and be designed to carry a 30-ampere load. The current ratings specified are computed with a tungsten filament load. The signal bus mercury contactor shall be energized to provide power to the signal bus.
9)
Signal circuits shall not be controlled by relays. However, other circuits which require control by relays shall have relays which plug into an octal socket
904-34
Traffic Control Facilities
composed of high dielectric phenolic insulator material and cadmium plated brass contact material. The pin configuration of each socket shall be as follows:
Pin 1 ................. Moveable Contact
Pin 5 .........................N. C. Contact
Pin 2 ............................. Relay Coil
Pin 6 ........................ N. O. Contact
Pin 3 ........................ N. O. Contact
Pin 7 .............................. Relay Coil
Pin 4 ........................ N. C. Contact
Pin 8 ................. Moveable Contact
Pins 1, 3, and 4 shall constitute one contact set, and pins 5,6, and 8 shall constitute the other set. The relay contacts shall have a current rating of 1200 watts minimum per contact set, computed with a tungsten filament load. 10) The electrical connection(s) to the controller unit i.e., connectors A, B, and C, shall be made with quarter turn MS connector(s) as specified in the latest edition and revision of NEMA Standards Publication No. TS 2 Type 2, Traffic Control Systems. 11) The wiring harness(es) and harness connector(s) to the controller unit shall be complete, thereby including wiring for every pin in each connector. 12) A 15-ampere circuit breaker shall be provided to remove power from the cabinet light and ground fault circuit interrupter (GFCI) duplex outlet. A 30-ampere circuit breaker, with input in parallel with the above 15 ampere circuit breaker, shall be provided to remove all other incoming power. Each circuit breaker shall have an "On-Off" switch. 13) A CD containing the controller wiring diagrams for each signal installation and/or signal system shall be provided. The control wiring diagrams shall be in an electronic format compatible with MicroStation software. The diagrams shall be easy to read and match the cabinet wiring. All controller wiring diagrams shall be double referenced. Three paper copies of the controller wiring diagrams shall be provided for each signal installation and /or signal system. The controller wiring diagrams shall be prepared on a neat and clean 24 inch x 36 inch sheet(s) 904.4.6.3 Controller Phase Requirements. The phasing and interval sequence to be provided shall be as shown on the plans or as specified in the purchase order.
9/1/2023
1)
When the plans or purchase order specify a four phase actuated controller, an eight phase actuated controller unit shall be provided in the size cabinet specified and be completely wired for four vehicle phases, two pedestrian phases and two overlaps.
2)
When the plans or purchase order specify an eight phase actuated controller, an eight phase actuated controller unit shall be provided in the size cabinet specified and be completely wired for eight vehicular phases, four pedestrian phases and four overlaps.
904-35
Traffic Control Facilities
904.4.6.4 Actuated Controller Unit Features. The controller unit shall be a fully actuated controller unit with a full complement of operational, programming, and diagnostics capabilities. The controller unit shall meet or exceed both NEMA TS-1 1989 and TS-2 2003 Actuated Controller Unit Standards. The controller unit shall have an LCD alphanumeric backlit display unit (8-line 40 character/line). Programming shall use English language menus. The Controller can also be utilized as a master control unit using master software. An external 10 base-T Ethernet port with configurable IP shall be built in. 8MB of flash memory shall be required to retain all timing and control parameters even during power outages. The controller unit shall be capable of the following: 1)
16 vehicle phases
2) 3)
16 pedestrian phases 4 timing rings
4)
16 overlaps
5)
80 detectors
6)
Adaptive maximum routines
7)
Adaptive protected/permissive routines
8)
Coordination virtual split routine
9)
Diagnostics & status displays
10) Multiple reports 11) Peer to Peer communication 12) 4 phase banks that are programmable by time of day 13) Each phase shall have 2 Walk times and 2 Don’t Walk times that can be used in conjunction with the extended press feature. This feature shall be a standard component of the controller. Controllers updated with software to achieve this feature will be deemed as noncompliant to this specification. 904.4.6.4.1 Controller Unit Functional Standards. The following controller unit functional standards are required in addition to those specified in the latest edition and revision of NEMA Standards Publication No. TS 2 Type 2, Traffic Control Systems.
9/1/2023
1)
Each vehicle phase provided shall have volume-density capability.
2)
Dual ring controller units shall have the capability of dual entry operation without the use of external logic.
904-36
Traffic Control Facilities
904.4.6.4.2 Controller Unit Connector Pin Designations. Unless otherwise specified, all designated pins of the controller unit connectors shall be internally wired. The manufacturer shall not be allowed to internally wire the Reserved, Spare, and Test Input pins for any special use, unless otherwise approved by the Engineer. 904.4.6.4.3 Controller Unit Assembly Requirements. The actuated controller unit shall conform to the physical standards, as specified in the latest edition and revision of NEMA Standards Publication No. TS 2 Type 2, Traffic Control Systems, and to the assembly design requirements specified herein: 1)
The controller unit shall be designed for placement on a shelf.
2)
The front panel(s) of the controller unit shall be permanently marked to identify the fuses, indicators, switches, controls, etc., so that the operation of each shall be readily apparent.
3)
The controller unit shall be designed utilizing microprocessor based technology.
4)
The controller unit shall be modular by design. Modules shall be positively fastened to the frame and easily removed and replaced without the use of any special tools. An upper and lower guide or track shall be provided for each module assembly in the controller unit chassis. All modules of unlike function shall be mechanically keyed to prevent insertion into the wrong opening and subsequent damage to the controller unit.
5)
All connectors shall be front panel mounted.
6)
All switching functions shall be accomplished by fully solid state electronic circuitry.
7)
Timing shall be entered by a front panel keyboard and by computer. Easy to read keys shall provide either tactile or audio feedback.
8)
Menu driven programming shall be provided utilizing traffic engineering terminology prompts. Within a menu, each parameter shall be viewed for simple cursor control of data entries. Adding or changing data entries and instructions shall be accomplished without the use of an access code.
9)
During a power failure, no batteries shall be required to retain memory.
10) A minimum 8 line by 40 character, alpha-numeric, liquid crystal display shall be provided on the front panel of the controller unit. The display shall have adjustable contrast settings providing easy to read displays under all lighting conditions. The display shall provide comprehensive visibility of program entries, operational parameters, controller units, and the status of intersection operation. 11) All component parts and terminals shall be readily accessible when the boards are removed from the enclosure for adjustments, testing or maintenance.
9/1/2023
904-37
Traffic Control Facilities
12) All wiring for input and output functions shall be terminated on panel terminal strips. 13) Controller units shall have the capability to log and display critical alarms on the unit display. 904.4.6.4.4 Coordination. 1)
Coordination shall be an internal controller unit function which shall make it possible to incorporate actuated controllers into a coordinated system without seriously impairing individual controller flexibility.
2)
The controller unit of each actuated secondary controller shall have internal coordination which, if interconnected, shall respond to the individual cycle, reset, and mode of operation imposed by centrally located direct connect system or local Master Controller. The internal coordination of each actuated secondary controller shall impose control only upon the intersection where it is located.
3)
The controller unit of each actuated Master Controller shall have internal coordination which, if interconnected, shall supervise all pretimed and actuated secondary controllers within the system. The internal coordination of each actuated master controller shall also impose control upon the intersection where it is located.
4)
Coordination settings shall be entered and adjusted by the controller unit front panel keyboard without the use of an access code. Actuated controller units shall have internal coordination with the capability of being interconnected by the following methods:
5)
6)
9/1/2023
a)
Time base coordination.
b)
Fiber Optic
c)
Ethernet
Unless otherwise approved by the Engineer, internal coordination in actuated controller units shall have, as a minimum, the following functional features: a)
Four (4) adjustable cycle lengths.
b)
Three (3) offsets per cycle.
c)
Four (4) splits per cycle.
d)
Sync monitor.
e)
Shortway offset seeking.
f)
Automatic permissives/force-offs.
904-38
Traffic Control Facilities
7)
8)
Unless otherwise approved by the Engineer, internal coordination in actuated controller units shall have, as a minimum, the following capabilities: a)
Cycle length transfer.
b) c)
Reset transfer. Fully actuated operation.
d)
Semi-actuated operation.
e)
Fixed cycle length operation.
f)
Free operation.
g)
Permissive Mode
h)
Yield Mode
i)
Permissive Yield Mode
j)
Permissive Omit Mode
k)
Sequential Omit Mode
l)
Full Actuated Mode
Manually selecting any individual cycle, reset, or mode of operation in either actuated secondary or master controllers shall be achieved by utilizing the controller unit front panel keyboard.
904.4.6.4.5 Time Base Programming.
9/1/2023
1)
Time base programming shall include 250 Events for the control of Pattern Selection, Free, Flash, Dimming, Detector Diagnostic Parameters, System Detector Logging, 3 Auxiliary Functions, 8 Special Functions, 16 Traffic Functions, 99 Day Programs, and 10 Week Programs.
2)
Time base programming shall be an internal controller unit function which shall provide coordination in a signal system by establishing an extremely accurate time base that is uniform with all other time base coordinators in the system.
3)
All time base programming instructions, including time of day, day of week, and the operation of each output function, shall be entered, and adjusted by the controller unit front panel keyboard without the use of an access code.
4)
Changeover from standard time to daylight saving time, or vice versa, shall be accomplished automatically. Once the current year and week of year are entered, the changeover shall be accomplished at 2:00 a.m. on the Sunday morning specified by the present law.
5)
Automatic leap year adjustment shall be provided.
904-39
Traffic Control Facilities
6)
A capacitor back-up system shall be provided for maintaining timekeeping when 120 volts AC power is not available. This back-up system shall maintain timekeeping intact for not less than 48 hours when fully charged, and shall go online automatically upon failure of the primary power. When operating on the back-up system, the timing accuracy shall be plus or minus 4 seconds per 24 hours at worst case. Upon resumption of the primary power, the time base coordinator outputs shall immediately assume the configuration in which they would have been had power not been interrupted.
7)
The controller unit shall display the following as a minimum:
8)
a)
Time of day, either on a 24-hour format or a 12-hour (am/pm) format.
b)
Day of week.
c)
Status of each output (active or inactive).
d)
Cycle length in effect in seconds.
e)
All data required to verify programming prior to entry of an instruction.
During operation on the back-up system, the display shall be dark to conserve back-up power. The display shall be clearly illuminated during operation from the AC power line.
904.4.6.4.6 Preemption.
9/1/2023
1)
Preemption shall be an internal controller unit function. The controller unit shall be capable of providing a minimum of six (6) preemption sequences.
2)
All controllers shall be wired for preemption input and output functions from the controller unit to the back panel terminal strips.
3)
Preemption field wiring, relay(s), and a test push button for each preemption sequence shall be provided when preemption phasing is shown on the plans or purchase order. Preemption test button(s) shall be attached to a bracket and mounted to the preemption wiring panel.
4)
Upon actuation of preemption, the color sequence(s) specified shall be provided. After the preemption phase(s) have been released and cleared, normal operation shall be automatically resumed to the phase specified.
5)
Each interval of preemption shall be entered and adjusted by the controller unit front panel keyboard without the use of an access code.
6)
The controller unit shall display when a preemption sequence is actuated and when a preemption sequence has been released and cleared. The controller unit shall also display the status and value of each preemption phase and interval.
904-40
Traffic Control Facilities
904.4.6.5 Malfunction Management Unit. An external solid state management unit shall be provided as a standard cabinet feature and be capable of handling the total circuits The management unit shall comply with the latest edition and revision of NEMA standards publications No. TS2 Type 2, Traffic Control Systems including NEMA Amendment #42012. The management unit shall include a full intersection Liquid Crystal Display (LCD) along with the ability to communicate with a computer. Malfunction unit status, event logs, and signal sequence history logs shall be stored on nonvolatile memory for diagnostic and archival purposes. In the event of any incompatibility, the NEMA standards shall be superseded by the provisions described herein. 1)
Unless otherwise approved by the Engineer, only Type 16 management units shall be allowed: Size by Phase Designation
Minimum Acceptable Type Conflict Monitor
Four phase….………………………………… Type 16 (16 input channels) Eight phase…………………………………… Type 16 (16 input channels)
2)
If a conflict exists, the management unit shall cause the signals to go into emergency flash operation with stop timing applied simultaneously to the controller unit and an input shall be put into the controller unit through the "D" harness to show a conflict flash alarm. When the actual conflict has been cleared, a reset switch (front mounted) in the malfunction management unit shall return the controller to normal operation when depressed.
3)
The management unit shall be programmed by soldering jumpers on a printed circuit board for those inputs which are considered compatible. This card shall include a memory chip to transfer internal programming to a replacement management unit.
4)
Unless otherwise approved by the Engineer, the management unit must be capable of providing a visual indication of the following: a) Unsatisfactory operating voltages. b) Conflict. c) Red failure. d) Channels involved in conflicting signal indications. e) Channel(s) involved in red failure. f) LCD display of field indications.
5)
9/1/2023
Management unit shall be configured with Ethernet port and internet protocol capabilities.
904-41
Traffic Control Facilities
6)
Additional connector(s) on the management unit (i.e., other than the standard NEMA connectors and communications ports for the controller unit or computer) shall not be allowed, unless otherwise approved by the Engineer.
7)
The management unit shall be enclosed in a suitable finished case, be located on a shelf or partial shelf within the controller cabinet and have an integral power supply capable of handling the unit's requirements.
8)
All unused management unit wires shall be terminated on an easily accessible terminal block located on the back panel and all unused red inputs shall be tied to the signal buss power.
904.4.6.6 Solid State Load Switches. 1)
Provide a separate load switch for each vehicular phase, overlap, and pedestrian phase to switch power to all signal lamps required for the signal phasing shown on the drawings or as specified in the purchase order, including phases specified for future controller expansion. All load switches shall comply with the triple-signal solid state type load switch as specified in the latest edition and revision of NEMA Standards Publication No. TS 2 Type 2, Traffic Control Systems. The load switches shall be capable of handling a tungsten-lamp load of 10 amperes per circuit. All load switches shall have optically isolated solid state relay outputs. Dual signal type load switches shall not be allowed.
2)
The number of load switch bases to be provided shall be as specified in Section 904.4.6.2(2).
3)
Light emitting diode indicators shall be provided on the load switches to monitor the load switch inputs.
904.4.6.7 Flash Operation. 1)
Each controller shall be capable of dual flash operation. Dual flash is defined as follows: a) Internal time base or interconnect flash operation, which flashes Yellow-Red. b) Emergency flash operation (conflict monitor, police door, etc.), which flashes as follows: Intersection Signal ............................................... Flashes Red-Red Pedestrian Signal ................................................... Flashes Yellow Fire Station Signal ........................................... Flashes Yellow-Red Emergency flash operation shall override time base or interconnect flash operation.
2)
9/1/2023
Each controller shall be capable of being placed in flash operation by either an interconnect line or an internal time base.
904-42
Traffic Control Facilities
3)
The transition from normal operation to interconnect or internal time base flashing operation, and vice versa, shall be in accordance with the current edition and latest revisions of the Manual on Uniform Traffic Control Devices.
4)
In each controller the above transitions to and from interconnect line or internal time base flash operation shall be accomplished internally to the controller unit. Programmed flash is Yellow-Red.
5)
Flash operation shall also be obtained manually by utilizing either one of the two switches specified in Section 904.4.6.1.4. The flash transfer shall occur immediately and override interconnect line or internal time base flash.
904.4.6.8 Solid State Flasher Unit. The flasher unit shall be provided as a standard cabinet feature and be completely solid state and utilize digital design techniques. The flasher shall comply with the latest edition and revision of NEMA Standards Publication No. TS 2 Type 2, Traffic Control Systems. 1)
Each flasher shall be a Type 3 dual circuit flasher, capable of handling a tungstenlamp load of 15 amperes per circuit at a temperature of 165 degrees F (74 degrees C).
2)
The design shall be such as to simplify repair, utilizing only standard electronic components.
904.4.6.9 Traffic Signal Battery Backup System. The battery backup unit (BBU) shall be provided as a standard cabinet feature at all intersection signals. It shall be capable of providing power for signal operation for two hours or when 40% battery capacity is reached before putting the signal into emergency flash operation. The system shall be compatible with LED signal heads from different manufacturers.
9/1/2023
1)
The BBU shall have a minimum output rating of 1000 watts. The output voltage shall have a nominal voltage of 120 VAC and the output frequency shall be a regulated 60-hertz sine wave. The BBU shall operate in a temperature range of 40 degrees F to 165 degrees F.
2)
The minimum battery voltage will be 48 VDC using four 12VDC 33 amp hour batteries in plastic battery boxes, two batteries to a box. The battery charger shall be temperature compensated.
3)
When the AC line has failed, the BBU will supply power to keep the signal in operation for two hours or when 40% battery capacity is reached before putting the signal into emergency flash by breaking the controller voltage monitor input to the conflict monitor unit. The two-hour set point and the 40% battery power set point shall be user settable through the serial communications port. When the unit is running on battery operation, power will still be supplied to all equipment in the controller cabinet powered by the 30 amp circuit breaker.
4)
The front panel shall display battery charging, low battery or battery fault, unit processor fault, and unit running on battery. There will be dry contact outputs that
904-43
Traffic Control Facilities
mimic the front panel display. The output for running on battery will be wired to put an alarm into the controller unit when installed in a system cabinet. 5)
An automatic bypass switch shall be installed to keep power supplied to all equipment should the unit require service. Power to the bypass shall come from the output of the 30 amp circuit breaker. The Automatic Bypass Transfer Switch shall be a combination automatic/manual bypass switch.
6)
The unit shall have an Ethernet communications port that allows it to be monitored or configured from a remote location. The Ethernet port shall also serve as an alternative route for a technician to access, monitor, or manipulate configuration parameters on site.
7)
The unit shall be equipped to prevent a malfunction feedback to the cabinet or from feeding back to the utility service.
8)
The unit shall be equipped with an integral system to prevent the battery from destructive discharge or overcharge.
9)
The unit shall have an integral charger that is compatible with Gel and AGM battery technology. The charger shall be an intelligent charger with control systems that automatically incorporates bulk, absorption, and float charging modes.
10) The County shall be provided with a 4-year unconditional full replacement warranty for every battery purchased as part of a BBU system. Batteries must provide a minimum of 70% of their original capacity throughout the 4-year warranty period. 904.4.6.9.1 Approval of Battery Backup Systems. In order for manufacturers' battery backup system to be approved, the following requirements must be fulfilled, unless otherwise approved by the Engineer. 1) The manufacturers' equipment must satisfactorily meet the specifications as described herein. 2) The manufacturers' equipment must have been previously tested with satisfactory results by the Saint Louis County Department of Transportation. It shall be the prerogative of the Saint Louis County Department of Transportation to determine whether a new model of previously approved equipment will be accepted without retest. 3) The manufacturers' equipment must meet the subjective approval of the Saint Louis County Department of Transportation concerning the following: a) Appearance (suitable size of equipment and ease of installation). b) User friendly (ease of programming, accessibility for monitoring). c) Uniformity and Compatibility (ease of maintenance and convenient testing). 9/1/2023
904-44
Traffic Control Facilities
904.4.6.10 Unmanaged Ethernet Switch. An environmentally hardened (for an extreme environment) unmanaged network switch with external power supply shall be provided as a standard cabinet feature at all traffic signals. 904.4.6.10.1 Basic Requirements. 1) Environmentally hardened for extreme temperatures ranging from -40º C to 70º C 2) Shall work in a non-condensing humidity range of 5 to 95 %. 904.4.6.10.2 Port Configuration. The switch will have the following port configuration at a minimum: 1) Two SFP ports (100/1000X dual rate). 2) Ten RJ45 ports (10/100/1000Tx). 3) Two 155mbps Singlemode, 1310nm wavelength, 20km/ LC SFP transceivers shall be provided with each unmanaged Ethernet switch. a) Transceivers shall be temperature rated for -40˚ to +85˚C. 904.4.6.10.3 Power Supply. The power supply shall: 1) Operate from 85 to 260 VAC. 2) Output 24 VDC at 40 watts. 3) Have an operating temperature between -20 ºC and 70 ºC at 50% load and -20 ºC to 50º C at 100% load. 904.4.6.10.4 Installation. The switch and power supply shall be mounted on a panel utilizing a Din-Rail mounting system. The switch and power supply shall me mounted on the upper left side of the cabinet on the front most mounting rails. 904.4.6.10.5 Warranty. The unmanaged Ethernet switch shall come with a five year warranty and the power supply shall come with a three year warranty. 904.4.6.11 Singlemode Fiber Optic Patchcord. Singlemode patchcord(s) shall be Communication Supply Corporation part number 478727 or equivalent as approved by the Engineer with the following characteristics:
9/1/2023
1) Nominal Diameter:
8.2 µm
2) Number of Fibers:
2 (ZIPO)
3) Connectors:
Ceramic ST Connectors to Ceramic LC Connectors
4) Length:
≤ 2 meters
904-45
Traffic Control Facilities
904.4.6.12 Electronic Door Locking Mechanism. An electronic door locking mechanism is defined as the complete assembly of all required equipment and components necessary to monitor and control access to a controller cabinet by means of electronic methods. An electronic door locking mechanism shall be provided as a standard feature in all new cabinets or any signal modification project. 904.4.6.12.1 Lock Control Unit. 904.4.6.12.1.1 Basic Construction and Mounting. The lock control unit body shall be fixed-mounted on a surface inside the traffic signal controller cabinet. 904.4.6.12.1.2 Operational and Security Features. The lock control unit shall have features and abilities to meet the following specifications: 1) Validate or reject access codes. a) Access codes are entered by either keypad or swiping a radio frequency identification device card. b) A unique combination of tones and flashing light sequences shall indicate validation. c) Another unique combination of tones and flashing light sequences shall indicate rejection. 2) Operate electrical solenoid engage/disengage. 3) Provide a confirmation tone and light sequence upon engagement of the electrical solenoid. 4) Provide status indicators for: a) Power on or off b) Transmit or receive 5) Accept programming information from a central or remote location using the County’s traffic signal Ethernet network. 6) Report alarm messages using the County’s traffic signal Ethernet network. 7) Store up to 30 local event or alarms. 8) Record the following events with a date and time stamp: a) Authorized access with code
9/1/2023
904-46
Traffic Control Facilities
b) Unauthorized access with code c) Failed access with code d) Power restored e) Communications lost f) Communications restored g) Access code change event h) Door closed 9) Store up to 30 entry codes in one of the following format forms: a) Radio frequency identification device card. b) Keypad sequence c) Radio frequency identification device card with keypad sequence. 10) Information programmed into the lock control unit shall be stored using a hard memory. If the lock control unit loses power for any time period, all information and programmed data shall be retained. 11) When power is restored after a power outage event and an internal startup sequence is conducted, the lock control unit shall return to normal operation without any user intervention. 904.4.6.12.2 Card Reader with Keypad. 904.4.6.12.2.1 Basic Construction and Mounting. The card reader with keypad shall be installed in the auxiliary door of the main cabinet door. 904.4.6.12.2.2 Operational and Security Features. The card reader with keypad shall have features and abilities to meet the following specifications: 1) The card reader with keypad shall be a single unit. 2) Shall be water resistant. 3) Card reader shall be radio frequency identification device card compatible. 4) Keypad is a 10 digit keypad (zero through nine with a pound sign and an asterisk symbol).
9/1/2023
904-47
Traffic Control Facilities
5) Light indicators and tone generators shall be mounted on the interior of the auxiliary door of the main cabinet door. 6) Rated for outdoor cabinet environments with temperature range of -20 ⁰F to +150 ⁰F. 7) Access shall be granted by the lock control unit recognizing entry request from the following source(s). a) A valid radio frequency identification device card b) A valid keypad sequence c) A combination of valid radio frequency identification device card followed by a valid keypad sequences
904.4.6.12.3 Power Supply. The lock control unit is to be powered by a Power over Ethernet (PoE) single port passive injector with the following specifications: Voltage in .......................................................................... 110VAC Voltage out .......................................................................... 24VDC 904.4.6.12.3.4 Auxiliary Power Input. A flush mounted 110 VAC female power receptacle is to be installed to the right/left of the card reader/keypad as a means of providing external power to the lock control unit in the event of a power outage. The 110 VAC female power receptacle is to only power the components associated with the electronic door locking mechanism. 904.4.6.12.5 Electric Solenoid. A 24V electric solenoid shall be provided to work in conjunction with the Number 2 lock. The electric solenoid shall inhibit the number 2 lock from opening unless an approve code has been entered or a radio frequency identification device card has been swiped. In the case of a power outage the electric solenoid shall be programmed to fail closed. 904.4.6.12.6 Documentation. For all installations completed the Contractor shall have the wiring diagram for the controller cabinet modified to incorporate the electronic locking mechanism. 904.4.6.13 Power Strip. A ten outlet power strip shall be provided as a standard feature in all traffic signals and shall meet the following requirements: 904.4.6.13.1 Basic Requirements. 1) Shall be IP addressable. 2) Eight outlets can be individually switched remotely while the remaining two outlets cannot be switched. 3) The power strip can cycle the power to programmed outlets using an auto-ping monitor.
9/1/2023
904-48
Traffic Control Facilities
4) All ten (10) outlets shall be surge protected using a 3600 watt metal oxide varistor. 5) The power cord feeding the strip shall plug into the unit allowing easy replacement. 904.4.6.13.2 Security Features. 1) The power strip can be controlled via a simple web page or by menus on the unit itself. 2) The unit will be password protected for web access. 904.4.6.13.3 Installation. The power strip shall be mounted on the left side of the cabinet beneath the bottom shelf. The outlet strip shall be hard wired to M6B, NB1 & SG1, M6B shall also be wired to LF load using a 14awg wire. 904.4.6.14 Approval of Controller Equipment. In order for manufacturers' controller equipment, including panel wiring, to be approved, the following requirements must be fulfilled, unless otherwise approved by the Engineer. 1)
The manufacturers' equipment within the controller cabinet, including panel wiring, must satisfactorily meet the specifications as described herein.
2)
The manufacturers' equipment within the controller cabinet must have been previously tested with satisfactory results by the Saint Louis County Department of Transportation. It shall be the prerogative of the Saint Louis County Department of Transportation to determine whether a new model of previously approved equipment will be accepted without retest.
3)
Prior to approval of equipment within the controller cabinet, the Engineer shall be provided with a certification(s) by an independent testing laboratory stating that the equipment complies with the latest edition and revision of NEMA Standards Publication No. TS 2 Type2, Traffic Control Systems.
4)
The manufacturers' equipment within the controller cabinet, including panel wiring, must meet the subjective approval of the Saint Louis County Department of Transportation concerning the following: a) Appearance (suitable size of equipment, ease of reading functions and displays, neat arrangement of wiring panels). b) User friendly (ease of programming, accessibility for monitoring). c) Technician compatibility (ease of maintenance, convenient board testing and removal, state of the art board layout and design, accessible wiring panels).
904.4.7 Detectors. 904.4.7.1 Pedestrian Push Button Detector. The pedestrian push button detector shall be able to operate as either a standard push button detector or as an accessible pedestrian signal (APS). 9/1/2023
904-49
Traffic Control Facilities
904.4.7.1.1 Basic Construction and Mounting The pedestrian push button detector shall be vandal resistant, pressure activated piezo type, with momentary LED, a push button locator tone, and a tactile arrow with high visual contrast. The push button shall be connected to the controller cabinet by means of a two conductor cable as outlined in section 904.3.2.5. The detector shall be a removable contact assembly mounted in an aluminum round case. The back of each case shall be designed for mounting to a round pole. A 1/2 inch opening for cable shall also be provided in the back of each case. Holes shall be formed in the assembly case for mounting the push button unit. The operating button shall be sturdy, secure against electrical shock to the user, and of such construction as to withstand continuous hard usage. Push buttons shall be mounted forty-two (42) inches above the paved landing with the face of the push button parallel with the associated crosswalk. 904.4.7.1.1.1 Control Module The pedestrian push button detector shall be connected to a control module located in the pedestrian head assembly by means of a four conductor cable outlined in section 904.3.2.6. The control module shall be supplied by the same manufacturer of the pedestrian push button detector to ensure compatibility. The control module shall be installed per the manufacture’s recommendations. 904.4.7.1.2 Accessible Pedestrian Signal (APS) Features. Every pedestrian push button detector shall have the following specifications and features: 1) An accessible walk indication (a speech message or percussion tone) that runs concurrent with the pedestrian WALK signal indication shall be considered a standard feature. The accessible walk indication shall have the same duration as the pedestrian WALK signal indication except when the pedestrian signal rest in walk. If the pedestrian signal rests in walk, the accessible walk indication should be limited to the first 7 seconds of the walk interval. The accessible walk indication should be recalled by a button press during the walk interval provided that the crossing time remaining is greater than the pedestrian change interval. 2) A speech push button information message such as “wait” and / or “wait to cross Main Street”. 3) All tones, messages, and alerts shall be programmed by the manufacture per the plans, specifications and construction documents before the buttons are installed. 4) Speech messages shall be generated by an approved speech generating program. Project site recordings of speech messages will not be permitted. 5) All tones, messages, and alerts shall be in an uncompressed Waveform audio file format (WAVE or more commonly known as .WAV format due to its filename extension). 6) Be capable of utilizing the extended push button features outlined in the MUTCD.
9/1/2023
904-50
Traffic Control Facilities
904.4.7.1.3 Maintenance and Operational Features. The pedestrian push button shall have the following basic features. 1) The push button shall be designed in a way to allow the accessible walk indication to be programmed and electronically updated by means of an easily accessed and weatherproof USB Type A port. Programming and electronic updates shall have a layer of security that ensures only authorized personnel can program, update or access the audio features. The push button shall be designed to allow for bidirectional electronic transfer of all tones, messages and alerts in individual uncompressed .WAV files. 2) The push button shall be designed in a way to allow all APS features to be turned off. 3) Automatic volume adjustment in response to ambient traffic sound levels. 4) The operating voltage shall not exceed 24 volts. 5) The Circuit board(s) shall be potted. 6) The push button shall be designed in a way to facilitate the repair or replacement of components such as the speaker and circuit board with ease. 904.4.7.1.4 Pedestrian Push Button Detector Extension Assembly. A pedestrian push button detector extension assembly shall be a standard feature where an obstruction creates a horizontal side reach of more than ten (10) inches to the push button detector. 1) The pedestrian push button detector extension assembly shall be installed in accordance with standard detail drawing C904.20. 2) The pedestrian push button detector extension assembly shall be considered incidental to the cost of the pedestrian push button detector. No direct payment will be made for an extension assembly. 3) The pedestrian push button detector extension assembly should not exceed eight (8) inches in length. 904.4.7.1.4.1 Installation, Assembly, and Mounting. 1) The pedestrian push button detector extension assembly shall be banded onto the steel mast arm pole or aluminum post using a 5/8 inch by 0.30 inch stainless steel banding and stainless steel mounting hardware. 2) The push button case shall be attached to the extender plate weldment by means of two counter sink head bolts with flat washers, split lock washers, and hex head nuts. All bolts, washers and nuts shall be stainless steel. 904.4.7.1.5 Approval of Pedestrian Push Button Detector. In order for manufacturers' push button equipment to be approved, the following requirements must be fulfilled, unless otherwise approved by the Engineer. 9/1/2023
904-51
Traffic Control Facilities
1) The manufacturers' equipment must satisfactorily meet the specifications as described herein. 2) The manufacturers' equipment must have been previously tested with satisfactory results by the Saint Louis County Department of Transportation. It shall be the prerogative of the Saint Louis County Department of Transportation to determine whether a new model of previously approved equipment will be accepted without retest.
3) The manufacturers' equipment must meet the subjective approval of the Saint Louis County Department of Transportation concerning the following: a) Appearance (suitable size of equipment and ease of installation). b) User friendly (ease of programming, accessibility for monitoring). c) Uniformity and Compatibility (ease of maintenance, convenient board testing and removal, state of the art board layout and design,). 904.4.7.2 Vehicle Inductive Loop Detection System. 904.4.7.2.1 Card Rack Mounted Type. This type of vehicle inductive loop detection system shall have two (2) channels per card, be rack mounted, and be designed to employ digital techniques to the fullest extent. Card rack mounted inductive loop detectors shall be Type 7T detectors with relay outputs and comply with the latest edition and revision of the NEMA Standards Publication No. TS 2 Type 2, Traffic Control Systems. In the event of any incompatibility, the NEMA Standards shall be superseded by the provisions described herein. 1) The number of detector cards to be provided shall be as specified in the contract or shown on the plans. 2) When card rack mounted type inductive loop detectors are shown on the plans, the following minimum number of two-channel detector card positions shall be provided in the detector rack(s): Size by Phase Designation
Min. No. of Detector Card Positions Provided in Detector Rack(s)
Four Phase ........................................................................................ 4 Eight Phase........................................................................................ 8 Unless otherwise shown on the plans, detector card rack(s) shall not be required in controller cabinets used exclusively for fire station signals.
3) The following number of integral detector power supplies shall be provided in the detector rack(s):
9/1/2023
904-52
Traffic Control Facilities
Size by Phase Designation
No. of Integral Power Supplies in Detector Rack(s)
Four Phase ........................................................................................ 1 Eight Phase........................................................................................ 2 Each power supply shall have a minimum current rating of 0.75 amps per output. Each power supply shall be mounted on the left side of the detector cards it powers (front view) and be capable of supplying the power requirements of the detector card units.
4) The rack(s) shall be neat in appearance, and sufficiently rugged to withstand normal usage with each opening properly labeled. All hardware functions shall be permanently marked so that their identity and operation is readily apparent. The card rack shall be permanently and neatly wired in the cabinet (no removable connectors from the card rack to the back panel). There shall be enough slack in the wiring so the rack can be removed from the shelf and the back accessed without having to remove any wiring from the card rack or the back panel. Printed circuit boards shall not be accepted as part of the card rack assembly. 5) Adjustable, digital timed delay capability with delay override and call extension shall be incorporated on each channel of each detector card. 6) Each channel on each detector card shall be self-tuning. 7) Each channel on each detector card shall have a relay output with the relay coil energized for the "no call" condition. 904.4.7.3 Overhead Vehicle Video Detection Systems. 904.4.7.3.1. Camera System with Internal Processor. The number of cameras to be provided for each intersection overhead vehicle video detection system shall be as specified in the contract or shown on the plans. The camera system shall include fixed video camera(s), each with an internal Machine Vision Processor (MVP) sensor, an MVP cable and a universal mounting bracket. The camera system shall also include a communications interface panel(s), a power transformer panel(s), a detector port master, and a color monitor with a four-channel video switching unit, all of which shall be placed in the controller cabinet. The system shall be capable of producing accurate adjustable detection zones for individual lanes in all weather and lighting conditions. The system shall be equivalent to the Solo Terra manufactured by Autoscope, as approved by the Engineer. 1) Each camera shall be weatherproof and designed for outdoor use. The MVP sensor video camera shall combine an integrated high-speed, color imaging CCD array with zoom lens optics, image-processing hardware and a generalpurpose CPU bundled into a sealed enclosure. The sensor shall be equipped with a sunshield to reflect solar heat and to shield the CCD array and faceplate from direct exposure to the sun. The sensor shall also be equipped with a
9/1/2023
904-53
Traffic Control Facilities
faceplate heater to melt accumulated ice, snow, or condensation from obscuring the view of the camera. 2) The MVP sensor shall be an integrated imaging color CCD array with zoom lens optics, high-speed, dual-core image processing hardware bundled into a sealed enclosure. The CCD array shall be directly controlled by the dual-core processor, thus providing high-quality video for detection that has virtually no noise to degrade detection performance. It shall provide JPEG video compression as well as standard MPEG-4 digital streaming video with flashing detector overlay. The MVP shall provide direct real-time iris and shutter speed control. The MVP image sensor shall be equipped with an integrated 22x zoom lens that can be changed using either configuration computer software. The digital streaming video output and all data communications shall be transmitted over the three-wire power cable. 3) Each communications interface panel shall support up to eight MVPs. The communications interface panel shall accept 110/220 VAC, 50/60 Hz power and provide predefined wire termination blocks for MVP power connections, a Broadband-over-Power-Line (BPL) transceiver to support up to 10MB/s interdevice communications, electrical surge protectors to isolate the modular cabinet interface unit and MVP sensors, and an interface connector to cable directly to the modular cabinet interface unit. 4) One transformer to supply 24 VAC power to four MVP sensor video cameras shall be provided on an external panel as part of the communications interface equipment. 5) The detector port master provides a simple, reliable interface between any standard traffic controller and up to eight MVP sensors. It monitors phase colors and gathers detection information. The detector port master is a singlecard device that can stand alone or slide easily into a detector rack. Its advanced microcontroller-based communication circuitry passes real time detection states or traffic alarms as discreet detector outputs to a traffic controller. The real time detector outputs from the rear edge connector or front connector shall be fully compatible with existing loop detector systems. A 25 pin I/O harness shall also be furnished with each unit and be compatible with the front connector on the unit. The detector port master may also be inserted into a detector rack solely for power. 6) A 10-inch color monitor shall be provided to observe the operation of the vehicle video detection zones. The monitor shall have a minimum of 280 TV lines of resolution. The monitor must incorporate a universal power supply, allowing it to be compatible with a voltage range of 90 - 260 VAC (50/60 Hz). The power supply must be regulated to maintain excellent performance during fluctuations in line voltage. Power consumption must not exceed 50 watts. The monitor must have two looping composite video inputs. The video inputs must have auto termination circuitry. All user controls shall be conveniently located on the front panel and must include sharpness, tint, color, bright, contrast, volume +/-, input selection, and power on/off. The monitor must also have an indicator light for power. The monitor must have a heavy duty metal cabinet to protect the CRT and circuitry. The monitor must be able to operate 9/1/2023
904-54
Traffic Control Facilities
to full specifications within the normal temperature range of 0 degrees to 40 degrees C (32 to 104 degrees F). 7) A four channel video switching unit with quad output shall be provided to allow video from four cameras to be shown on the color monitor either individually or simultaneously. 904.4.8 Fiber Optic Termination Housing. The housing shall be suitable for under shelf mounting (to be mounted between the top of the back panel, and the bottom shelf) and be capable of mounting a minimum of 30 singlemode and 6 multimode hub ST type connectors. A minimum of 36 ST type connectors shall be installed in the housing. The housing shall have a splice tray kit capable of a minimum of 30 splices. It shall be capable of housing up to 48 fibers and provide for the stacking of fibers. It shall have ample room for feed through cable and provide strain relief for multiple cables within the unit. 904.4.9 Vehicle Video Detection Camera Mounts. 904.4.9.1 Camera Mount on Luminaire Arm. Each steel luminaire arm assembly for mounting a camera out from an extended height mast arm pole shall consist of a galvanized steel cantilever arm of a specified length. This assembly shall include a plastic end cap bushing and a steel bolted clamp for attachment to an extended height mast arm pole. A universal mounting bracket, for mounting a camera to the luminaire arm, shall be furnished with each camera. 904.4.9.2 Camera Mount on Post Extension. Each post extension assembly for mounting a camera higher than a mast arm pole shall consist of a 14 foot straight continuous Schedule 80 extruded aluminum pipe, with a 4-1/2 inch nominal outside diameter. The post shall be equal to aluminum alloy 6061-T6 and have a spun finish. This assembly shall include a removable aluminum post cap, with stainless steel set screws and mounting brackets for attachment to a mast arm pole. A universal mounting bracket, for mounting a camera to the post extension, shall be furnished with each camera. 904.4.9.3 Camera Mount on Mast Arm. Each pipe assembly for mounting a camera to a mast arm shall consist of a 6-foot straight continuous Schedule 40 extruded aluminum pipe, having a 1-1/2 inch nominal pipe size. The pipe shall be equal to aluminum alloy 6061-T6 and have a natural aluminum finish. This assembly shall include a plastic end cap, an astro-bracket for attachment to a mast arm, and a bracket for mounting a camera to the top of the pipe assembly. 904.4.10 Pan Tilt Zoom (PTZ) Internet Protocol Video Surveillance Camera. 904.4.10.1 PTZ Surveillance Camera. A PTZ camera shall be provided and installed on all intersection traffic signals installations and reconstruction projects, unless specified otherwise on plans. The PTZ camera shall meet the following minimum specifications: Imager Shutter Exposure Min. Illumination White Balance 9/1/2023
½.8” inch progressive scan CMOS 1/33000 s to 1/4s at 60HZ Auto 0.3 Lux (Color) 0.03 Lux (B/W) Auto
904-55
Traffic Control Facilities
Iris Gain Focus Zoom Ratio View Angle Focal Length F-Number Pan Angle Tilt Angle Memory
Auto Auto and Manual Auto 62.8 – 2.23 32x Optical; 12x Multiplier 57.2° - 1.7° 4.44-142.6 mm F1.6-4.41 360° 220deg 512mb ram, 128mb flash and up to 64gb SD/SDHC/SDXC Ethernet 100Base-TX/10BaseT (RJ-45) I/O Terminals None Resolution 1920x1080 (HDTV 1080) to 320 x 180 Compression MJPEG, H.264 Frame Rate Up to 50/60fps (50/60 Hz) in HDTV 720p Operating Software ONVIF-S compatible, AVHS (Axis Video Hosting System) Protocols TCP/IP, HTTP, FTP, SMTP, Bonjour, IPV4/IPV6 Power Req. High Power over Ethernet ((High POE) 60watt max. (supplied with camera) Operating Temp. -58° to +122° Fahrenheit Warranty 3 years 1) The PTZ Camera must be compatible with the current software utilized by St. Louis County at the time of installation. The contractor shall be responsible for contacting the St. Louis County Signal Shop at 314-615-0213 to inquire as to what software is currently utilized by St. Louis County. The PTZ camera shall be accessed and controlled by a Web Browser. Confirmation of Compliance with software shall be provided before construction begins. 904.4.10.2 PTZ Camera Mount on Post Extension. Each post extension assembly for mounting a camera higher than a mast arm pole shall consist of a 14-foot straight continuous Schedule 80 extruded aluminum pipe, with a 4-1/2 inch nominal outside diameter. The post shall be equal to aluminum alloy 6061-T6 and have a spun finish. This assembly shall include a removable aluminum post cap, with stainless steel set screws and mounting brackets for attachment to a mast arm pole. A mounting bracket, for mounting a PTZ IP camera to the post extension, shall be furnished with each camera. 904.4.10.3 Special Cables and Connections Needed For PTZ Camera. 904.4.10.3.1 Twisted Pair Video Communication Cable. Cameras shall be provided with a Video Communication Cable. The Cable shall meet the following specifications: Number of pairs Total Number of Conductors AWG Stranding Insulation Material Insulation Wall Thickness Outer Shield Material 9/1/2023
904-56
4 8 24 Solid PO – Polyolefin ≥ .010 in. Aluminum Foil-Polyester Tape Traffic Control Facilities
Outer Shield % Coverage Outer Shield Drain Wire AWG Outer Shield Drain Wire Stranding Outer Jacket Material Outer Jacket Ripcord Overall Diameter Operating Temperature Range Suitability – Outdoor Sunlight Resistance Oil Resistance Other Specification
100% 24 7x32 PVC – Polyvinyl Chloride Yes ≥ .265 in. - 40°C To +75°C Yes Yes Yes NEMA WC-63.1 Category 5e, UL verified to Category 5e
904.4.10.3.2 RJ45 Connectors. The Video Communication Cable shall have a shielded RJ45 connector attached to each end. One RJ45 connector shall then be connected to the Camera and the other to the factory supplied power injector. The RJ45 connector’s shielding shall be terminated to the twisted pair video communication cable’s outer shield drain wire. The remaining wires shall be installed according to the following wiring configuration: Wire 1 Wire 2 Wire 3 Wire 4 Wire 5 Wire 6 Wire 7 Wire 8
W/O O W/G BL W/BL G W/BR BR
904.4.10.4 Managed Ethernet Switch. An environmentally hardened (for an extreme environment) managed network switch with external power supply shall be provided when a PTZ camera is installed at a traffic signal. The cabinet shall be supplied with a Managed Ethernet switch, in lieu of unmanaged switch, as described in Section 904.4.6.10 if a PTZ camera is in place or a design feature. 904.4.10.4.1 Basic Requirements. 1) Environmentally hardened for extreme temperatures ranging from -40º C to 70º C 2) Shall work in a non-condensing humidity range of 5 to 95 %. 3) Manages redundant rings with the Spanning Tree protocol.
904.4.10.4.2 Port Configuration. The switch will have the following port configuration at a minimum: 1) Twelve SFP ports (100/1000 dual rate) 2) Eight RJ45 ports (10/100/1000 Tx) 9/1/2023
904-57
Traffic Control Facilities
3) Four (4) - 155mbps Singlemode, 1310nm wavelength, 20km/ LC SFP transceivers shall be provided with each managed Ethernet switch. a) Transceivers shall be temperature rated for -40˚ to +85˚C. 4) Two (2) - 1000mbps Singlemode, 1310nm wavelength, 20km/ LC SFP transceivers shall be provided with each managed Ethernet switch. a) Transceivers shall be temperature rated for -40˚ to +85˚C.
904.4.10.4.3 Power Supply. The power supply shall: 1) Operate from 85 to 260 VAC. 2) Output 24 VDC at 40 watts. 3) Have an operating temperature between -20 ºC and 70 ºC at 50% load and 20 ºC to 50º C at 100% load. 904.4.10.4.4 Installation. The switch and power supply shall be mounted on a panel utilizing a Din-Rail mounting system. The switch and power supply shall me mounted on the upper left side of the cabinet on the front most mounting rails. 904.4.10.4.5 Warranty. The managed Ethernet switch shall come with a five year warranty and the power supply shall come with a three year warranty. 904.4.11 Fiber Optic Cable Termination Cabinet. Each termination cabinet shall be a weatherproof cabinet conforming to the following requirement. 904.4.11.1 Basic Construction. 1) Termination cabinets shall be 1/8 inch reinforced sheet aluminum alloy (5052H32). All termination cabinets shall be neat in appearance and sufficiently rugged to withstand normal usage. 2) Termination cabinets shall have all exterior and interior surfaces solvent cleaned. 3) A hinged main door shall provide complete access to the interior of the termination cabinet. A rain tight gasket shall provide a tight fit between the door and the cabinet. (Foam Rubber Gaskets will not be accepted). 4) The door hinges and pins shall be of corrosion resistant metal. Each pin shall be a solid rod, at least 1/8 inch in diameter. If continuous hinges are furnished, the pins shall be rigidly fastened to both the termination cabinet and the door. Fastening of hinges with sheet metal screws shall not be acceptable.
9/1/2023
904-58
Traffic Control Facilities
5) The termination cabinet door shall be equipped with at least two position stop and catch arrangement to hold the door open at positions of 90 degrees and 180 degrees, plus or minus 10 degrees. 6) The termination cabinet door shall be provided with a No. 2 Cabinet lock and padlock hasp. The cabinet door handle shall be made of stainless steel. 7) Termination cabinets shall have a single back panel mounted on uni-strut rails. 8) Termination cabinets shall have one shelf mounted on uni-strut side rails. The shelf shall be the full width of the cabinet and have a minimum depth of 10 inches. 9) Termination cabinet shall have two 19 inch rack angles welded to the sides. 10) The termination cabinet shall have the following items supplied and installed as standard features: a) An Ethernet to RS232 (DB9) single port device server b) A media convertor – RS232 to 850nm multimode fiber with ST connectors c) An Ethernet surge protector configured for RJ45 connections. d) Cabinet Light e) Six outlet power strip f) GFIC protected outlet g) A power panel that includes two 15 amp breakers. The first breaker will power the surge protector and a 6 outlet power strip. The second breaker will power the GFIC protected outlet and cabinet light. h) A thermostatically controlled heater and fan. i)
Door switch bracket
j)
Top sunshield
k) All necessary cables and wiring required to interconnect the devices listed above l)
A fiber termination housing as detailed in section 904.4.8
All components dedicated to traffic signal communications shall be mounted to the right side of the termination cabinet.
9/1/2023
904-59
Traffic Control Facilities
904.4.11.2 Size and Mounting. 1) The termination cabinet shall provide space for housing all equipment and components. The size of the termination cabinet shall be 36 inches high, 24 inches wide, and 22 inches deep. 2) The termination cabinet shall be ground mounted. a) Mounting flanges for bolting each ground mount cabinet to a Type E concrete base shall be located inside the cabinet along the bottom perimeter. Mounting flanges located outside a ground mount cabinet shall not be acceptable. b) Anchor bolts for ground mount cabinets shall conform to ASTM A-307 and have a minimum yield strength of 36,000 psi. The bolts shall have a diameter of either 5/8 inches or 3/4 inches and be 18 inches long, plus a right angle hook having a minimum length of 2 inches. The bolts shall extend a maximum of 21/2 inches above the cabinet base and be threaded. Each bolt shall be furnished with a hex nut and washer. All anchor bolts, nuts, and washers shall be hot dipped galvanized and meet the requirements of ASTM A-153. 904.4.11.3 Ventilation. 1) Each termination cabinet shall be supplied with a replaceable furnace type fiberglass air filter mounted behind louvers and in the lower one third of the cabinet door. The air filter mounted behind louvers and in the lower one third of the cabinet door. The air filter shall be 12 inches by 12 inches. 2) A fan plate shall be bolted inside the cabinet by two ¾ inch stainless steel bolts. The fan plate shall be the full width of the cabinet and have a minimum depth of 4 inches. 904.4.12 School Zone Beacon Wireless Communication Equipment. The Contractor shall provide the following equipment for each location. One location shall be defined as encompassing two school zone beacons and one traffic signal. 904.4.12.1 Wireless Radio Communication Equipment. The Contractor shall provide three wireless radio communication devices to the County per location. The wireless radio communication devices shall meet the following specifications: Input Power
6-30VDC
Power Consumption
Master Repeater Remote
9/1/2023
Typical @ 24 VDC Normal
Low Current Mode
45 mA 76 mA 45 mA
9mA 9mA 9mA
904-60
Sleep Mode N/A N/A 7.56 mA
Traffic Control Facilities
Humidity
0-95% non-condensing
Enclosure Type
Milled aluminum
Warranty
5 years
Programming Port
RJ12
Inputs
Eight (8) ground activated
Outputs
Eight (8) digital open collector (max 500 mA load current per output)
Indicators
Power, input, output, link
Connector
Terminal block
Configuration software shall have the following functions: 1) Radio configuration 2) I/O mapping 3) Spectrum analyzer 4) Remote diagnostics and configuration 904.4.12.2 Antenna Assembly. The Contractor shall provide one antenna assembly to the County per location. The antenna assembly shall consist of a 900 MHz open spiral antenna housed in a ¾ inch PVC pipe. The pipe shall have a weather tight cap on the top and a Myers Hub on the bottom. The antenna assembly shall have a RP TNC-M connector. 904.4.12.3 Delivery of Equipment. The Contractor shall deliver the equipment, as listed in section 904.4.12.1 and 904.4.12.2 to the Department of Transportation’s Traffic Operations Building, Signal Shop, 2688 Adie Road, Maryland Heights, Missouri 63043, Phone (314) 615-0226. 904.4.13 Rapid Rectangular Flashing Beacon Assembly. A rapid rectangular flashing beacon assembly is defined as the complete assembly of all required equipment and components to provide actuated pedestrian crossing enhancements by means of flashing beacons and advisory signing. All rapid rectangular flashing beacon shall be solar powered unless dictated otherwise by construction plans and specifications. 904.4.13.1 Beacon Assembly. Each beacon assembly shall meet the following specifications: 904.4.13.1.1 General Requirements.
1) All equipment shall be weatherproof. 9/1/2023
904-61
Traffic Control Facilities
2) Each beacon assembly shall consist of two light bars that form an assembly to provide LED indications on both the front and back of the aluminum post. The assembly shall be designed for ease of removal and replacement. 3) LEDs shall be Yellow in color. 4) Each assembly shall conform to MUTCD interim approval IA-21 including the presence of a pilot light giving confirmation the beacon is in operation. 5) The beacon assembly shall be hardwired to the beacon control unit cabinet. 904.4.13.1.2 Size and Mounting. 1) The assembly shall be installed below the pedestrian sign and above the downward pointing arrow on the aluminum post and square pedestal base assembly. 2) The beacon assembly shall have the nominal dimension of 25 inches long, 10 inches deep and 5 inches in height. The nominal 10-inch depth implies all beacon assemblies will consist of two light bars placed back to back on the aluminum post. 904.4.13.2 Beacon Control Unit Cabinet. A beacon control unit cabinet is defined as the complete assembly of all required equipment and components to flash a beacon in an actuated manner. 904.4.13.2.1 General Requirements. 1) Each cabinet shall be a weatherproof cabinet. 2) Each control unit cabinet shall have the ability to communicate wirelessly with the same model cabinet on other aluminum posts within a 1000 foot range. 3) Each cabinet shall be supplied with the following features: a) A back panel prewired for ease of installation. b) Switches or dials to program the duration (in seconds) the beacon is scheduled to flash when actuated. c) Switches or dials that can modify the flashing pattern. A wig wag pattern and a simultaneous flashing pattern options shall be mandatory flashing pattern options. d) Controls that allow the beacons flashing duration to be modified as needed between a range of 7 seconds and one minute. e) Calendar with an internal time clock function f) The ability to select/change radio channels as necessary. Unit shall have a minimum of 10 channels to choose from g) Automatic dimming capability during nighttime hours h) Automatic intensity adjustment during bright daytime hours i) Necessary wireless communication equipment. j) Solar charging controller/regulator 9/1/2023
904-62
Traffic Control Facilities
k) AC power connection terminal l) Battery(s) specified by the manufacturer of the beacon assembly provided by the Contractor. Contractor shall provide certification the battery(s) provided are sufficient by means of a power budget evaluation specific for each site. 904.4.13.2.2 Basic Construction. 1) Each cabinet shall be ⅛ inch reinforced sheet aluminum alloy (5052-H32). All cabinets shall be neat in appearance and sufficiently rugged to withstand normal usage. 2) Cabinets shall have all exterior and interior surfaces solvent cleaned. 3) A hinged main door shall provide complete access to the interior of the cabinet. A rain tight gasket shall provide a tight fit between the door and the cabinet (foam rubber gaskets will not be accepted). 4) The door hinges and pins shall be of corrosion resistant metal. Each pin shall be a solid rod, at least ⅛ inch in diameter. If continuous hinges are furnished, the pins shall be rigidly fastened to both the cabinet and the door. Fastening of hinges with sheet metal screws shall not be acceptable. 5) The cabinet door shall be provided with a No. 2 cabinet lock and padlock hasp. The cabinet door handle shall be made of stainless steel.
904.4.13.2.3 Size and Mounting. 1) The cabinet shall provide space for housing all equipment and components. The size of the cabinet shall be 21 inches high, 16 inches wide, and 8 inches deep. 2) The cabinet shall be post mounted. a) Two U bolts shall be used to attach the cabinet to aluminum post b) The cabinet shall be mounted typically above the pedestrian signage as directed by the Engineer. 904.4.13.2.4 Ventilation. Ventilation shall be provided by means of louvers on the side or front of the cabinet.
. 904.4.13.3 Solar Panel 1) The solar array shall be rated for 80 W. 2) The solar modules shall have a weatherproof junction box. 3) The solar array shall not exceed a 31 inch width or 27 inch length.
9/1/2023
904-63
Traffic Control Facilities
4)
The solar array mount shall be a nominal 4 ½ inch diameter round top of pole mount recommend for use by the solar panel manufacturer.
5)
The array tilt angle shall be between 45 and 60 degrees facing true south in an un-shaded location.
904.4.13.4 Pedestrian Push Button Detector. The pedestrian push button detector
shall be vandal resistant, pressure activated piezo type, with momentary LED and audible alert using existing 2 conductor switch wires. The detector shall be a removable contact assembly mounted in a rectangular aluminum case. The operating voltage shall not exceed 24 volts. The back of each case shall be designed for mounting to a round pole. A 1/2 inch opening for cable shall also be provided in the back of each case. Holes shall be formed in the assembly case for mounting the push button unit. The operating button shall be sturdy, secure against electrical shock to the user, and of such construction as to withstand continuous hard usage. The push button case shall have a natural aluminum finish. Push buttons shall be mounted forty-two (42) inches above the paved landing with the face of the push button parallel with the associated crosswalk. 904.4.13.4.1 Push Button Cable. This type of cable shall be 600 volt, two conductor shielded cable and twisted two to three turns per foot, meeting the requirements of the current IMSA Specification 50-2. The conductors shall be No. 18 AWG, stranded tinned copper wire with a color-coded polyethylene insulation. The cable shall also be provided with a mylarbacked aluminum foil shield, a stranded tinned copper un-insulated drain wire over the twisted pair, and a polyethylene outer jacket. 904.4.13.5 Luminaire Arm with Light Fixture. The light fixture and luminaire arm shall meet the following specifications: 904.4.13.5.1 Luminaire Arm. The luminaire arm shall have a rounded hub plate on one end to facilitate the banding of the arm and plate to the aluminum pole in a secure manner. The arm shall also connect securely to the light fixture and provide a weatherproof connection. The arm shall not exceed two feet in length unless otherwise approved by the Engineer. 904.4.13.5.2 Light Fixture
1) Shall be white or similar colored LED fixture 2) Shall be equipped with an integral photocell that allow the light fixture to operate during a dusk to dawn timeframe. 3) Shall operate only in conjunction with the crosswalk beacon assembly using an on-board energy management system. 4) Shall not exceed 15 pounds in weight.
9/1/2023
904-64
Traffic Control Facilities
5) Shall have nominal dimensions of approximately 24 inches in length, 10 inches in width and 6 inches in height.
904.5 Construction Requirements. 904.5.1 Location of Existing Underground Facilities, Structures and Utilities. Existing underground facilities, structures, and utilities, if shown on the plans, shall be considered approximate only. Verification of the locations of all existing underground facilities, structures, and utilities, either shown or not shown on the plans, shall be the responsibility of the Contractor, and shall be verified prior to any grading, excavation, or construction of improvements. The Contractor/Developer shall contact Saint Louis County Department of Transportation, Traffic Operations personnel, at (314) 615-0215, a minimum of 48 hours in advance of construction work for locating and spotting existing traffic signal conduit. In the event the Contractor/Developer damages the conduit and/or cable, repairs shall be made at their cost, by an Electrical Contractor within 72 hours, as directed by Saint Louis County. 904.5.2 Location of New Concrete Bases, Pull Boxes and Detector Loops. The Contractor shall notify the Saint Louis County Department of Transportation, Traffic Operations personnel, at (314) 615-0226, when ready for the construction/installation of new concrete bases, pull boxes, and detector loops. This notice shall be a minimum of 48 hours in advance of construction work. The Contractor shall stake the locations of improvements, easements, and/or rights of way on the ground to facilitate the placement of the new traffic signal items. The Contractor shall not proceed with construction until Traffic Operations personnel have completed verifying the proposed location of the new traffic signal items. 904.5.3 Traffic Signal Construction in Solid Rock. If solid rock is encountered, all conduit, pull boxes, concrete bases and other roadway improvement items requiring excavation shall be installed, as directed by the Engineer. All costs for installing these items in solid rock shall be considered incidental to the contract prices bid for these items. 904.5.4 Construction of Concrete Bases. Concrete bases for pedestal posts, mast arm poles, and controller cabinets shall be located in accordance with Section 904.5.2 and conform to dimensions shown on the standard detail drawings. 1) The top surfaces of Type B, Type C, and Type P concrete bases shall be constructed flush with adjacent surfaced areas and be constructed to the elevations shown on the standard detail drawings in seeded or sodded areas. In seeded or sodded areas, the top surface elevations shall be constructed as shown on the traffic signal detail drawing C904.50. The height above sidewalk or a concrete pad of each Type D and Type E concrete base shall be as shown on the standard detail drawings. 2) Excavation for bases shall be made in a neat and workmanlike manner. Each base shall be formed from the top of the base to a minimum of 12 inches below finish grade. Forms shall be sufficiently rigid to prevent warping or deflection. The forms shall be level and held rigidly in place before and during the placement of concrete. 3) Concrete shall be Class B concrete in accordance with Section 501, or concrete of a commercial mixture as approved by the Engineer. Concrete shall be placed, finished, and cured in accordance with the applicable provisions of Section 703. Anchor bolts and conduit shall be carefully inspected and held rigidly in place before and during the 9/1/2023
904-65
Traffic Control Facilities
placement of concrete. The placement of anchor bolts and conduit shall be in accordance with the dimensions shown on the standard detail drawings. Vibration of concrete may be necessary to fill all voids. The Contractor shall be required to protect anchor bolt threads during the concrete operation. All concrete shall be removed from the threads immediately after finishing has been completed. The tops of all bases shall be finished level in a workmanlike manner. Backfill material shall be compacted around each base in layers not exceeding six (6) inches in depth. 4) Type B concrete bases shall be cured at least 72 hours prior to installing mast arms. Type C, Type D, Type E, and Type P concrete bases shall be cured at least 48 hours prior to installing pedestal posts and ground mount controller cabinets. 904.5.5 Construction of Concrete Pads. A four (4) inch thick concrete pad shall be constructed in front of each Type D and Type E concrete base or preformed type slip over controller cabinet base, when sidewalk is not provided. The size of the concrete pads shall conform to dimensions shown on the standard detail drawings. The top surface of each concrete pad shall be flush with adjacent surfaced areas and be approximately one (1) inch above seeded or sodded areas. Concrete pads shall be Class B concrete in accordance with Section 501, or concrete of a commercial mixture as approved by the Engineer. Concrete shall be placed, finished, and cured in accordance with the applicable provisions of Section 608. 904.5.6 Installation of Preformed Pull Boxes. Preformed pull boxes shall be located in accordance with Section 904.5.2 and conform to dimensions shown on the standard detail drawings. 1) A stone drain, consisting of one (1) inch clean gravel or crushed stone, shall conform to dimensions shown on the standard detail drawings and be constructed below each preformed pull box. Backfill material shall be compacted around each preformed pull box in layers not exceeding six (6) inches in depth. 2) The top surface of each preformed pull box shall be flush with adjacent surfaced areas. In seeded or sodded areas, a four (4) inch thick concrete apron twelve (12) inches wide shall be constructed flush around the perimeter of each preformed pull box. The concrete apron shall be approximately one (1) inch above adjacent seeded or sodded areas. Concrete aprons shall be Class B concrete in accordance with Section 501, or concrete of a commercial mixture as approved by the Engineer. Concrete shall be placed, finished and cured in accordance with the applicable provisions of Section 608. 904.5.7 Construction of Concrete Pull Boxes. Pull boxes shall be located in accordance with Section 904.5.2 and conform to dimensions shown on the standard detail drawings. 1) Each concrete pull box shall be cast in place in a neat and workmanlike manner. Inside surfaces of the pull box walls shall be formed. If the excavation is irregular, outside surfaces of the walls shall also be formed. An outside form shall be installed across trenches leading into the excavation for the pull box. The ends of all conduit through the walls of the pull box shall fit tightly against the inside form. Concrete shall be Class B concrete in accordance with Section 501, or concrete of a commercial mixture as approved by the Engineer. Concrete shall be placed, finished, and cured in accordance with the applicable provisions of Section 703.
9/1/2023
904-66
Traffic Control Facilities
2) The frame, cover and cable hooks shall be installed conforming to dimensions shown on the standard detail drawings. 3) A stone drain, consisting of one (1) inch clean gravel or crushed stone, shall conform to dimensions shown on the standard detail drawings and be constructed below each pull box. Backfill material shall be compacted around each concrete pull box in layers not exceeding six (6) inches in depth. 4) The top surface of each concrete pull box shall be flush with adjacent surfaced areas and be approximately one (1) inch above seeded or sodded areas. 5) A ground rod shall be placed inside each concrete pull box. The top of the ground rod shall be one (1) foot above the top of the stone drain. 904.5.8 Adjustment of Existing Concrete Pull Boxes. This work shall consist of adjusting an existing concrete pull box to finish grade. The existing cast iron frame(s) and cover(s) shall be removed in such a manner so as not to damage the concrete walls of the pull box below the existing frame(s). A concrete collar shall be formed and placed atop the existing pull box walls in a neat and workmanlike manner using Class B concrete in accordance with Section 501, or concrete of a commercial mixture as approved by the Engineer. Concrete shall be placed, finished and cured in accordance with the applicable provisions of Section 703. Unless otherwise approved by the Engineer, the concrete collar shall be tied to the existing pull box walls with #3 tie bars equally spaced as directed by the Engineer. The existing cast iron frame(s) and cover(s) shall be placed in the new concrete collar and shall be flush with adjacent surfaced areas and approximately one (1) inch above seeded or sodded areas. Any portion of the existing pull box that is damaged shall be repaired or replaced with new materials at the Contractor's expense. 904.5.9 Installation of Conduit. It shall be the Contractor’s option to install traffic signal conduit by the directional boring method, conventional trenching method, or conventional pushing method. The size of conduit to be installed shall be as specified in the contract or noted on the plans. The top surface of underground conduit shall be placed from a minimum of 18 inches to a maximum of 36 inches below finish grade, or a minimum of 12 inches below subgrade, unless otherwise shown on the plans or approved by the Engineer. A change in direction of conduit shall be accomplished by bending the conduit uniformly to a radius which will fit the location or by the use of standard bends or elbows, with approval of the Engineer. All conduit and fittings shall be free from burrs and irregularities. All conduit shall be cleaned and swabbed before cables are installed. All fittings shall be tightly connected to the conduit per the manufacturer’s recommended guidelines. Open ends of conduit placed for future use shall be capped or plugged with a rigid watertight cap. Conduit placed for future interconnect or future traffic signal cable shall contain an insulated, No. 16 AWG, stranded copper trace wire. All costs for the trace wire shall be considered incidental with no separate payment being made. Payment for furnishing and installing conduit will be based upon the unit price bid for the size of conduit and quantities shown on the Itemized Bid, regardless of the installation method chosen by the Contractor. 904.5.9.1 Conduit in Trench. All trenches shall be excavated to the width and depth necessary for conduit installation. No dirt or debris shall be placed in the street, nor shall it be placed on the sidewalk so as to leave less than three (3) feet of walkway available. Materials which might cause mechanical damage to the conduit shall not be used for backfilling below an elevation six (6) inches above the conduit. The bottom of the trench 9/1/2023
904-67
Traffic Control Facilities
shall be free of such materials before the conduit is placed. No conduit shall be placed without approval of the trench by the Engineer. All trenches shall be backfilled as soon as practicable. Backfill material shall be deposited in the trench in layers not exceeding six (6) inches in depth. Each layer shall be compacted to the approximate density of the adjacent material before the next layer is placed. Where excavation is made in parkways, tree lawns or other turfed areas, topsoil shall be replaced as nearly as practicable to its former condition with seeding and strawing operations, unless otherwise shown on the plans. Where excavation is made across planting beds, stabilized shoulders, or rocked areas, these materials shall be replaced in kind so as to restore the areas to their former condition. Where excavation is made in proposed sidewalk, roadway, or shoulder areas, or wherever prevention of backfill settlement is considered essential by the Engineer, the trench shall be backfilled with granular fill from a level of 6 inches above the conduit to finish subgrade. Red burial tape imprinted with “CAUTION – BURIED CABLE BELOW” shall be installed in all trenches at approximately one-third to one-half of the depth of the trench. Granular backfill shall consist of 3/4 inch minus crusher-run limestone (Designation MSD 3 Backfill). The entire area involved in trenching operations shall be left in a neat and presentable condition. All restoration costs shall be included in the unit price bid for the size of conduit installed, unless otherwise provided for as a separate pay item. All couplings, connectors, and elbows necessary for installing conduit in trench shall also be included in the unit price bid for the size of conduit installed. 904.5.9.2 Pushed Conduit. All pushed conduit shall be installed without disturbing the existing surface, unless otherwise approved by the Engineer. Pushed conduit may be placed by jacking, pushing, boring, or other approved means. Push pits and receiving pits shall be backfilled in the same manner as described for "Conduit in Trench" in Section 904.5.9.1. If any existing pavement, shoulders, sidewalk, or curbing is removed and replaced for installing pushed conduit, all restoration costs shall be included in the unit price bid for the size of conduit installed, unless otherwise provided for as a separate pay item. If concrete sidewalk or pavement is broken or removed, full slab replacement will be required. All couplings, connectors, and elbows necessary for installing pushed conduit shall also be included in the unit price bid for the size of conduit installed. 904.5.9.3 Directional Boring. Directional boring shall be used to install polyethylene (PE) duct and limit the disturbance of the existing ground surface. The boring machine shall be set up at locations which will minimize damage to existing improvements. An output signal shall be supplied inside the housing of the boring machine drill bit. The output signal shall be constant to allow a person to track the location of the drill bit at all times. The directional head shall be capable of accepting a variety of cutting bits for varied soil conditions. The operators of the boring machine shall check the bore path and make the necessary corrections to stay along the intended alignment. The boring machine shall be equipped with either water or a drilling fluid to facilitate drilling operations and the lubrication of the PE duct during pull-back. The Contractor shall make the necessary provisions to keep water and soil out of the new PE duct. Agents may be added to the water or drilling fluid to assist in holding the hole open during duct pull-back. If any existing pavement, shoulders, sidewalk, or curbing is removed and replaced to bore conduit, all restoration costs shall be included in the unit price bid for the size of conduit installed, unless otherwise provided for as a separate pay item. If concrete sidewalk or pavement is broken or removed, full slab replacement will be required.
9/1/2023
904-68
Traffic Control Facilities
904.5.9.4 Conduit in Doweled-On Concrete Median. When 1 inch conduit in a doweledon concrete median is specified for detector loop installations, the conduit shall be installed in conformance with the standard detail drawings. Most of the conduit shall be laid on the surface of the pavement prior to construction of the concrete median. One end of the 1 inch conduit shall be connected to a pull box in the proposed median. The other end of the conduit shall be installed by embedding a minimum 12 inches of conduit in the pavement below the edge of the proposed median. After constructing the median and removing concrete forms, cut the conduit flush with the face of the median below finish grade and remove the excess conduit. The open end of the conduit located below finish grade at the face of the median shall be cleaned and temporarily sealed with "duct" seal or an equivalent removable sealant. 904.5.9.5 Conduit on Wood Pole. If conduit on wood pole is specified, the conduit shall be PVC and installed in a straight, neat, and workmanlike manner. The conduit shall be supported by conduit clamps at a maximum spacing of four (4) feet. Conduit extended to near the top of a wood pole shall be capped with an approved entrance head fitting and positioned to allow for formation of a drip loop in the entering cable. Conduit extended to the base of a wood pole for either one (1) or two (2) detector loops shall include a 6 inch x 6 inch x 4 inch weatherproof PVC junction box with a screw down cover. This box shall be mounted to the wood pole approximately 18 inches above finish grade. All couplings, connectors, elbows, tees, hubs, clamps and access fittings necessary for installing conduit on a wood pole, including the above referenced PVC junction box with a screw down cover, shall be included in the unit price bid for the size of PVC conduit on a wood pole. 904.5.9.6 Conduit Repair. The Contractor shall locate broken conduit (PVC, steel, or PE duct), excavate, remove existing cable, repair/replace conduit, reinstall/replace cable, backfill and restore area. Payment for this work will be as specified in the contract or noted on the plans. If existing pavement, shoulders, sidewalk, or curbing is removed and replaced for a conduit repair, the cost for this work shall be provided for as a separate pay item(s). If concrete sidewalk or pavement is broken or removed, full slab replacement will be required. 904.5.10 Connecting Conduit to Existing Concrete Pull Boxes. This work shall consist of connecting new conduit to an existing concrete pull box as indicated on the plans. An opening for the new conduit shall be drilled through the wall of the existing concrete pull box at a minimum of 18 inches below finish grade. The new conduit shall be properly fitted in place and extend a minimum of two (2) inches from the inner face of the pull box. After the conduit is in place, the opening around the conduit shall be sealed watertight in an approved manner. Any portion of the existing pull box that is damaged shall be repaired or replaced with new materials, at the Contractor's expense. 904.5.11 Installation of Signal Posts and Mast Arm Assemblies. Each steel mast arm pole and aluminum post with a square pedestal base shall be securely fastened to a concrete base with anchor bolts. 1) Aluminum posts with square pedestal bases shall be erected vertically without the use of leveling nut. Washers as specified in Section 904.4.2.1(5) can be used for securing the square pedestrian base. Each square pedestal base shall be positioned so the handhole cover is located adjacent to a sidewalk or walkway where such paved areas exist.
9/1/2023
904-69
Traffic Control Facilities
2) Steel poles for cantilever mast arms shall be installed plumb by adjustment of leveling nuts. Poles for cantilever mast arms may be raked only when approved or directed by the Engineer. 3) All mast arm assemblies shall be grounded by a No. 6 AWG, 7 strand, bare copper wire from a grounding lug inside each mast arm assembly to a common ground provided by a ground rod in the nearest concrete pull box. 4) All signal post assemblies shall be grounded by a No. 6 AWG, seven strand, bare copper wire between two flat washers attached to one of the base mounting bolts to a ground provided by a ground rod inside the nearest concrete pull box. The flat washers shall be hot dipped galvanized and meet the requirements of ASTM A-153 904.5.12 Installation of Wood Poles, Guys and Span Wire Assemblies. Wood poles, guys and span wire assemblies shall be installed as shown on the plans and in accordance with the standard detail drawings. 1) Wood poles shall be Class II or better and installed a minimum of 7 feet below finish grade. The depth shall be increased one (1) foot for each five (5) foot increase in length above 35 feet. 2) Upon installation of guy wires, a yellow plastic guy wire guard, as specified in Section 904.4.4(1.c.), shall be installed on each down guy. 3) Stand off guys, when specified, shall be installed with the stand off pipe a minimum of ten (10) feet above finish grade. The stand off pipe shall be of sufficient length to allow positioning of the guy anchor at the location shown on the plans or at a location spotted in the field by the Engineer. 4) When a wood pole in concrete embedment is required, a three (3) foot diameter hole shall be drilled. Loose material at the bottom of the hole shall be either removed or compacted to the approximate density of the adjacent material. A masonry block shall be placed at the bottom of the hole upon which the pole shall be set. Concrete embedment shall be poured around the pole up to a level 24 inches below finish grade. The concrete shall be Class B concrete in accordance with Section 501, or concrete of a commercial mixture as approved by the Engineer. Concrete embedment around the wood pole shall be cured at least 72 hours prior to the wood pole being subjected to concentrated loads. The remaining 24 inches below finish grade shall be backfilled and compacted in layers not exceeding six (6) inches in depth. 5) Guy wires, clamps, guards, stand off pipe, fittings, anchors, rods, concrete embedment, and other items used for the installation and support of wood poles shall be included in the unit price bid for Class II wood poles. 6) The span wire assembly shall be installed at a sufficient height to provide a minimum clearance of 16' and a maximum clearance of 19' to each signal head assembly. 7) Span wire, tether wire, clamps, cable straps, insulators and other items used for installation of a span wire assembly shall be included in the lump sum price bid for span wire assembly.
9/1/2023
904-70
Traffic Control Facilities
904.5.13 Installation of Power Supply Assemblies. Each power supply assembly shall be installed in accordance with the standard detail drawings. The location of each power supply installation shall be coordinated with Ameren Missouri and other utilities as required. 904.5.13.1 Type Mounted on Utility Pole. Each power supply mounted on a utility pole shall be installed within the pole quadrant specified by Ameren Missouri and in accordance with the standard detail drawings. The bottom of the meter socket glass shall be a maximum of 5-1/2 feet above finish grade, except over walkways where the bottom of the meter socket shall be 6-1/2 feet above the walkway. 904.5.13.2 Type Mounted on Steel Post with Concrete Embedment. The location of each power supply base shall be determined by the location of the underground service provided by Ameren Missouri. The top of the embedded concrete base with steel post shall be flush with adjacent surface areas and be constructed to the elevations shown on the standard detail drawings. The bottom of the meter socket glass shall be a maximum of 5-1/2 feet above finish grade, except over walkways where the bottom of the meter socket shall be 6-1/2 feet above the walkway. 904.5.14 Installation of Signal Heads. All signal head assemblies shall be constructed and installed in accordance with the standard detail drawings, unless otherwise approved by the Engineer. 1) The vertical clearance to the bottom of an overhead signal head assembly shall be at least 16 feet but not more than 19 feet above the roadway. 2) Within the limits of normal vertical clearance, signal heads shall have a horizontal clearance of not less than 2 feet from the face of a vertical curb or from the outside edge of a shoulder. In a median, the above 2 foot minimum clearance should be obtained where possible. 3) Signal head fittings, brackets, terminal compartments, and hardware shall be securely tightened and fastened in position. When banding is used to attach a signal head, a 5/8 inch by .030 inch stainless steel band shall be used. Prior to placing signal heads in operation, all signal faces shall be covered or turned away from approaching traffic. 4) When ready for operation, the signal heads shall be securely fastened in position and face approaching traffic. Signal faces shall be aimed laterally at the approximate center of the lane or lanes they control, unless otherwise directed by the Engineer. They shall be aimed at a point back of the stop line a distance corresponding to the following requirements: Approach Speed (M.P.H.)
Distance (Feet)
30 ............................................................................................. 160 40 ............................................................................................. 240 50 ............................................................................................. 330
9/1/2023
904-71
Traffic Control Facilities
904.5.15 Installation of Controller Cabinets. Each cabinet shall be installed in accordance with the standard detail drawings. The controller cabinet size and type of mounting shall be as shown on the plans or as specified in the contract. 1) Each cabinet shall be mounted on a Type D concrete base. The height of each Type D concrete base shall be as specified on the standard detail drawings. The anchor bolt spacing shall be as specified by the manufacturer of each cabinet. After the controller cabinet is bolted using washers, specified in Section 904.4.2.1(5), to the concrete base, the outside perimeter of the cabinet shall be sealed with silicone caulk. 904.5.16 Installation of Detector Loops. 1) Detector loops will be marked on the pavement by Division of Operations personnel after receiving a minimum 48 hour notice from the Contractor in accordance with Section 904.5.2. 2) Prior to sawing the detector loops, traffic control protection shall be provided to detour traffic around the work area. 3) Slots for the installation of detector loop cable shall be sawed in the pavement with a power concrete saw. Newly constructed concrete pavement shall not be sawed for 72 hours, unless directed otherwise by the Engineer. All sawed slots shall be thoroughly cleaned using compressed air to blow out dirt and all free water. 4) Each sawed slot for detector loops shall be 3/8 inch wide and 2 inches deep regardless of the number of detector loop cables to be installed. The intersection of slots shall overlap enough to maintain full 2 inch depth. Where slots intersect, a 1-1/4 inch diameter hole shall be drilled to full 2 inch depth. The practice of sawing diagonal cuts across the corners of a loop shall not be permitted. 5) One slot for loop leads, 3/8 inch wide and 2 inches deep, shall be sawed from each detector loop to a separate 1 inch conduit. The lateral distance between each of the loop lead slots shall be 1 foot minimum. The lateral distance between transverse pavement joints and the nearest loop lead slot shall also be 1 foot minimum. 6) The 1 inch conduits for loop leads shall be located near the edge of pavement or near the face of a curb, median or island. These conduits shall be installed in accordance with the standard detail drawings. 7) After 1 inch conduit is installed for detector loop leads, the face of each median, island or curb above each conduit shall be marked and scored with a concrete saw. If the pavement is ever overlayed, this scoring of concrete faces will provide a permanent mark to aid in locating the end of each 1 inch conduit in the event the detector loops must ever be replaced.
8) Detector loop cable shall be pushed into the sawed slots with blunt tools without damaging the tube jacket. The number of loop turns required shall be as shown on the plans. The loop leads shall be pushed into the slot leading to a 1 inch conduit and pulled through the conduit to a pull box for connection to a shielded lead-in cable. The
9/1/2023
904-72
Traffic Control Facilities
detector loop wire and outer tube jacket for each detector loop shall be continuous without splice. 9) Detector loop leads shall be connected to shielded lead-in cable in a pull box as shown on the plans and in accordance with Section 904.5.17(4). 10) Prior to pouring the detector loop sealant, each 1 inch conduit opening shall be sealed with "duct" seal or an equivalent removable sealant. This "duct" seal will keep the detector loop sealant from running into the 1 inch conduit to prevent future maintenance problems if a loop must ever be replaced. 11) Prior to pouring the detector loop sealant, wedges shall be inserted into the sawed slots on 3 foot centers to prevent the air space in the tube jacket from causing the detector loop cable to float in the slot when the loop sealant is poured. The wedges shall be 1 inch sections of plastic tubing which are folded before insertion. 12) After the detector loop cable is connected to a shielded lead-in cable and before the slot is sealed, the resistance of the detector loop and lead-in cable to ground shall be checked. After a satisfactory test, which shows resistance of not less than fifty (50) megohms, the slot shall be sealed with detector loop sealant. 13) The placement of the detector loop sealant shall be in strict accordance with the directions of the manufacturer regarding the preparation of the sealant mix, its application, and the proper curing procedures subsequent to reopening of the road to traffic. 14) Where a 1 inch conduit joins a loop lead slot, loop sealant shall be poured into the space between the pavement and the 1 inch conduit causing the conduit to be bonded to the pavement. 15) Where future detector loops are to be installed, 1 inch conduit shall be installed for the future detector loop leads. The ends of the 1 inch conduit shall be sealed with "duct" seal or an equivalent removable sealant. This will keep dirt and debris out of the unused 1 inch conduit. The face of each median, island or curb above each 1 inch conduit shall be marked and scored with a concrete saw to aid in the future locating of each conduit. 904.5.17 Installation of Wiring. 1) All signal cable runs shall be continuous without splice from the terminal block of each signal head to a terminal strip in the controller cabinet, or from the terminal block of one signal head to the terminal block of another signal head when a jumper is shown on the plans or directed by the Engineer. All conductor cable combinations to signal heads shall be as shown on the plans or as directed by the Engineer. 2) Power cable runs shall be continuous without splice from the power supply circuit breaker panel to the traffic signal controller cabinet. Energized power cables shall be black and terminated on circuit breakers inside the power supply circuit breaker panel and the controller cabinet. The neutral cable shall be white and terminated on the ground bus bar inside the power supply circuit breaker panel and the controller cabinet.
9/1/2023
904-73
Traffic Control Facilities
3) Pedestrian push button detectors and vehicle detector loops shall be connected to the controller by separate No. 18 AWG, 2 conductor, shielded lead-in cables which shall be continuous without splice. 4) Detector loop leads shall be connected in series to shielded lead-in cable. These connections shall be made in a pull box near the loops as shown on the plans. All connections between detector loop leads and shielded lead-in cable shall be made by using a 3M direct bury splice kit #DBR/Y or compatible connection approved by the Engineer. Shielded lead-in cable runs shall be continuous without splice from a pull box near the loops to the controller cabinet. If more than one shielded lead-in cable is wired to the same loop detector channel, the lead-in cables shall be wired in series in the controller cabinet, not connected together in series in a pull box. 5) All signal posts, mast arm assemblies and controller cabinets shall be grounded by a No. 6 AWG, 7 strand, bare copper wire from a grounding lug inside each signal post, mast arm assembly and controller cabinet to a ground provided by a ground rod inside the nearest concrete pull box. 6) All signal post assemblies shall be grounded by a No. 6 AWG, seven strand, bare copper wire between two flat washers attached to one of the base mounting bolts to a ground provided by a ground rod inside the nearest concrete pull box. 7) Cables shall be pulled through conduit by a cable grip providing a firm hold on exterior coverings. Cable shall be pulled with a minimum of dragging on the ground or pavement. Frame mounted pulleys, or other suitable devices, shall be used for pulling cables out of conduits into pull boxes. Lubricants may be used to facilitate pulling cable. Slack in each cable run shall be provided by coiling six (6) feet of cable in each pull box. 8) All wiring connections shall be securely tightened. Copper barrel lugs shall be used for all field connections inside the controller cabinet. Insulated crimped-on connectors of an approved type shall be used for all other terminal connections. All spare field wires shall be capped with closed end insulated terminals of an approved type. 9) Color codes shall be followed so that the red insulated conductor connects to the red indication terminal, yellow to yellow, green to green, and white to neutral. The power cables shall be color coded so that black connects to AC(+) and white to neutral.
10) At an existing traffic signal installation, where new/existing cable is to be installed/relocated into an existing conduit, all existing cable and wire not used shall be removed from the conduit. All costs for relocating/ removing existing cable and wire shall be considered incidental with no separate payment being made. All cables removed shall be returned, in a neatly coiled bundle, to the Department of Transportation Operations Building, Signal Shop, 2688 Adie Road, Maryland Heights, Missouri 63043, Phone (314) 615-0200. 11) When existing conduit needs to be repaired/replaced, the existing cable needs to be removed and then reinstalled/replaced through the repaired/new conduit, or as directed by the Engineer.
9/1/2023
904-74
Traffic Control Facilities
12) When the existing conduit is to be intercepted with a new pull box, existing cable shall be removed from the intercepted location and replaced after the pull box is installed and conduits are properly angled within the pull box. 904.5.18 Fiber Optic Cable. The fiber optic cable installation shall be supervised by trained and experienced personnel. The Contractor shall, upon request of the Engineer, provide documentation of qualifications and experience for fiber optic installations. The Engineer shall determine if the Contractor is qualified to perform this work. 904.5.18.1 Installation of Fiber Optic Cable. 1) All fiber optic signal interconnect cable shall be continuous without splice between interconnected controllers. 2) A suitable cable feeder guide shall be used between the cable reel and the face of the duct or conduit to protect and guide the cable off the reel into the duct or conduit. It shall be carefully inspected for jacket defects. If defects are noticed, the pulling operation shall be stopped immediately, and the Engineer notified. 3) Precautions shall be taken during installation to prevent the cable from being kinked or crushed. A pulling eye shall be attached to the cable and used to pull the cable through the conduit system. A pulling swivel shall be used to eliminate twisting of the cable. 4) As the cable is played off the reel into the cable feeder guide, it shall be sufficiently lubricated with a type of lubricant recommended by the cable manufacturer. Dynamometers or break away pulling swings shall be used to ensure that the pulling line tension does not exceed the installation tension value specified by the cable manufacturer. The mechanical stress placed on a cable during installation shall not be such that the cable is twisted or stretched. 5) The pulling of cable shall be hand-assisted at each controller cabinet, pull box, and junction box. The cable shall not be crushed, kinked, or forced around a sharp corner. If a lubricant is used it shall be of water-based type and approved by the cable manufacturer. Sufficient slack shall be left at each end of the cable to allow proper cable termination. 6) Additional slack cable shall be neatly coiled and left in each pull box. A pull box adjacent to a traffic signal controller cabinet, or fiber optic cable termination cabinet, shall have a minimum of thirty (30) feet of additional cable coiled. All other pull boxes shall have a minimum of ten (10) feet of additional cable coiled. 7) After cable connections are made inside the controller cabinet, the unused additional slack cable in the cabinet shall be pulled back, coiled, and stored with the additional slack cable in the pull box next to the controller cabinet. Storage of additional slack cable shall be coiled and bound at a minimum of three points around the coil perimeter and supported in the static storage positions. At each controller cabinet, fiber termination cabinet and pull box the cable shall be visibly marked or tagged as “CAUTION FIBER OPTIC CABLE”
9/1/2023
904-75
Traffic Control Facilities
8) Maximum length of cable pulling tensions shall not exceed the cable manufacturer’s recommendations. 9) Existing cable (or pull rope) shall remain in place; however, it may be pulled out to assist in pulling the fiber optic cable. Existing cable (or pull rope) shall always be returned to the conduit system before the end of work each day and connected in each controller cabinet. The Engineer shall be notified before the existing cable is disconnected. The contractor shall only use the existing cable (or pull rope) to assist in pulling the fiber optic cable with the approval of the Engineer. 10) When existing cable is not present or when plans call for its removal, an insulated, No. 16 AWG, stranded copper wire shall be pulled in with the fiber optic cable to facilitate future locating of the conduit. All costs for this wire shall be considered incidental with no separate payment being made. 11) For static storage, the cable shall not be coiled at any location to less than ten times the diameter of the cable outside diameter or as recommended by the manufacturer. During installation, the cable shall not be coiled at any location to less than twenty times the diameter of the cable outside diameter or as recommended by the manufacturer. 904.5.18.2 Fiber Optic Cable Terminations. 1) All multimode fiber ends shall be fusion spliced and / or terminated per the Engineer. The cost of which is incidental to the cost of the cable. 2) The above referenced ST connectors shall be fusion spliced using a kit with 6 each FPC MM 62 1F 900um ST/00 1 meter, blue, orange, green, brown, slate, and white with ST connectors with ceramic ferrule, part number S212580-1M. 3) The housing shall be suitable for under shelf mounting (to be mounted between the top of the back panel, and the bottom shelf) and be capable of mounting a minimum of 30 singlemode and 6 multimode hub ST type connectors. A minimum of 36 ST type connectors shall be installed in the housing. The housing shall have a splice tray kit capable of a minimum of 30 splices. It shall be capable of housing up to 48 fibers and provide for the stacking of fibers. It shall have ample room for feed through cable and provide strain relief for multiple cables within the unit. 4) Patch cords shall be terminated through ST connectors mounted on the termination housing and plug into the internally provided controller unit fiber optic modem. The patch cord assemblies shall be fully compatible with the fiber optic interconnect cable and connecting modems and modules. The patch cords shall be no longer than four (4) feet. 5) All singlemode fiber ends shall be fusion spliced and / or terminated per the Engineer. The cost of which is incidental to the cost of the cable. 904.5.18.3 Testing of Fiber Optic Cable and Terminations. Each section of cable shall be tested for continuity and attenuation. The contractor shall provide all personnel, equipment, instrumentation and supplies necessary to perform all testing. All testing shall be performed in an accepted manner and in accordance with the testing equipment 9/1/2023
904-76
Traffic Control Facilities
manufacturer’s recommendations. All data shall be recorded and submitted to the Engineer. The data shall be legible, organized and bound in a hard copy paper format. 904.5.18.3.1 Optical Time Domain Reflectometer. The optical time domain reflectometer (OTDR) shall be used to test each section of cable. A LED light source with an 850 µm wavelength shall be used. The LED shall be stable within 0.1 db in intensity over a time period sufficiently long to perform the measurement. The output of the LED shall overfill the input end of the launch fiber/cable in both numerical aperture and core diameter. 1) OTDR shall be used to evaluate the quality and length of cable reels prior to their use on the project. The fiber loss in db/km and the length of each reel shall be recorded in the documentation. The maximum attenuation of the cable shall be 3.5 db/km nominal, measured at room temperature at 850 nm. A copy of OTDR signature traces for all system links shall be made and provided in the documentation. 904.5.18.3.2 Documentation. The results of all testing shall be recorded, along with date of test, name of person performing test, locations of the starting and ending points of the fiber, brand name, model number, serial number of equipment used during test, and any other pertinent information and data. All test results and other information must be given to the Engineer in a legible, organized and bound hard copy paper format for verification of fiber cable work. This work shall be submitted to the engineer within two weeks of the completion of the fiber cable work for a signal system(s). The County has the sole right to define the limits of a signal system(s). 904.5.19 Removal of Existing Concrete Pull Boxes. Unless otherwise noted on the drawings, existing concrete pull boxes to be removed shall be removed twelve (12) inches below finish grade and backfilled to finish grade with material of the same grade and type as the adjacent surface. 904.5.20 Removal of Existing Concrete Bases. Unless otherwise noted on the drawings, existing bases to be removed shall be removed twelve (12) inches below finish grade and backfilled to finish grade with material of the same grade and type as the adjacent surface. 904.5.21 Removal of Existing Reinforced Polymer Concrete Pull Boxes. Unless otherwise noted on the drawings, existing reinforced polymer concrete pull boxes to be removed shall be removed entirely and backfilled to finish grade with material of the same grade and type as the adjacent surface. 904.5.22 Relocation or Removal of Existing Signal Equipment. 1) Traffic signal equipment shall be relocated or removed only with the approval of the Engineer. The Contractor shall notify the Saint Louis County Department of Transportation, Traffic Operations personnel, at (314) 615-0226 48 hours in advance of any relocation/removal. The Contractor shall exercise care in his dismantling operations so as not to damage traffic signal equipment to be relocated or removed. All traffic signal equipment to be relocated or removed shall be assumed to be in good condition unless indicated otherwise by a previous inspection by the Engineer. It will be the Contractor's responsibility to request and set up an inspection appointment with the Engineer prior to the relocation or removal of equipment to determine the extent of any damage to equipment. 9/1/2023
904-77
Traffic Control Facilities
2) County maintained traffic signal equipment to be removed shall be delivered to the Department of Transportation, Traffic Operations Building, Signal Shop, 2688 Adie Road, Maryland Heights, Missouri 63043, Phone (314) 615-0226. 3) State maintained traffic signal equipment to be removed shall be delivered to the Missouri Highway and Transportation Department Signal Shop, 2309 Barrett Station Road, Ballwin, Missouri, 63021, Phone (314) 340-4100. 904.5.23 Modification of Existing Traffic Signals. 1) Existing traffic signals, including detectors and interconnect, shall remain in effective operation, except during the period of time when the traffic signal must be shut down for alterations or changeover to new traffic signal equipment. The Contractor shall notify (1) The Construction Division’s Resident Engineer, (2) the Department of Transportation’s Media Coordinator, and (3) Division of Traffic Construction Inspection personnel 48 hours in advance of any traffic signal shutdown. During the time traffic signals are turned off, "Stop" signs shall be installed by the Contractor adjacent to each lane approaching the intersection as directed by the Engineer. The length of time existing traffic signals are turned off for alterations or changeover to new equipment shall be held to a minimum. The times of day and days of week existing traffic signals may be shutdown shall only be allowed during the following times unless directed otherwise by the Engineer:
Monday thru Friday .................................................................. 9:00AM to 3:00PM Monday thru Friday .................................................................. 7:00PM to 5:00AM Saturday and Sunday ................................................................................ All Day The County reserves the right to revise the time periods listed above. 2) Any portion of an existing traffic signal installation or system that is modified shall be maintained by the Contractor in accordance with Section 904.5.24. In addition, any portion of an existing traffic signal installation that is damaged by construction operations shall be repaired at the Contractor's expense, including portions of an existing signal not modified by the Contractor.
904.5.24 Signal Maintenance During Construction. 1) This maintenance shall include all repairs and/or adjustments to signal materials and equipment, furnished and installed by the Contractor, which the Engineer has determined are necessary due to malfunctions, construction operations, vandalism, knockdowns, and/or acts of God. The Contractor shall be responsible for obtaining recovery of all damages, including replacement of any signal equipment. 2) In any event, if in the opinion of the Director and at his/her sole discretion, immediate repairs and/or adjustments are determined to be necessary to provide for the safe and efficient movement of traffic, and the Contractor is not capable of making such repairs 9/1/2023
904-78
Traffic Control Facilities
and/or adjustments to the satisfaction of the Director; the Director will order County personnel or other qualified Engineers or technicians to make immediate repairs and/or adjustments. The Contractor will be charged the entire cost of the work performed by County or other qualified personnel (if paid by the County). The Contractor will be charged for all labor (including benefits and indirect overhead), materials, and equipment furnished by the County in making immediate repairs and/or adjustments. There will be a three (3) hour minimum call-up time for overtime. The work performed by County or other qualified personnel will in no way jeopardize any part of the guarantee as specified in Section 904.10. 904.5.24.1 Daily Cleanup During Construction. All dirt, trash, and other related construction debris shall be removed from the right-of-way before the end of the workday. If in the opinion of the Engineer, the construction site is unclean and presents a hazard to vehicular and/or pedestrian traffic, the Engineer may order County personnel to provide cleanup efforts with the entire cost of the work performed by the County to be deducted from monies due to the Contractor from forthcoming payments. 904.5.24.2 Traffic Handling During Construction. Signal construction should be accomplished with as little interruption to traffic as possible. When interruptions to traffic become inevitable, it will be the Contractor's responsibility to furnish, place, and maintain, standard traffic control devices in accordance with the current edition and latest revisions of the Manual on Uniform Traffic Control Devices (Part VI) or as directed by the Engineer. All costs for traffic handling shall be considered incidental with no direct payment being made, unless otherwise provided for as a separate pay item. The traveled portion of the roadway must be clear of all equipment and materials from 3:30 PM to 9:00 AM, unless determined otherwise by the Engineer. 904.5.24.3 Maintenance of Interconnect Facilities During Construction. The County’s traffic signal communication links are all vital to the operation of County’s signal systems and shall be maintained for the duration of all construction projects. It shall be the Contractor’s responsibility to maintain these links within their work zones. 1) Any approved scheduled disruption of a traffic signal communication link shall be kept to an absolute minimum and shall only be allowed during the following times: Monday thru Friday ............................................................ 9:00AM to 3:00PM Monday thru Friday ............................................................ 7:00PM to 5:00AM Saturday and Sunday ........................................................................... All Day The Contractor performing the permitted work shall contact the St. Louis County Department of Transportation’s Division of Operations, Signal Shop at (314) 6150213 a minimum of two business days prior to any approved scheduled disruption of a traffic signal communication link. The County reserves the right to revise the time periods listed above. If the scheduled disruption cannot occur during the approved times, then the Contractor shall submit a plan, for the County’s approval, to provide a TEMPORARY traffic signal communication link. If approved, the Contractor shall
9/1/2023
904-79
Traffic Control Facilities
install the TEMPORARY communication link and verify the link is functional before proceeding with the scheduled disruption. Failure to comply with these requirements shall result in the Contractor’s construction work within the public right-of-way being halted until all requirements are met. 2) If an unanticipated disruption of a traffic signal communication link occurs as a result of permitted work conducted by a Contractor, the Contractor’s construction work within the right-of-way shall be halted. The Contractor’s work within the rightof-way shall not be allowed to proceed until a temporary repair to the link is completed, unless approved otherwise by a representative from the St. Louis County Department of Transportation, Construction Division. Temporary repairs shall not be considered final repairs. The Contractor shall be responsible for restoring all traffic signal communication links to the same condition prior to the unanticipated disruption or to the condition specified in the approved construction plans. Failure to comply with these requirements will result in liquidated damages being assessed or escrow funds will be withheld. 904.5.24.3
Maintenance of Vehicle Detection Systems During Construction
1) Vehicle detection systems are essential to the efficient operation of all traffic signals. Prior to any disruption of service to an existing vehicle detection system, the Contractor shall furnish and install a temporary vehicle detection system for the approach(es) where the existing vehicle detection system is to be disrupted. The Contractor shall make any and all necessary adjustment(s) for the proper operation of the temporary detection equipment. The Contractor will also be responsible for the maintenance of the temporary detection system equipment until the permanent vehicle detection system is installed and operational. The Contractor shall provide to the County the type of temporary vehicle detection system to be used a minimum of two business days in advance of installing the temporary equipment for approval, by contacting the St. Louis County Signal Shop at (314) 615-0213. The County has the sole right to approve, modify, or reject the temporary vehicle detection system proposed by the Contractor. The Contractor shall not disrupt any existing vehicle detection system before a temporary vehicle detection system is operational and approved by the County. Failure to comply with these requirements shall result in the Contractor’s work within the public right-of-way being halted until all requirements are met. 2) In the event the Contractor causes a disruption to a vehicle detection system and there is no temporary vehicle detection system in place, the Contractor’s construction work within the public right-of-way shall be halted. The Contractor’s construction work within the public right-of-way shall not be allowed to proceed until a temporary vehicle detection system is installed, unless approved otherwise by a representative from the St. Louis County Department of Transportation Construction Division.
9/1/2023
904-80
Traffic Control Facilities
If the Construction Division approves the Contractor’s construction work to proceed without providing a temporary vehicle detection system, the Contractor has a maximum of 14 calendar days to either install an approved temporary or permanent vehicle detection system. The Contractor shall provide to the County within two business days of the disruption of the vehicle detection system: a) The vehicle detection system to be used. b) A schedule detailing the timeline for installation of the temporary vehicle detection system. The County has the sole right to approve, modify, or reject the temporary vehicle detection system and schedule proposed by the Contractor. Temporary vehicle detection systems shall not be considered final improvements. The Contractor shall be responsible for restoring all vehicle detection systems to the same condition prior to the disruption or to the condition specified in the approved construction plan. Failure to comply with these requirements will result in liquidated damages being accessed at a rate of $100 per lane per day or escrow funds being withheld. 904.5.25 Restoration. All pavement, shoulders, sidewalk, curbing, embankments, planting beds, and turfed areas disturbed by construction shall be restored as directed by the Engineer. All costs for restoration shall be considered incidental with no direct payment being made, unless otherwise provided for as a separate pay item. 904.5.26 Final Clean Up. All signal equipment shall be cleaned in such a manner so as to be free of grease, oil and excess dust. The lens and reflector of each signal indication shall be wiped clean. All debris or scrap material shall be removed from the inside of each pull box, handhole, signal head and controller cabinet. The final cleaning up of the right-of-way shall meet the requirements of Section 104.8. 904.6 Temporary Traffic Signals. 1) When specified, temporary traffic signals shall be provided for the handling of traffic during construction. The operation period of temporary traffic signals shall be held to a minimum. Unless otherwise provided, a plan of each proposed temporary signal shall be submitted to the Engineer for approval prior to the installation of the signal. When temporary traffic signals are installed, the signal heads shall be covered until the installation is placed in operation. Temporary traffic signals, when required, shall be kept in effective and continuous operation except for shutdowns required for changeover to new equipment. 2) If an existing traffic signal is to be replaced with a temporary traffic signal installation, the existing traffic signal shall not be taken out of operation until such time as approval is received from the Engineer for a changeover. The downtime for this changeover shall be kept to an absolute minimum. Existing traffic signals taken out of operation shall be covered until removed.
9/1/2023
904-81
Traffic Control Facilities
3) Unless otherwise noted, the Contractor shall be required to furnish and install the necessary materials and equipment for the operation of temporary traffic signals. The maintenance of temporary traffic signals shall be in accordance with Section 904.5.24. The Contractor shall remove each temporary traffic signal installation when its use is no longer deemed necessary by the Engineer. No direct payment will be made for the removal of the temporary signal; and the temporary signal equipment will remain the property of the Contractor. The Contractor shall comply with all existing electrical codes, ordinances and regulations of Saint Louis County and municipalities involved. The Contractor shall also comply with the requirements of Ameren Missouri to obtain power for the operation of each temporary traffic signal installation.
904.7 Signal Acceptance Procedures. 904.7.1 Signal Inspection. When the Contractor is certain all traffic signal equipment that was furnished and installed by the Contractor for a new or modified traffic signal installation, is operating properly, he shall make an inspection appointment with the Engineer. After a thorough inspection of the signal equipment and installation, the Engineer may authorize the Contractor to put the signal into permanent operation. This authorization will be given if all signal equipment is working properly, or if public safety and convenience warrants the operation of the signal before all corrections have been made. If the inspection reveals signal deficiencies, the Contractor shall correct them expeditiously and within the time allowed for the completion of the project. If the signal must be put into flashing operation or completely shut down to make the necessary corrections, the Contractor must receive approval from the Engineer before this action is taken. This inspection procedure shall be repeated until all corrections have been made. 904.7.2 Signal Test Period. 1) After all deficiencies to signal equipment furnished and installed by the Contractor have been corrected, the signal shall remain in operation for a 30 consecutive day test period. Any failure or malfunction of equipment during the test period shall be corrected by the Contractor. The signal shall then be tested for an additional 30 consecutive day period. This procedure shall be repeated until the signal equipment has operated to the Engineer's satisfaction for 30 consecutive days. However, it should be noted that if the signal is part of a system within the project, that portion of the signal installation associated with systems operation shall not be tested until all signals in the system within the project are ready to be tested. 2) After a signal and/or signal system that was furnished and installed by the Contractor has been satisfactorily tested for 30 consecutive days, the County will make emergency repairs and/or adjustments determined to be necessary due to malfunctions. However, prior to final acceptance, the Contractor shall still be responsible for any repairs and/or adjustments which the Engineer has determined are necessary due to construction operations, vandalism, knockdowns and/or acts of God. The Contractor shall be responsible for obtaining recovery of all damages. 904.7.3 Signal Maintenance Information. Before final acceptance of the work, the Contractor shall furnish the Engineer the following information for signal equipment furnished and installed by the Contractor.
9/1/2023
904-82
Traffic Control Facilities
1) Three (3) copies of the manufacturers' instructions for the maintenance and operation of all signal equipment. 2) A CD containing the controller wiring diagrams for each signal installation and/or signal system shall be provided. The control wiring diagrams shall be in an electronic format compatible with MicroStation software The diagrams shall be easy to read and match the cabinet wiring. All controller wiring diagrams shall be double referenced. Three paper copies of the controller wiring diagrams shall be provided for each signal installation and /or signal system. The controller wiring diagrams shall be prepared on a neat and clean 24 inch x 36 inch sheet(s) 904.7.4 Final Acceptance. Upon presumptive completion of the entire project, including completion of the signal test period, the Director will make an inspection. If all construction contemplated by the contract, or indicated on the plans, has been completed to his satisfaction that inspection will constitute the final inspection. The Director will make the final acceptance and notify the Contractor in writing of this acceptance as of the date of the final inspection. 904.8 Method of Measurement. 1) Measurement of conduit will be made to the nearest linear foot as indicated on the plans. Contract quantities will be used in final payment except as provided in Section 904.8(3). 2) Measurement of cable and wire will be made to the nearest ten (10) linear feet as indicated on the plans. Contract quantities will be used in final payment except as provided in Section 904.8(3). 3) Field measurements will be made only for authorized changes during construction, or where appreciable errors are found in the contract quantity. Each revision or correction will be computed and added to or deducted from the contract quantity. 904.9 Basis of Payment. Accepted traffic signals will be paid for at the unit bid price for each of the pay items included in the contract. No separate payment will be made for any incidental items necessary to complete the work unless specifically provided as a pay item in the contract. 904.10 Guarantee. 1) The Contractor shall guarantee satisfactory in-service operation of all Contractor supplied and installed electrical equipment and related components for a period of one (1) year from date of the final acceptance of the entire project. 2) Upon notice from the Engineer of unsatisfactory in-service operation of Contractor supplied and installed electrical equipment and/or related components, the Contractor shall immediately begin the correction, repair, or replacement process. This notice from the Engineer may be given anytime within the guarantee period specified in Section 904.10(1). The Contractor shall be responsible for having the defective work, materials or equipment corrected, repaired, or replaced within three (3) working days after notification by the Engineer. Unless otherwise approved by the Engineer, if defective materials or equipment cannot be repaired or replaced within this time, the Contractor shall make arrangements for their temporary replacement with similar materials or equipment. In any event, if in the opinion of the Director and at his sole discretion, immediate repairs and/or adjustments are determined to be necessary to provide for the 9/1/2023
904-83
Traffic Control Facilities
safe and efficient movement of traffic, and the Contractor is not capable of making such repairs and/or adjustments to the satisfaction of the Director; the Director will order County personnel or other qualified Engineers or technicians to make immediate repairs and/or adjustments. The Contractor will be charged the entire cost of the work performed by County or other qualified personnel (if paid by the County). The Contractor will be charged for all labor (including benefits and indirect overhead), materials, and equipment furnished by the County in making immediate repairs and/or adjustments. There will be a three (3) hour minimum call-up time for overtime. The work performed by County or other qualified personnel will in no way jeopardize any part of this guarantee.
9/1/2023
904-84
Traffic Control Facilities
Division 1000
MATERIAL DETAILS
9/1/2023
1000-1
Material Details
(This Page Intentionally Left Blank)
9/1/2023
1000-2
Material Details
Standard Specifications for Road and Bridge Construction Division 1000 - Material Details Section
Description
Revision Date
1001......... General Requirements for Material .............................................................. 9/16/2008 1002......... Aggregate for Superpave Asphaltic Pavement............................................. 9/16/2008 1003......... Aggregate for Seal Coats............................................................................. 9/16/2008 1004......... Aggregate for Bituminous Concrete ............................................................... 3/1/2016 1005......... Aggregate for Concrete ................................................................................. 2/1/2017 1006......... Aggregate Surfacing Material ...................................................................... 9/16/2008 1007......... Aggregate for Base ........................................................................................ 7/1/2016 1008......... Blank ........................................................................................................................... 1009......... Aggregate for Drainage ................................................................................. 2/4/2011 1010......... Select Granular Backfill for Structural Systems and Box Culvert Bedding ...... 9/1/2023 1011......... Geotextile .................................................................................................... 12/9/2013 1012......... Geocomposite Drainage Material................................................................. 1/31/2007 1013......... Miscellaneous Drainage Material ................................................................... 2/3/2014 1014......... Blank ........................................................................................................................... 1015......... Bituminous Material ....................................................................................... 2/1/2017 1016......... Silica Fume (Microsilica) .............................................................................. 2/13/2013 1017......... Ground Granulated Blast Furnace Slag ....................................................... 12/9/2013 1018......... Fly Ash for Concrete ...................................................................................... 2/4/2011 1019......... Cement ........................................................................................................ 12/9/2013 1020......... Corrugated Metallic Coated Steel Culvert Pipe, Pipe Arches and End Sections ................................................................................... 1/31/2007
9/1/2023
1000-3
Division 1000 - Index
Section
Description
Revision Date
1021......... Bituminous Coated Corrugated Metal Culvert Pipe & Pipe Arches ............... 1/31/2007 1022......... Corrugated Metallic Coated Steel Pipe Underdrain ...................................... 10/1/2012 1023......... Structural Plate Pipe and Pipe Arches ......................................................... 1/31/2007 1024......... Corrugated Aluminum Alloy Culvert Pipe and Corrugated Aluminum Alloy Structural Plate ............................................................. 1/31/2007 1025......... Corrugated Aluminum Alloy Pipe Underdrains ............................................... 2/4/2011 1026......... Reinforced Concrete Culvert, Storm Drain and Sewer Pipe ......................... 1/31/2007 1027......... Polymer Coated Corrugated Metal Culvert Pipe and Pipe Arches................ 1/31/2007 1028......... Corrugated Poly Vinyl Chloride (PVC) Culvert Pipe ..................................... 1/31/2007 1029......... Prestressed Concrete Members for Bridges ................................................ 1/31/2007 1030......... Vitrified Clay Products ................................................................................. 1/31/2007 1031......... Blank ........................................................................................................................... 1032......... Precast Concrete Flared End Sections ........................................................ 1/31/2007 1033......... Precast Drainage Units ................................................................................ 1/31/2007 1034......... Reinforced Concrete Elliptical Culvert, Storm Drain and Sewer Pipe ........... 1/31/2007 1035......... Reinforced Concrete Arch Culvert, Storm Drain and Sewer Pipe ................. 1/31/2007 1036......... Reinforcing Steel for Concrete ....................................................................... 4/8/2013 1037......... Shear Connectors ........................................................................................ 1/31/2007 1038......... Bearing Pad for Structures........................................................................... 1/31/2007 1039......... Epoxy Resin Material ................................................................................... 1/31/2007 1040......... Guardrail, End Terminals, One-Strand Access Restraint, Cable and Three-Strand Guard Cable Material ................................................ 10/1/2012 1041......... Polypropylene Culvert Pipe.......................................................................... 12/9/2013 1042......... Blank ........................................................................................................................... 1043......... Fence Material ............................................................................................. 1/31/2007 1044......... Post for Markers and Delineators................................................................. 1/31/2007 1045......... Paint for Structural Steel .............................................................................. 1/31/2007 1046......... Blank ........................................................................................................................... 1047......... Corrugated Polyethylene Culvert Pipe ......................................................... 1/31/2007 1048......... Pavement Marking Material ......................................................................... 11/1/2016 1049......... Precast Concrete Box Culvert ...................................................................... 1/31/2007 1050......... Lumber, Timber, Piling, Posts and Poles ..................................................... 11/1/2016
9/1/2023
1000-4
Division 1000 - Index
Section
Description
Revision Date
1051......... Slotted Drain ................................................................................................ 1/31/2007 1052......... Mechanically Stabilized Earth Wall System Components............................. 11/1/2016 1053......... Penetrating Protective Sealer Material ........................................................... 2/4/2011 1054......... Concrete Admixtures ................................................................................... 12/9/2013 1055......... Concrete Curing Material ............................................................................. 12/9/2013 1056......... Concrete Tinting Material ............................................................................... 2/4/2011 1057......... Material for Joints ........................................................................................ 10/1/2017 1058......... Polyethylene Sheeting ................................................................................. 10/1/2012 1059......... Protective Coating Material ............................................................................ 2/1/2017 1060......... Electrical Conduit ......................................................................................... 1/31/2007 1061......... Blank ........................................................................................................................... 1062......... Blank ........................................................................................................................... 1063......... Temporary Traffic Control Devices ................................................................ 7/1/2016 1064......... Temporary Concrete Traffic Barrier ............................................................. 1/31/2007 1065......... Concrete Traffic Barrier Delineators ............................................................. 1/31/2007 1066......... Mortars and Grout........................................................................................ 1/31/2007 1067......... Blank ........................................................................................................................... 1068......... Calcium Chloride ........................................................................................... 2/1/2015 1069......... Blank ........................................................................................................................... 1070......... Water ............................................................................................................. 2/1/2017 1071......... Asphalt Release Agents and Liquid Anti-Strip Additives .............................. 11/1/2016 1072......... Blank ........................................................................................................................... 1073......... Joint Material for Structures ......................................................................... 1/31/2007 1074......... Blank ........................................................................................................................... 1075......... Centrifugally-Cast Fiberglass-Reinforced Polymer Mortar Pipe.................... 1/31/2007 1076......... Blank ........................................................................................................................... 1077......... Blank ........................................................................................................................... 1078......... Blank ........................................................................................................................... 1079......... Blank ........................................................................................................................... 1080......... Structural Steel Fabrication.......................................................................... 10/1/2012 1081......... Coating of Structural Steel ........................................................................... 1/31/2007
9/1/2023
1000-5
Division 1000 - Index
Section
Description
Revision Date
1082......... Blank ........................................................................................................................... 1083......... Blank ........................................................................................................................... 1084......... Blank ........................................................................................................................... 1085......... Blank ........................................................................................................................... 1086......... Blank ........................................................................................................................... 1087......... Blank ........................................................................................................................... 1088......... Blank ........................................................................................................................... 1089......... Blank ........................................................................................................................... 1090......... Blank ........................................................................................................................... 1091......... Blank ........................................................................................................................... 1092......... Blank ...........................................................................................................................
9/1/2023
1000-6
Division 1000 - Index
Section 1001
General Requirements for Material
1001.1 All requirements of Section 106 shall apply to material hereinafter specified. Materials or processes requiring pre-qualification or pre-acceptance shall be in accordance with the applicable sections of these specifications. After approval, the material or process will be placed on either the qualified list or the pre-acceptance list (PAL) maintained on the MoDOT web site by Construction and Materials. The Contractor shall select materials or processes from the appropriate list for use in County work. Final acceptance may be based on field inspection. 1001.2 All packaged material shall be plainly marked showing the quantity and nature of contents and shall be delivered intact. 1001.3 A description of the visual characteristics of deleterious rock types most likely to be encountered at any specific aggregate source may be obtained by the supplier upon written request to the Engineer. 1001.4 At local plants installed for production of any sand or gravel required for highway work, the oversize shall not be returned to the deposit or to the stream. 1001.5 Chat is defined as aggregate tailings from mills in which metallic minerals have been recovered. 1001.6 Crushed stone is defined as the product obtained by the artificial reduction in the size of rock which has been mined or excavated from ledge formation. Chat as defined in Section 1001.5 is not included. 1001.7 Gravel is defined as the coarse granular material, generally considered as material retained on the Number 4 or Number 10 sieve but may include finer sizes, resulting from the natural disintegration and abrasion of rock or from processing of weakly bound conglomerate. Gravel may include such material that has been further reduced in size by artificial means. 1001.8 Porphyry is defined as a fine-grained, dense, igneous rock generally occurring in the Missouri counties of Iron, Madison, St. Francois and their adjacent counties. 1001.9 Wet bottom boiler slag is defined as a hard, angular by-product of the combustion of coal in wet bottom boilers. 1001.10 Lightweight (Low mass density) aggregates shall be prepared by expanding, calcining or sintering argillaceous material such as clay, shales and slates. 1001.11 Sieves specified for gradation requirements shall have openings as prescribed in AASHTO M92.
9/16/2008
1001-1
General Requirements for Material
1001.12 Storage and Handling of Aggregates. 1001.12.1 When coarse aggregate for concrete or bituminous mixtures, the aggregate shall be handled, placed in horizontal layers, ramped and matted or stockpiled by conveyor belts, as specified below. Coarse aggregate for Sections 301, 401 and 402, bituminous mixtures, is exempt if the aggregate has 90 percent or more passing the ½ inch sieve. Equipment used in stockpiling and in reclaiming from stockpile, both at the source and the batching plant setup, shall be so operated as to minimize segregation, degradation and contamination. 1001.12.1.1 Horizontal Stockpiling. Equipment that moves the material by pushing will be permitted on the stockpile only as necessary for ramp and runway construction and for leveling of the top of a completed lift. When stockpiling, the aggregates shall be deposited in place in successive increments over the length and width of the stockpile. Material in the layer being placed shall not be allowed to flow down over the edges of the adjacent under layer. The thickness of each layer shall be not more than the thickness of a single deposit from a hauling unit. If trucks or other types of hauling equipment are used, all ramps and runways on the stockpile shall be covered by mats, boards or other approved material. For unloading purposes, hauling equipment will be permitted off the runway a distance of approximately two hauling unit lengths. Clam shells or drag lines when permitted by the Engineer for use in stockpiling aggregates specified to be placed in horizontal layers and ramped, shall have areas of travel upon the stockpile covered by mats, boards or other approved material. 1001.12.1.2 Conveyor Belt Stockpiling. All conveyor belts, whether mobile or stationary shall have a device fitted to the discharge end of the conveyor to stop the forward movement of the aggregate and mix and discharge the material vertically downward. Only those devices meeting the approval of the Engineer will be permitted. a) When a mobile conveyor belt is used to stockpile the aggregate with specified stockpile requirements and no further handling is done for stockpiling purposes, the maximum height from the head pulley centerline to the ground surface shall not exceed 15 feet when stockpiling is started. After the initial conical pile is built, the vertical free fall of the aggregate shall not exceed 5 feet. The conveyor belt shall be automated to travel laterally or vertically only the distance needed to comply with the free fall requirements. Manual operation of the conveyor will only be allowed for the time necessary to make repairs. b) When a stationary conveyor belt is used, the maximum height from the head pulley centerline to the ground surface shall not exceed 30 feet. Aggregates initially deposited in a conical pile by a stationary conveyor shall be moved at least one more time for stockpiling purposes. The aggregates shall ultimately be stockpiled in horizontal layers and shall comply with Section 1001.12.2. 1001.12.2 Regardless of the method of storage and handling, all aggregates which are segregated, degraded or contaminated to the extent that they do not meet specifications, will be considered unacceptable. However, they may be reconditioned by any method that produces satisfactory material. Disposal of unacceptable material shall be the responsibility of the Contractor.
9/16/2008
1001-2
General Requirements for Material
1001.13 Approval of Aggregate Sources. All sources of aggregate shall be evaluated and approved by the Engineer for initial approval and source approval as herein prescribed, prior to acceptance of aggregate from that source. 1001.13.1 Sources of crushed stone shall be evaluated for initial approval on a ledge-byledge basis. Each exposed ledge will be identified and the Engineer will describe the ledge boundaries. A sample for initial approval will be required from each ledge. Resampling will be required if source approvals or production samples indicate a significant change has occurred. 1001.13.2 Source approvals will be required a minimum of every two years. Resampling will be required at closer intervals if, in the judgment of the Engineer, any significant change has occurred to the source. 1001.13.3 Sources of natural sand, gravel and manufactured lightweight aggregates shall be evaluated for initial approval, except if a plant-produced product meeting all other specification requirements is available, that product may be evaluated for source approval without first obtaining initial approval. In that case, all initial approval and all source approval tests will also be performed, and those limits applied to the source approval evaluation. 1001.13.4 Sources of aggregate such as chat, slag and other by-products from previously produced material or any other undefined sources will be evaluated on an individual basis. 1001.13.5 Samples of aggregate for source approval will be taken while the Engineer is present and shall be from material produced to meet a specific specification and intended for a specific use. 1001.13.6 Only approved ledges shall be used in the manufacture of the final product. Approval for use as Section 1005, Portland cement concrete pavement coarse aggregate constitutes approval for all other uses. Approval for use as Section 1002, asphaltic concrete coarse aggregate constitutes approval for all other uses except for any Portland cement concrete product. 1001.14 Mining By-Product Aggregates. Aggregates produced as a by-product from lead or zinc mining operations may be furnished under the following requirements. No blending or dilution of these aggregates with other material will be allowed in order to comply with these specifications. 1001.14.1 The supplier shall separate out all aggregate to be furnished into individual stockpiles not exceeding 5,000 cubic yards each. No material will be accepted that has not been moved at least once to a stockpile area specifically for this purpose. The supplier shall randomly sample each stockpile by combining several small samples from the pile into one sample. The sample shall be tested by an approved laboratory for the required lead tests specified in Section 1001.14.2. A minimum of one set of tests shall be performed for each individual stockpile.
9/16/2008
1001-3
General Requirements for Material
1001.14.2 For aggregate not encapsulated in asphalt or Portland cement mixtures and delivered to County construction projects or property, the concentration of leachable lead in the aggregate as determined by Method 1311, Toxicity Characteristics Leaching Procedures (TCLP), 40 CFR 261, Appendix II, shall be less than 3.0 ppm, and the total lead content shall be less than 500 ppm as determined by EPA Method 3050A, Acid Digestion of Sediments, Sludges, and Soils (particle size reduced to 1 mm or less). For each individual aggregate meeting Sections 1002, 1004 and 1005, which is encapsulated in asphalt or Portland cement mixtures and delivered to County construction projects or property, there will be no limit on the leachable lead, but the total lead content shall be less than 4,500 ppm. No lead tests are required, and there are no limits on leachable or total lead content, for asphalt or Portland cement materials milled from County projects and reprocessed into a mixture for re-use on County projects. 1001.14.3 Prior to any approval, shipment or use of this material, the supplier shall furnish the Engineer a report of the laboratory test results. The report shall specifically identify the stockpile, estimated quantity, location, date of sample, date of test and the specific test results for each lead test. Attached to the report shall be a certification from the supplier that the material being furnished does not exceed the lead amounts specified. The supplier shall test as necessary beyond the requirements of this specification to ensure that this specification is met. All costs for setting the material aside for testing and the testing shall be borne by the supplier. 1001.15 Dust Suppressants. Approved dust suppressant additives may be used during the crushing or aggregate handling process, provided there is no detrimental effect to the aggregate or subsequent products made from the affected aggregates. 1001.15.1 Manufacturer and Brand Name Approval. Prior to approval and use of a dust suppressant additive, the manufacturer shall submit to the Construction Division Manager, a certified test report from an approved independent testing laboratory showing specific test results when tested in accordance with MoDOT Test Method T 62. The certified test report shall contain the manufacturer's name, brand name of material, date tested, date of manufacture and dosage rate of the additive used. In addition the manufacturer shall submit to the Construction Division Manager, a sample representing the additive tested by the independent testing laboratory and accompanied by a material data sheet, a material safety data sheet showing the brand name, composition or description of the product, the normal and maximum recommended dosage rates, the manner of identification on containers and a copy of the infrared spectrum. The manufacturer shall certify that the material, when used at or below the maximum dosage rate, does not affect the properties of the aggregate or subsequent products made from the treated aggregate. The manufacturer shall also guarantee that as long as the material is furnished under that brand and designation, the material will be of the same composition as originally approved and will in no way be altered or changed. Upon approval of the additive, the manufacturer and brand name will be placed on a list of prequalified dust suppressant additives for aggregates. 1001.15.2 The aggregate supplier shall keep the inspector advised of the use of any dust suppressant material and provide for the inspection of such facilities. No dust suppressant shall be applied above the manufacturer's maximum recommended rate. 1001.16 Plant Laboratory. The material supplier shall provide a Type 2 Field Laboratory in accordance with Section 601.
9/16/2008
1001-4
General Requirements for Material
Section 1002
Aggregate for Superpave Asphaltic Concrete
1002.1 Coarse Aggregate. 1002.1.1 All coarse aggregate shall consist of sound, durable rock, free from objectionable coatings. When the coarse aggregate is tested in accordance with AASHTO T 96 (Los Angeles Abrasion), the percentage of wear shall not exceed 45. Coarse aggregate tested in accordance with AASHTO T 327 Micro Deval Abrasion Test the percent loss shall not exceed 21. The percentage of deleterious substances shall not exceed the following values and the sum of percentages of all deleterious substances shall not exceed 8 percent. Item
Percent by Weight
Deleterious rock
8.0
Shale
1.0
Other foreign material
0.5
The requirements of this section apply to each size or fraction of aggregate produced. 1002.1.2 Crushed porphyry aggregate meeting the approval of the Engineer shall be a uniform product, furnished in one or more fractions. When special asphaltic concrete mixture porphyry & limestone (LP) is specified, the total crushed porphyry aggregate shall be uniformly graded and shall have material passing each sieve from the maximum size aggregate through the Number 200 sieve. Total aggregate gradations consisting of essentially one size aggregate will not be permitted. 1002.1.3 Steel slag aggregate meeting the approval of the Engineer shall be a uniform product, furnished in one or more fractions. Steel slag consisting principally of a fused mixture of oxides and silicates is a synthetic aggregate produced as a by-product of basic oxygen, electric or open-hearth steel making furnaces. The steel slag shall be aged at least 3 months after crushing and screening. Material that is screened after it has been crushed, initially screened, and aged 3 months, will not be required to receive additional aging. Steel slag from one source shall not be mixed with or used with steel slag from a different source. When special asphaltic concrete mixture slag & limestone (LS) is specified, the total steel slag aggregate shall be uniformly graded and shall have material passing each sieve from the maximum size aggregate through the Number 200 sieve. Total aggregate gradations consisting of essentially one size aggregate will not be permitted. 1002.1.4 When a density requirement is specified for asphaltic concrete, the total quantity of chert in each size or fraction of produced crushed stone aggregate, including that permitted as deleterious, shall not vary more than 10 percentage points from the quantity present in the aggregates used in the approved laboratory job mixtures.
9/16/2008
1002-1
Aggregate for Superpave Asphaltic Concrete
1002.1.5 Gravel aggregate shall be washed sufficiently to remove any objectionable coating. Gravel aggregate for SP190 mixtures shall be crushed from gravel that has a maximum of 10 percent passing a 1-inch sieve. Gravel aggregate for SP125 mixtures shall be crushed from gravel that has a maximum of 10 percent passing a ¾-inch sieve. Crushed gravel shall comply with the requirements for mechanically induced faces in Section 1002.1.8. 1002.1.6 Pile-run chat will not be approved for use in asphaltic concrete unless the chat has been conditioned to meet a specific gradation. A tolerance of 7 percent, plus or minus, on each sieve fraction will be permitted providing the aggregate complies with other provisions of this specification. 1002.1.8 Coarse Aggregate Angularity. Coarse aggregate angularity is measured on the coarse portion of the blended aggregate. It is defined as the percent by weight of the aggregate particles larger than the Number 4 sieve with one or more fractured faces. A fractured face is an angular, rough or broken surface of an aggregate particle created by crushing or other artificial means. When tested in accordance with ASTM D 5821, "Standard Test Method for Determining the Percentage of Fractured Particles in Coarse Aggregate", the coarse aggregate shall meet the following criteria. As shown, the criteria denotes the minimum allowable percentage of the coarse aggregate with "one / two" fractured faces, e.g. an "85 / 80" requirement means that the coarse aggregate shall have a minimum of 85 percent particles by weight with one fractured face and a minimum of 80 percent particles by weight with two fractured faces. Design Level
Mixture Depth from Surface 4 inches > 4 inches
F
55/-
-/-
E
75/-
50/-
D
85/80
60/-
C
95/90
80/75
B
100/100
95/90
1002.1.10 Flat and Elongated Particles. When tested in accordance with ASTM D 4791, no more than 10 percent by mass of the blended aggregate particles retained on the Number 4 sieve shall have a ratio of maximum to minimum dimensions greater than 5. This applies when design traffic ESAL's are greater than 1,000,000. 1002.1.11 Absorption. The absorption value of the aggregate used shall not exceed 4.0 percent measured by weight.
9/16/2008
1002-2
Aggregate for Superpave Asphaltic Concrete
1002.2 Fine Aggregate. 1002.2.1 Fine aggregate for asphaltic concrete shall be a fine, granular material, naturally produced by the disintegration of rock of a siliceous nature and / or manufactured by the mechanical reduction of sound durable rock with a percentage of wear not exceeding 45 when tested in accordance with AASHTO T 96. With written approval of the Engineer and compliance with this specification, chat sand produced from flint chat in the Joplin area, dolomite chat sand as produced in the southeast lead belt area, fines manufactured from igneous rock and chert gravel, or wet bottom boiler slag may be used as fine aggregate for asphaltic concrete. Fine aggregate shall be free from cemented or conglomerated lumps and shall not have any coating or injurious material. The percentage of deleterious substances shall not exceed the following values: Item
Percent by Weight
Clay lumps and shale
1.0
Total lightweight particles, including coal and lignite
0.5
Other deleterious substances
0.1
Lightweight sand particles are not considered deleterious lightweight particles. The total lightweight particles requirement shall not apply to wet bottom boiler slag, angular chert sand, or manufactured sand. 1002.2.2 Fine Aggregate Angularity. When, in accordance with AASHTO T 304 Method A, aggregate particles passing the Number 8 sieve shall meet the following criteria for the minimum percent air voids in loosely compacted fine aggregate. Fine aggregate angularity is measured on fine portion of the blended aggregate.
Design Level
Mixture Depth from Surface 4 inches > 4 inches
F
-
-
E
40
40
D
45
40
C
45
40
B
45
45
1002.2.3 Fine aggregates manufactured by the mechanical reduction of sound durable rock shall be manufactured from ledges that meet the same soundness requirements as for the coarse aggregate.
9/16/2008
1002-3
Aggregate for Superpave Asphaltic Concrete
1002.3 Clay Content. When tested in accordance with AASHTO T 176, aggregate particles passing the Number 4 sieve shall meet the following sand equivalent criteria: Design Level
Sand Equivalent Minimum, Percent
E, F
40
C, D
45
B
50
1002.4 Mineral Filler. Mineral filler shall consist of limestone dust, Portland cement, or other suitable mineral matter. It shall be thoroughly dry and free of lumps consisting of aggregations of fine particles. When tested by means of laboratory sieves in accordance with AASHTO T 37, the mineral filler shall conform to the following requirements: Sieve Size
Percent Passing By Weight
Number 30
100
Number 50
95 - 100
Number 100
90 - 100
Number 200
70 - 100
1002.5 Soundness. When testing in accordance with AASHTO T 104, the loss of coarse aggregate in 5 cycles of the accelerated soundness test shall not be greater than 12 percent when sodium sulfate is used. Aggregates to be tested shall be made available for testing a minimum of 10 calendar days prior to the intended time of use. It shall be the responsibility of the Contractor to notify St. Louis County when samples are available. A soundness test taken on aggregate sampled from a well-defined quarry ledge or gravel pit may be considered to represent that entire ledge or pit, and any fine or coarse aggregate fractions from that ledge or pit. Should any change in ledge or pit characteristics be observed, retesting might be required at the discretion of the Engineer. If approval of a stockpile is requested, the stockpile shall contain material for 5 days of the intended usage or 500 tons, whichever is greater. No material shall be removed from or added to the stockpile during the testing period. Unapproved material shall be segregated from approved materials in stockpiles at all times. This specification shall not apply to siliceous sands from the Missouri, Mississippi, or Meramec Rivers.
9/16/2008
1002-4
Aggregate for Superpave Asphaltic Concrete
1002.6 Hydrated Lime. Hydrated lime shall be thoroughly dry and free of lumps. Hydrated lime produced from limestone shall comply with ASTM C 206, Type N or S. Hydrated lime produced from dolomite shall comply with ASTM C 206, Type S. The plasticity requirements of ASTM shall not apply to either Type N or S, and the gradation shall be determined in accordance with AASHTO T 37. 1002.7 Salvaged Bituminous Materials. requirements of Section 413.
9/16/2008
Salvaged bituminous materials shall meet the
1002-5
Aggregate for Superpave Asphaltic Concrete
(This Page Intentionally Left Blank)
9/16/2008
1002-6
Aggregate for Superpave Asphaltic Concrete
Section 1003
Aggregate for Seal Coats
1003.1 Scope. This specification covers aggregate to be used for seal coat. 1003.2 Aggregate. Aggregate for seal coats shall consist of either Porphyry Trap Rock sound durable rock particles, free from objectionable coatings; or coated Haydite® Expanded Shale Lightweight Aggregate, free from objectionable coatings. 1003.2.1 When tested in accordance with AASHTO T 96, the percentage of wear for Porphyry Trap Rock and uncoated Haydite® Expanded Lightweight Aggregate (tested in accordance with MoDOT Test Method T 78) shall not exceed 25 percent. The sum of the percentages of all deleterious substances shall not exceed 2.0 percent by weight of aggregate, and the aggregate shall meet the following criteria:
Porphyry Trap Rock
Haydite® Expanded Shale Lightweight Aggregate
Deleterious rock, percent by weight, max.
2.0
2.0
Shale, percent by weight, max.
0.5
N/A
Other foreign material, percent by weight, max.
0.5
0.5
Two fractured faces, percent, min.
100
N/A
Thin, elongated particles, ASTM D 4791, 5:1, percent, max.a
10
N/A
Micro-Deval, AASHTO T 327, percent, max.
20
20
Property
a
9/16/2008
Test material retained on the Number 4 sieve.
1003-1
Aggregate for Seal Coats
1003.2.2 The Porphyry Trap Rock and uncoated Haydite® Expanded Lightweight Aggregate shall be in accordance with the following requirements for the type specified in the contract. Aggregate production shall be in accordance with the approved mix design target value and Quality Control (QC) range specified. The aggregate gradation shall not be outside the limits of percent passing for each sieve for each aggregate type. The aggregate size shall meet the following gradation requirements as tested by ASTM C 136: Porphyry Trap Rock (Percent Passing by Weight)
Haydite® Expanded Shale Lightweight Aggregate (Percent Passing by Weight)
Quality Control Range (Percent ±)
½ Inch
100
95-100
N/A
⅜ Inch
80-100
85-100
5
Number 4
0-5
0-30
7
Number 8
N/A
0-10
4
Number 200
0-1.0
0-2.0 a
N/A
Sieve Size
a
The percent passing the Number 200 sieve may be increased by 1.0 percent provided the aggregate is pre-coated with bituminous material.
1003.2.3 Crushed stone shall be obtained from rock of uniform quality. Crushed Porphyry stone shall meet the following criteria: Property
Porphyry Trap Rock
Absorption, AASHTO T 85, percent, max
2.0
Stripping, AASHTO T 182, at 95 , percent, max
25
1003.2.4 Haydite® Expanded Shale Lightweight Aggregate, the product resulting from the expanding of shale in a rotary kiln at temperatures exceeding 1,850°F, shall be obtained from a single shale source deposit of uniform quality. No blending of Haydite® ® manufactured from different sources is allowed. Haydite tested for initial source approval shall be in accordance with the following density requirements: Haydite® Expanded Shale Lightweight Aggregate
Property Density, ASTM Test Method C 29 (C 29M) shoveling procedure, lb/ft3
9/16/2008
1003-2
35-60
Aggregate for Seal Coats
1003.2.4.1 Pre-coating binder shall be in accordance with Section 1015 for PG binder or emulsions. The Contractor shall determine the design quantity of a pre-approved asphalt cement (PG64-22) to use for pre-coating. Enough asphalt cement shall be added to produce a black, shiny appearance. The Haydite® aggregate shall be precoated with 0.5 to 2.0 percent by weight of residual binder on the dry weight of aggregate by heating the aggregate in a standard hot-mix plant to a temperature within the range of 160°F to 185°F. The actual binder type and percent of asphalt used shall be as specified in the submitted mix design. The furnished pre-coated aggregate shall be coated within 0.3 percent of the target value specified in the mix design. Asphalt binder for pre-coating Haydite® shall meet the following criteria: ASPHALT BINDER REQUIREMENTS Tests on Asphalt Binder a
Test Method
Minimum
Maximum
Penetration @ 77°F
ASTM D 5
60
150
AASHTO T 301
65
---
Elastic Recovery @ 50°F, Percent a
These tests shall be done on the asphalt residue for emulsions and cutbacks.
1003.2.4.2 Additives to reduce stripping or improve adhesive compatibility with the AC 20-5TR shall be indicated by manufacturer, brand name, and rate of application in the mix design and approved by the Engineer. 1003.3 Aggregate Storage Requirements. This material shall be stockpiled on an asphalt or concrete surface, not located in a flood plain, which shall be enclosed with a locked gate for security. A release form is needed from the property owner of each different site approving use of the site, and a final release form from the property owner notifying the Engineer that all dirt and debris had been cleaned up. The Contractor shall submit to the Engineer these release forms no later than the Final Inspection. 1003.3.1 Pre-coated aggregate shall be cooled to prevent asphalt or aggregate damage due to excessive heat buildup in stockpiles. The Engineer will reject stockpiles showing evidence of damage due to excessive heat buildup.
9/16/2008
1003-3
Aggregate for Seal Coats
(This Page Intentionally Left Blank)
9/16/2008
1003-4
Aggregate for Seal Coats
Section 1004
Aggregate for Bituminous Concrete
1004.1 Coarse Aggregate. 1004.1.1 All coarse aggregate shall consist of sound, durable rock, free from objectionable coatings. When the coarse aggregate is tested in accordance with AASHTO T 96 (Los Angeles Abrasion), the percentage of wear shall not exceed 45. Coarse aggregate tested in accordance with AASHTO T 327 Micro Deval Abrasion Test the percent loss shall not exceed 20. The percentage of deleterious substances shall not exceed the following values and the sum of percentages of all deleterious substances shall not exceed 8 percent. At least 60 percent of the particles, retained on a Number 4 sieve, for use in bituminous concrete shall have two or more mechanically induced faces. Item
Percent by Weight
Deleterious Rock
8.0
Mud Balls and Shale Combined
2.0
Clay, uniformly dispersed
3.0
Other Foreign Material
0.5
The requirements of this section apply to each size or fraction of aggregate produced. 1004.1.2 When a density requirement is specified for bituminous concrete, the total quantity of chert in each size or fraction of produced crushed stone aggregate, including that permitted as deleterious, shall not vary more than 10 percent from the quantity present in the aggregates used in the approved laboratory job mixtures. 1004.1.3 Gravel aggregate shall be washed sufficiently to remove any objectionable coating. Gravel aggregate for Type X mixtures shall be crushed from gravel that has a maximum of 10 percent passing a 1-inch sieve. Gravel aggregate for Type C mixtures shall be crushed from gravel that has a maximum of 10 percent passing a ¾-inch sieve. Crushed gravel shall comply with the requirements for mechanically induced faces in Section 1002.1. 1004.1.4 Pile-run chat will not be approved for use in bituminous concrete unless the chat has been conditioned to meet a specific gradation. A tolerance of 7 percent, plus or minus, on each sieve fraction will be permitted providing that the aggregate complies with other provisions of this specification.
3/1/2016
1004-1
Aggregate for Bituminous Concrete
1004.1.5 The gradation of coarse aggregate shall be such that the combinations of coarse aggregate fractions, when combined with fine aggregate, will meet the gradation requirements for the type of bituminous concrete specified for Type C and Type X bituminous concrete mixtures. At least one fraction of coarse aggregate, which comprises not less than 20 percent of the total mixture, shall comply with the following requirements. The maximum size of each fraction is defined by the smallest sieve through which 100 percent will pass: Maximum Percent Passing Sieve Maximum Size of Fraction
Number 8
Number 200
1 inch
----
2.0
¾ inch
12.0
3.5
½ inch
12.0
3.5
⅜ inch or smaller
14.0
4.0
1004.1.6 Absorption. Crushed stone shall be obtained from rock of uniform quality. Rock from individual ledges and gravel tested for initial source approval shall meet the following criteria: Absorption, AASHTO T 85, percent, maximum ............................... 4.5 1004.2 Fine Aggregate. 1004.2.1 Fine aggregate for bituminous concrete shall be a fine, granular material naturally produced by the disintegration of rock of a siliceous nature and / or manufactured by the mechanical reduction of sound durable rock with a percentage of wear exceeding 45 when tested in accordance with AASHTO T 96. With written approval of the Engineer and compliance with this specification, chat sand produced from flint chat in the Joplin area, dolomite chat sand as produced in the southeast lead belt area, or fines manufactured from igneous rock and chert gravel, or wet bottom boiler slag may be used as fine aggregate for asphaltic concrete. Fine aggregate shall be free from cemented or conglomerated lumps and shall not have any coating or injurious material. The fraction passing a Number 40 sieve shall be non-plastic. The percentage of deleterious substances shall not exceed the following values: Item
Percent by Weight
Clay lumps and shale
1.0
Total lightweight particles, including coal and lignite
0.5
Other deleterious substances
0.1
3/1/2016
1004-2
Aggregate for Bituminous Concrete
Lightweight sand particles are not considered deleterious lightweight particles. The total lightweight particles requirement shall not apply to wet bottom boiler slag, angular chert sand, or manufactured sand. 1004.3 Material designated as Limestone Screenings shall not be used in bituminous concrete unless the material can meet the following gradation and quality requirements:
Sieve Size ⅜ inch
Percent Passing by Weight 95 percent minimum
Number 8
± 10 percent of approved design material
Number 200
± 5 percent of approved design material *
* Material not meeting the passing Number 200 sieve minimum may be supplemented by mineral filler meeting the requirements of 1002.3 in order to produce the final mix composition.
The fraction passing the Number 40 sieve shall exhibit a maximum plasticity index of 5 when tested in accordance with AASHTO T 90. Fine aggregate manufactured in accordance to Section 1002.2.3 may be used in lieu of or in combination with Limestone Screenings, provided that the approved mix design is structured to accommodate the blending of these two materials. 1004.4 Mineral Filler. Mineral filler shall consist of limestone dust, Portland cement, or other suitable mineral matter. It shall be thoroughly dry and free of lumps consisting of aggregations of fine particles. When tested by means of laboratory sieves in accordance with AASHTO T 37 the mineral filler shall conform to the following requirements: Sieve Size
Percent Passing by Weight
Number 30
100
Number 50
95-100
Number 100
90-100
Number 200
70-100
1004.5 Salvaged Bituminous Materials. requirements of Section 413.
3/1/2016
Salvaged bituminous materials shall meet the
1004-3
Aggregate for Bituminous Concrete
1004.6 Soundness. When testing in accordance with AASHTO T 104, the loss of coarse aggregate in 5 cycles of the accelerated soundness test shall not be greater than 12 percent when sodium sulfate is used. Aggregates to be tested shall be made available for testing a minimum of ten calendar days prior to the intended time of use. It shall be the responsibility of the Contractor to notify the St. Louis County Department of Transportation when samples are available. A soundness test taken on aggregate sampled from a well-defined quarry ledge or gravel pit may be considered to represent that entire ledge or pit and any fine or coarse aggregate fractions from that ledge or pit. Should any change in ledge or pit characteristics be observed, retesting might be required at the discretion of the Engineer. If approval of a stockpile is requested, the stockpile shall contain material for 5 days of the intended usage or 500 tons, whichever is greater. No material shall be removed from or added to the stockpile during the testing period. Unapproved material shall be segregated from approved materials in stockpiles at all times. This specification shall not apply to siliceous sands from the Missouri, Mississippi, or Meramec Rivers. 1004.7 Hydrated Lime. Hydrated lime shall be thoroughly dry and free of lumps. Hydrated lime produced from limestone shall comply with ASTM C 206 Type N or S. Hydrated lime produced from dolomite shall comply with ASTM C 206 Type S. The plasticity requirements of ASTM shall not apply to either Type N or S, and the gradation shall be determined in accordance with AASHTO T 37.
3/1/2016
1004-4
Aggregate for Bituminous Concrete
Section 1005
Aggregate for Concrete
1005.1 Scope. This specification covers aggregate to be used for concrete construction. 1005.2 Coarse Aggregate. Aggregate sampling and grading shall be performed in accordance with AASHTO T 2 and AASHTO T 27, respectively. 1005.2.1 Deleterious Substances and Physical Properties. All coarse aggregate for concrete shall consist of sound, durable rock, free from objectionable coatings and frozen and cemented lumps. The percentage of deleterious substances shall not exceed the following values and the sum of percentages of all deleterious substances, exclusive of Items 5 and 6, shall not exceed 6.0 percent.
Item No.
Deleterious Material
Test Method
Maximum (Percent by Weight)
1
Deleterious Rock
2
Shale
3
Chert in Limestone
4
Other Foreign Material (Clay lumps, mud balls, lignite, coal, roots, sticks)
5
Material Passing No.200 Sieve, Gradations B, D & E
AASHTO T 11
2.5
6
Flat and Elongated Pieces (5:1)
ASTM D 4791
5.0
1005.2.1.1 produced.
6.0 MoDOT TM 71
1.0 4.0 0.5
The above requirements apply to each size or fraction of aggregate
1005.2.1.2 Crushed Stone Physical Properties. Crushed stone shall be obtained from rock of uniform quality. Rock tested for initial approval shall be in accordance with the criteria below. Source approval and production samples shall also meet the following criteria:
2/1/2017
1005-1
Aggregate for Concrete
Physical Property
Test Method
Bulk Specific Gravity (Oven-Dry)
Allowable Limits Minimum
Maximum
AASHTO T 85
2.590
--
Los Angeles Abrasion, percent
AASHTO T 96
--
45
Micro Deval Abrasion Test, percent
AASHTO T 327
--
20
Absorption (percent): a) Portland Cement Concrete Pavement b) Portland Cement Concrete All Other
AASHTO T 85
---
2.0 3.0
Sodium Sulfate Soundness (5 cycles), percent:
AASHTO T104
--
10
Durability Factor, percent: a) Portland Cement Concrete Pavement b) Portland Cement Concrete Masonry
AASHTO T 161 Procedure B
75 a --
---
a
Approval will be based on maximum aggregate size produced that meets durability requirements. The test data shall not be more than two years old at the time of submittal.
1005.2.1.3 Gravel Physical Properties. Gravel shall be washed and shall be in accordance with the criteria below for initial approval. Source approval and production samples shall also meet the following criteria:
Property
Test Method
Allowable Limits (Percent)
Los Angeles Abrasion
AASHTO T 96
45
Micro Deval Abrasion Test
AASHTO T 327
20
Absorption
AASHTO T 85
4.5
Sodium Sulfate Soundness
AASHTO T104
12
Maximum
1005.2.1.4 The Engineer reserves the right to use additional test methods, such as ASTM C 586, AASHTO T 161 or other appropriate tests, to measure the soundness and durability of aggregate for use in concrete when maximum allowable limits of physical properties listed above are exceeded. 1005.2.2 Coarse aggregate for concrete pavement, pavement repair or base course shall be crushed stone or porphyry.
2/1/2017
1005-2
Aggregate for Concrete
1005.2.3 Recycled Content. Up to 10 percent of the weight of the total coarse aggregate may be replaced with recycled crushed concrete coarse aggregate fraction that meets the quality requirements of Section 1005.2.1.2 for pavements or structures, or Section 1005.2.1.3 for structures. The recycle concrete coarse aggregate, when combined with virgin coarse aggregate, shall meet the gradation requirements in accordance with applicable Sections 1005.2.4, 1005.2.5 or 1005.2.6. 1005.2.4 Pavement, Joint or Base Repair Requirements. Coarse aggregate for concrete pavement, pavement repair, or base course shall be crushed stone or porphyry and shall be graded to meet Gradation B or Gradation D. AASHTO coarse aggregate gradations may be substituted as referenced. All sizes shall be determined by means of laboratory sieves having square openings and conforming to AASHTO M 92. Gradation B (AASHTO M 43, Size No. 57) Sieve Size
Percent Passing by Weight
1½ inch
100
1 inch
95-100
½ inch
25-60
No. 4
0-10
No. 8
0-5
No. 200
0-2.5
1005.2.5 Structural Concrete Requirements. Coarse aggregate for concrete for structures, except as specified in Section 1005.2.6, may be gravel or crushed stone. Coarse aggregate for Class B, B-1, B-2, B-2 Modified or Seal concrete shall meet the requirements of either Gradation D or E. Coarse aggregate for Class A-1 concrete shall meet the requirements of Gradation E. AASHTO coarse aggregate gradations may be substituted as referenced. The maximum size of coarse aggregate that can be used in a mix depends on the size, shape, and reinforcing of a member. The maximum size of coarse aggregate shall not exceed the smallest of either ¾ of the clear spacing between rebar or between rebar and forms (cover distance). When structural concrete is to be pumped the maximum size of coarse aggregate shall not exceed ⅓ the internal diameter of the hose.
2/1/2017
1005-3
Aggregate for Concrete
Gradation D (AASHTO M 43, Size No. 67) Sieve Size
Percent Passing by Weight
1 inch
100
¾ inch
85-100
⅜ inch
15-55
No. 4
0-10
No. 8
0-5
No. 200
0-2.5
Gradation E (AASHTO M 43, Size No. 7) Sieve Size
Percent Passing by Weight
¾ inch
100
½ inch
70-100
⅜ inch
30-70
No. 4
0-20
No. 8
0-6
No. 200
0-2.5
1005.2.6 Chert Limitations. Coarse aggregate for sidewalks, steps, medians and drive approaches concrete shall be crushed stone meeting the requirements of Section 1005.2.5, Gradation D or E. However, the use of coarse aggregate containing more than 2 percent chert will not be permitted. 1005.2.7 Aggregates to be tested shall be made available for testing a minimum of ten calendar days prior to the intended time of use. It shall be the responsibility of the Contractor to notify St. Louis County when samples are available. 1005.2.8 Soundness. When testing in accordance with AASHTO T 104 the loss of coarse aggregate in 5 cycles of the accelerated soundness test shall not be greater than the percent specified when sodium sulfate is used. Aggregates to be tested shall be made available for testing a minimum of ten calendar days prior to the intended time of use. It shall be the responsibility of the Contractor to notify St. Louis County when samples are available.
2/1/2017
1005-4
Aggregate for Concrete
A soundness test taken on aggregate sampled from a well-defined quarry ledge or gravel pit may be considered to represent that entire ledge or pit, and any fine or coarse aggregate fractions from that ledge or pit. Should any change in ledge or pit characteristics be observed, retesting may be required at the discretion of the Engineer. If approval of a stockpile is requested, the stockpile shall contain material for 5 days of the intended usage or 500 tons, whichever is greater. No material shall be removed from or added to the stockpile during the testing period. Unapproved material shall be segregated from approved materials in stockpiles at all times. 1005.2.9 Bulk Density (Unit Weight) and Voids in Aggregate. The aggregate bulk density and voids shall be tested and reported in accordance with AASHTO T 19. 1005.3 Fine Aggregate. 1005.3.1 Fine aggregate for concrete shall be a fine granular material naturally produced by the disintegration of rock of a siliceous nature or manufactured from an approved limestone or dolomite source as defined in Section 1005.2. By specific approval from the Engineer, fines manufactured from igneous rock or chert gravel may be used. Fine aggregate shall be free from cemented or conglomerated lumps and shall not have any coating of injurious material. The percentage of deleterious substances shall not exceed the following values:
Deleterious Material
Test Method
Allowable Limits (Percent by Weight)
Clay Lumps and Friable Particles
AASHTO T 112
0.25
Coal and Lignite
AASHTO T 113
0.50
Total Lightweight (low mass density) Particles, Including Coal and Lignite
AASHTO T 113
0.50
Material Passing Number 200 Sieve a) Natural Sand b) Manufactured Sand
AASHTO T 11
2.0 4.0
Other Deleterious Substances (such as shale, alkali, mica, coated grains, and soft and flaky particles)
MoDOT TM 71
0.10
Sodium Sulfate Soundness (5 cycles)1
AASHTO T 104
10
1
Maximum
This specification shall not apply to siliceous sands from the Missouri, Mississippi, or Meramec rivers.
1005.3.2 Lightweight (Low mass density) sand particles will not be considered deleterious lightweight (low mass density) particles. The total lightweight (low mass density) particle requirement shall not apply to angular chert sand or manufactured sand.
2/1/2017
1005-5
Aggregate for Concrete
1005.3.3 Organic Impurities in Fine Aggregate. Fine aggregate subjected to the mortar strength test shall produce a mortar having a compressive strength at the age of 7 days of at least 90 percent of that developed at the same age by mortar of the same proportions using standard Ottawa sand. Tests shall be performed in accordance with AASHTO T 106. Cement used in the tests shall be Type I meeting the requirements of Section 1019. AASHTO T 106 may be waived provided the fine aggregate produces a glass color standard lighter than Organic Plate No. 3, in accordance with AASHTO T 21. 1005.3.4 Recycled Content. Up to 10 percent of the weight of the total fine aggregate may be replaced with recycled crushed concrete fine aggregate fraction that meets the deleterious requirements of Section 1005.3.1 and the soundness requirement of Section 1005.3.6. The recycle concrete fine aggregate, when combined with virgin fine aggregate, shall meet the gradation requirements in accordance with Section 1005.3.7. 1005.3.5 Lignite-Free Material. Fine aggregate for concrete to be used in sidewalks, steps, medians and drive approaches shall not contain more than 0.05 percent coal and lignite material when tested in accordance with AASHTO T 113. 1005.3.6 Gradation. 1005.3.6.1 All fine aggregate shall meet the following gradation requirements (AASHTO M 6 fine aggregate gradation may be substituted): Sieve Size
Percent Passing (by Weight)
⅜ inch
100
No. 4
95-100
No. 8
70-100
No. 16
45-90
No. 30
15-65
No. 50
5-30
No. 100
0-10
1005.3.6.2 Uniformity of Grading. Fine aggregate shall have a fineness modulus not less than 2.3 or more than 3.1. The uniformity of the fineness modulus shall not vary by 0.20 from the base fineness modulus typical of the source. See AASHTO M 6, Note 5 for additional information on uniformity of grading. 1005.4 Lightweight (Low Mass Density) Aggregates. Lightweight aggregates shall be tested and reported in accordance with ASTM C330 Lightweight Aggregates for Structural Concrete. 1005.4.1 Lightweight (Low mass density) aggregates shall be prepared by expanding, calcining or sintering products such as blast-furnace slag, clay, shales and slates.
2/1/2017
1005-6
Aggregate for Concrete
1005.4.2 Grading. The grading shall be uniform and conform to the requirements given in the following table: TABLE I Grading Requirements for Lightweight Aggregate Percent Passing Grade
Sieve Sizes
Size
Fine Aggregate, No. 4 to 100
1"
¾"
½"
⅜"
No. 4
No. 8
No. 16
No. 50
No. 100
No. 200
….
….
….
100
85-100
….
40-80
10-35
5-25
….
Coarse Aggregate 1
1" to No. 4
95-100
….
25-60
….
0-10
….
….
….
0-10
2
¾" to No. 4
100
90-100
….
10-50
0-15
….
….
….
0-10
3
½" to No. 4
….
100
90-100
40-80
0-20
0-10
….
….
….
0-10
4
⅜" to No. 8
….
….
100
80-100
5-40
0-20
0-10
….
….
0-10
Combined Fine and Coarse Aggregate 5
½"
….
100
95-100
….
50-80
….
….
5-20
2-15
0-10
6
⅜"
….
….
100
90-100
65-90
35-65
….
10-25
5-15
0-10
1005.4.3 Unit Weight. The unit weight of lightweight (low mass density) aggregates shall not exceed the following: Maximum Dry Loose Bulk Density (Pounds per cubic foot)
Material Fine Aggregate
70
Coarse Aggregate
55
Combined Fine and Coarse Aggregate
65
2/1/2017
1005-7
Aggregate for Concrete
1005.4.3.1 Uniformity of Weight. If the unit weight of any shipment of lightweight (low mass density) aggregate when tested in accordance with AASHTO T 19 is found to vary by more than 10 percent from that of the sample submitted for source approval, the aggregate in the shipment may be rejected. 1005.4.4 Allowable Clay Lumps. The amount of clay lumps shall not exceed 2 percent by dry weight. 1005.4.5 Soundness. When tested in accordance with AASHTO T 104, the loss of lightweight (low mass density) fine or coarse aggregate in 5 cycles of the accelerated soundness test shall not exceed 8 percent when sodium sulfate is used. 1005.4.6 Drying Shrinkage. The drying shrinkage of concrete specimens prepared and tested in accordance with Section 9.1.4 of AASHTO M 195, shall not exceed 0.07 percent. 1005.4.7 Sampling. Samples of fine and coarse aggregate shall be furnished by the Contractor for source approval. Other samples shall be taken from shipments at intervals specified by the Engineer. 1005.4.8 Storage and Handling of Aggregates. Storage and handling of lightweight aggregates shall be in accordance with Section 1001.12 and the following requirements. 1005.4.8.1 Supply. The Contractor should communicate the volume of concrete containing lightweight aggregate to the material producer/supplier at least 2 weeks in advance of use. The amount of lightweight material required plus an additional amount to account for product waste or loss shall be on hand prior to initial production of concrete with lightweight aggregate. The aggregate will have the minimum required moisture content for use at the time of concrete production. 1005.4.8.2 Stockpile Construction and Maintenance Moisture Control. Uniformly pre-wet or pre-saturate the aggregates in such a manner that uniform penetration of the concrete will be maintained. Construct lightweight aggregate stockpile(s) at the production facility so as to maintain uniform moisture throughout the pile without segregation of the material. Using a sprinkler system approved by the Materials Engineer, continuously and uniformly sprinkle the stockpile(s) with potable water for a minimum of 48 hours, or until the aggregate minimum "Absorbed Moisture Content" of the stockpile(s) is reached, in accordance with an approved test method, at the time of batching. If a steady rain of comparable intensity occurs, the producer may turn off the sprinkler system at the direction of the Materials Engineer, until the rain ceases. At the end of the wetting period, or after the rain ceases, allow the stockpile(s) to drain for 12 to 15 hours immediately prior to use, unless otherwise directed by the Materials Engineer.
2/1/2017
1005-8
Aggregate for Concrete
1005.5 Optimized Aggregate Blend Guidelines. For concrete pavements an optimized aggregate blend of three or more aggregate sizes may be required. Coarse and Fine aggregate fractions shall meet the quality and sampling requirements specified in Section 1005. For coarse aggregate, 100 percent of each fraction shall pass the one-inch sieve and no more that 2.5 percent shall pass the No. 200 sieve. For fine aggregate, no more than 2.0 percent shall pass the No. 200 sieve for natural sand, and no more than 4.0 percent shall pass the No. 200 sieve for manufactured sand. Gap graded blends and aggregate blends that are deficient in coarse aggregate may be rejected by the Engineer. A gradation is considered optimum when the sum of the percent retained on two consecutive sieves are a minimum of 13 percent and no less than 5 percent retained on one or more intermediate sieves. Intermediate sieves are considered No. 4 through No. 30 sieves. The grading shall be uniform and conform to the requirements given and the following table: Optimized Gradation Sieve Size
Percent Retained (by Weight)
1½ inch
0
1 inch
0-16
¾ inch
0-20
½ inch
4-20
No. 4
4-20
No. 8
0-12
No. 16
0-12
No. 30
4-12
No. 50
4-20
No. 100
0-10
No. 200
0-4
1005.6 Combined Aggregate Gradation Requirements. Coarseness, workability and the aggregate combined gradation are important indicators of how successful a concrete mix design may be in the field. The following items are required when submitting aggregates for approval with a concrete mix design. Concrete mixtures produced with a combined aggregate gradation that produces a dense aggregate matrix tend to: 1) Reduce the water demand. 2) Reduce the cementitious material demand. 3) Reduce the shrinkage potential.
2/1/2017
1005-9
Aggregate for Concrete
4) Improved workability. 5) Require minimal finishing. 6) Consolidate without segregation. 7) Enhance strength. 1005.6.1 Coarseness and Workability. The mathematically combined coarse and fine aggregate gradation, expressed as a percent passing and percent retained, shall be calculated for each sieve size specified in Section 1005.3. In addition to the grading requirements specified for coarse aggregate and for fine aggregate, the combined aggregate grading shall meet the following requirements. The materials selected and the proportions used shall be such that when the Coarseness Factor (CF) and the Workability Factor (WF) are plotted on a diagram as described in Section 1005.6.6, the point thus determined shall fall within the parallelogram described therein. The CF and WF values are to be reported to the nearest 0.1. 1005.6.2 The Coarseness Factor (CF) shall be determined from the following equation: CF = [(cumulative percent retained on the ⅜ inch sieve) x (100)] / (cumulative percent retained on the No. 8 sieve) 1005.6.3 The Workability Factor (WF) is defined as the percent passing the No. 8 sieve based on the combined gradation. However, the WF shall be adjusted (W-adj) by 2.5 percentage points for each 94 pounds of cementitious material per cubic yard less than or greater than 564 pounds per cubic yard. The Adjusted Workability Factor (W-adj) shall be determined from the following equation: W-adj = WF + [(Amount of Cementitious Materials – 564)/94] x 2.5 1005.6.4 Coarseness / Workability Diagram. A diagram shall be plotted using a rectangular scale with WF on the Y-axis with units from 20 (bottom) to 45 (top), and with CF on the X-axis with units from 80 (left side) to 30 (right side). On this diagram a parallelogram shall be plotted with corners at the following coordinates (CF-75, WF-28.5), (CF-75, WF39.5), (CF-45, WF-32.5), and (CF-45, WF-43.5). If the point determined by the intersection of the computed CF and WF-adj does not fall within the above parallelogram, the grading of each size of aggregate used and the proportions selected shall be changed as necessary. 1005.6.5 Special Requirement for Slabs on Ground. For slabs on ground the W-adj computed in Section 1005.6.3 shall be compared to the computed W-adj range in this section. The gradation may need to be adjusted to fit within the range specified in this section. For slabs on ground, the ideal relationship between CF and W-adj should be within the following range: W-adj = [[(75-CF) / 6.67] + 34] ± 3
2/1/2017
1005-10
Aggregate for Concrete
1005.6.6 0.45 Power Curve. The 0.45 power curve plot is based on the mathematically combine percent passing combined gradation. The 0.45 power curve is created by plotting the mathematically combined percent gradation for each sieve on a semi-log chart having the percent passing on the y-axis and the sieve sizes raised to the 0.45 power on the x-axis. Sieve sizes to be included are the 1½ inch, 1 inch, ¾ inch, ½ inch, ⅜ inch, No. 4, No. 8, No. 16, No. 30, No. 50, No. 100 and No. 200. The plotted points are then connected and compared with the maximum density line. The maximum density line is plotted from the origin of the chart to the one size larger than the first sieve to have 90 percent or less passing. A well-graded combined aggregate gradation will follow the maximum density line closely from the largest sieve down to the No. 16 sieve. 1005.6.6.1 The combined grading should follow the maximum density line within ±7 percent for each percent passing. A slight deviation below the maximum density line is to be expected from the No. 16 sieve to the No. 200 sieve to account for the cementitious material(s). If the points determined do not fall within the above tolerances, the grading of each size of aggregate used and the proportions selected shall be changed as necessary. 1005.6.7 Cohesion and Workability for Pavements. The coarse sand amount needed for cohesion (the amount retained on the #8, #16, and #30 shall be greater than 15%) and fine sand for workability (between 24% and 34% retained on the #30 - #200).
2/1/2017
1005-11
Aggregate for Concrete
(This Page Intentionally Left Blank)
2/1/2017
1005-12
Aggregate for Concrete
Section 1006
Aggregate Surfacing Material
1006.1 Aggregate for seal coats shall consist of either Porphyry Trap Rock sound durable rock particles, free from objectionable coatings; or coated Haydite® Expanded Shale Lightweight Aggregate as designated in the contract documents. 1006.1.1 When tested in accordance with AASHTO T 96, the percentage of wear for Porphyry Trap Rock aggregate shall not exceed 25 percent. When tested in accordance with MoDOT Test Method T 78 for uncoated Haydite® Expanded Lightweight Aggregate, the percentage of wear shall not exceed 25 percent. The sum of the percentages of all deleterious substances shall not exceed 2.0 percent by weight of aggregate, and the aggregate shall meet the following criteria:
Porphyry Trap Rock
Haydite® Expanded Shale Lightweight Aggregate
Deleterious rock, percent by weight, maximum
2.0
2.0
Shale, percent by weight, maximum
0.5
N/A
Other foreign material, percent by weight, maximum
0.5
0.5
Two fractured faces, percent, minimum
100
N/A
Thin, elongated particles, ASTM D 4791, 5:1, percent, maximum a
10
N/A
Micro-Deval, AASHTO T 327, percent, maximum
20
20
Property
a
Test material retained on the Number 4 sieve.
1006.1.2 The Porphyry Trap Rock and uncoated Haydite® Expanded Lightweight Aggregate shall be in accordance with the following requirements for the type specified in the contract. Aggregate production shall be in accordance with the approved Mix Design target value and Quality Control (QC) range specified. The aggregate gradation shall not be outside the limits of percent passing for each sieve for each aggregate type. The aggregate size shall meet the following gradation requirements as tested by ASTM C 136:
9/16/2008
1006-1
Aggregate Surfacing Material
Porphyry Trap Rock
Haydite® Expanded Shale Lightweight Aggregate
Quality Control Range
Percent Passing by Weight
Percent Passing by Weight
Percent ±
½ Inch
100
95-100
N/A
⅜ Inch
80-100
85-100
5
Number 4
0-5
0-30
7
Number 8
N/A
0-10
4
Number 200
0-1.0
0-2.0 a
1
Sieve Size
a
The percent passing the Number 200 sieve may be increased by 1.0 percent provided the aggregate is pre-coated with bituminous material.
1006.1.3 Crushed Porphyry stone shall meet the following criteria: Property
Porphyry Trap Rock
Absorption, AASHTO T 85, percent, max
2.0
Stripping, AASHTO T 182
Pass
1006.1.4 Haydite® Expanded Shale Lightweight aggregate, the product resulting from the expanding of shale in a rotary kiln at temperatures exceeding 1,850°F, shall be obtained from a single shale source deposit of uniform quality. Haydite® tested for initial source approval shall be in accordance with the following density requirements:
Haydite® Expanded Shale Lightweight Aggregate
Property Density, ASTM Test Method C 29 (C 29M) shoveling procedure, pounds / foot 3
35-60
1006.1.5 Pre-coating binder shall be in accordance with Section 1015 for PG binder or emulsions. The Haydite® aggregate shall be precoated (with 0.5 to 3.0 percent by weight of residual binder on the dry weight of aggregate) by heating the aggregate in a standard hot-mix plant to a temperature within the range of 160°F to 185°F. The actual binder type and percent of asphalt used shall be as specified in the submitted mix design. The furnished pre-coated aggregate shall be coated within 0.3 percent of the target value specified in the mix design.
9/16/2008
1006-2
Aggregate Surfacing Material
1006.1.6 Aggregate Storage Requirements. This material shall be stockpiled on an asphalt or concrete surface, not located in a flood plain, which shall be enclosed with a locked gate for security. A release form is needed from the property owner of each different site approving use of the site, and a final release form from the property owner notifying the Engineer that all dirt and debris had been cleaned up. The Contractor shall submit to the Engineer these release forms no later than the Final Inspection. 1006.1.6.1 Pre-coated aggregate shall be cooled to prevent asphalt or aggregate damage due to excessive heat buildup in stockpiles. The Engineer will reject stockpiles showing evidence of damage due to excessive heat buildup.
9/16/2008
1006-3
Aggregate Surfacing Material
(This Page Intentionally Left Blank)
9/16/2008
1006-4
Aggregate Surfacing Material
Section 1007
Aggregate for Base
1007.1 Type 5 Aggregate. Type 5 aggregate for base shall consist of crushed stone or sand and gravel. 1007.1.1 Limitations. If crushed stone is used, sand may be added only for the purpose of reducing the plasticity index of the fraction passing the No. 40 sieve in the finished product. Any sand, silt and clay and any deleterious rock and shale shall be uniformly distributed throughout the material. When sand and gravel aggregate is used, the fraction passing the No. 200 sieve shall be less than one-half that of the fraction passing the No. 30 sieve. Type 5 Aggregate shall meet the following criteria: Property
Test Method
Requirements
Fractured Faces (two or more), percent minimum1
ASTM D 5821
75
Deleterious Rock and Shale, percent maximum
MoDOT TM 71
15
AASHTO T 89 & 90
6
Plasticity Index, maximum2
Notes: 1 Tested on the particles which are retained on a ⅜ inch sieve. 2 Tested on the fraction passing the No. 40 sieve.
1007.1.2 Gradation. Type 5 aggregate shall conform to the following gradation requirements when sampled in accordance with ASSHTO T 2 and tested in accordance with AASHTO T 11 and 27. In addition, the aggregate shall be so graded that the aggregate will readily compact to the specified density and withstand construction traffic without distortion and displacement.
Sieve Size
7/1/2016
Percent Passing by Weight (Mass) Minimum
Maximum
1 inch sieve
100
-
½ inch sieve
60
90
No. 4 sieve
35
60
No. 30 sieve
10
35
No. 200 sieve
0
15
1007-1
Aggregate for Base
1007.2 Reclaimed Aggregate Base. Reclaimed aggregate base may be substituted as Type 5 aggregate base in accordance with the following requirements. 1007.2.1 Aggregate for reclaimed concrete material aggregate base may include material processed from reclaimed Portland cement concrete, lean concrete base, cement treated base or other concrete containing pozzolanic binders. 1007.2.2 Gradation. The aggregate for reclaimed concrete material aggregate base shall conform to Section 1007.1.2, Aggregate Base Material. Gradation and plasticity index shall be in accordance with Sections 1007.1.1 and 1007.1.2. 1007.2.2.1 Preliminary samples of existing stockpiled reclaimed concrete material from at least three (3) locations shall be submitted to the engineer for testing 14 calendar days prior to any material being placed on a project. Stockpile pads shall be provided and haul roads / plant areas properly maintained to assure that acceptable material is not contaminated prior to use. Once a gradation is selected, the grading shall not be changed without written approval of the Engineer. 1007.2.3 Central Recycling Plant. Reclaimed concrete may be recycled by crushing at a central recycling plant. Concrete used as a raw feed at a central recycling plant shall not be contaminated with dirt or foreign matter. Concrete composed of gravel shall be crushed to produce aggregate particles retained on a ⅜ inch sieve that result in at least 75 percent of the material having two or more fractured faces. 1007.2.4 Limitations. Reclaimed concrete aggregate for base course shall consist of at least 90 percent, by weight, Portland cement concrete, with the following materials making up the remaining 10 percent. RAP, brick, mica, schist, other friable materials, and wood limitations shall be determined by weighing that material retained on the No. 4 sieve, and dividing by the total weight of recycled concrete aggregate material retained on the No. 4 sieve: 1007.2.4.1 RAP Content Limitations. Reclaimed asphalt pavement (RAP) content in the reclaimed aggregate base, derived from composite pavement sections, shall be limited to no more than 5 percent by weight, unless otherwise specified. 1007.2.4.2 Brick, Mica, Schist, or Other Friable Materials Limitation. Brick, mica, schist, or other friable materials, shall be limited to no more than 4 percent by weight, unless otherwise specified. 1007.2.4.3 Wood Limitations. Wood shall be limited to no more than 0.1 percent by weight, unless otherwise specified 1007.2.5 Storage. Reclaimed crushed materials of differing material types are not to be mixed and shall be stored in separate stockpiles. The Contractor shall avoid using methods that segregate coarse and fine reclaimed concrete material. Stockpiles shall be separated from water courses to keep fines from being carried off and deposited in water courses.
7/1/2016
1007-2
Aggregate for Base
Section 1009
Aggregate for Drainage
1009.1 Scope. This specification covers material requirements for aggregate as specified for various drainage systems. 1009.2 Quality. All aggregates shall be in accordance with Section 1002, and shall be of the material and gradation specified herein. 1009.3 Gradation. 1009.3.1 Grade 1. The aggregate shall be fine aggregate meeting the gradation requirements of Section 1005.3. 1009.3.2 Grade 2. The aggregate shall be a washed sand-gravel mixture meeting the following gradation requirements: Sieve Size
Percent Passing by Weight
1 inch
100
½ inch
55 - 90
No. 10
25 - 50
No. 40
10 - 30
No. 100
0 - 10
No. 200
0-3
1009.3.3 Grade 3. The aggregate shall be coarse aggregate material meeting one of the gradation requirements for Section 1005.2. 1009.3.4 Grade 4. The aggregate shall be a crushed limestone or dolomite meeting the following gradation requirements. Unless otherwise specified, either gradation may be used. Gradation A
2/4/2011
Sieve Size
Percent Passing by Weight
1½ inch
100
1 inch
95 - 100
½ inch
25 - 60
No. 4
0 - 10
No. 8
0-5
1009-1
Aggregate for Drainage
Gradation B Sieve Size
Percent Passing by Weight
1 inch
100
¾ inch
90 - 100
⅜ inch
20 - 55
No. 4
0 - 10
No. 8
0-5
1009.3.5 Grade 5. The aggregate shall be a crushed limestone or dolomite meeting the following gradation requirements:
2/4/2011
Sieve Size
Percent Passing by Weight
1½ inch
100
1 inch
95 - 100
½ inch
60 - 80
No. 4
40 - 55
No. 8
5 - 25
No. 16
0-8
No. 50
0-5
1009-2
Aggregate for Drainage
Section 1010
Select Granular Backfill for Structural Systems and Box Culvert Bedding
Scope. This specification covers granular backfill material that is used in the reinforcement zone of a mechanically stabilized earth wall system or in other applications requiring an engineered backfill material. This specification also includes culvert bedding material used for the placement of shot rock and 1½ inch minus crushed limestone to construct a crushed stone bedding beneath the new box culvert as shown on the plans. Material. The requirements for the gradation of the material, the general makeup of the material, and the testing of the material shall apply to all potential uses of this material unless otherwise specified on the design plans or in the contract documents. The electrochemical requirements listed in this specification shall apply to backfill material used for the reinforcement zone of mechanically stabilized earth wall systems. General. To ensure proper functioning of the structure, the backfill material that is used for structural applications shall be well-graded in accordance with ASTM D 2487 Unified Soil Classification System, homogeneous and in accordance with the gradation limits, as tested in accordance with AASHTO T 27, as follows: Panel Mechanically Stabilized Earth (MSE) Wall Sieve Size
Percent Passing by Weight
4 inch
100
No. 40
0-60
No. 200
0-15 Modular Block MSE Wall 1
1
Sieve Size
Percent Passing by Weight
¾ inch
100
No. 40
0-60
No. 200
0-15
For geosynthetic reinforced structures and for epoxy or PVC coated steel reinforcements.
Reinforced Soil Slope Structure
9/1/2023
Sieve Size
Percent Passing by Weight
¾ inch
100
No. 4
20-100
No. 40
0-60
No. 200
0-50
1010-1
Select Granular Backfill for Structural Systems and Box Culvert Bedding
Select Granular Backfill for Box Culvert Bedding. This work consists of furnishing all materials necessary for the placement of 1½ inch minus crushed limestone on well graded crushed limestone shot rock to construct crushed stone bedding beneath the new box culvert as shown on the plans. The aggregate shall meet the following qualities: Requirement Property
Test Method Minimum
Maximum
Plasticity Index of the material passing the No. 40 sieve
AASHTO T 90
-
6
Deleterious Content of Aggregate (Rock, Shale, and Mud Balls), percent
MoDOT TM 71
-
15.0
To ensure proper functioning of the structure, the backfill material that is used for structural applications shall be well-graded in accordance with ASTM D 2487, Unified Soil Classification System, homogeneous and in accordance with the gradation limits, as tested in accordance with AASHTO T 27, as follows: Shot Rock 1
1
Sieve Size
Percent Passing by Weight
12 inch
100
No. 200
0-10
The gradation of the shot rock shall be provided to the engineer for review and approval at least three weeks prior to use. The engineer will have the authority to request a crushed aggregate of a smaller maximum size gradation based on site conditions.
1½ Inch Minus Crushed Limestone Sieve Size
Percent Passing by Weight
1½ inch
100
1 inch
75-90
No. 200
0-12
Alternate gradations may be submitted by the contractor for consideration, provided they are well-graded with a maximum size of 1½ inch and less than 12 percent passing the #200 sieve. The engineer shall have the authority for acceptance or rejection. The frequency of job-site sampling of the backfill material necessary to assure gradation and plastic index control throughout construction and shall be no less than one test per 2,000 cubic yards of material placed.
9/1/2023
1010-2
Select Granular Backfill for Structural Systems and Box Culvert Bedding
The dry unit weight of the backfill material shall be determined in accordance with AASHTO T 19 and shall be no less than 105 lb/ft3. The plasticity index (PI) of the material shall be determined in accordance with AASHTO T 90 and be within the following limits: Panel and Block MSE backfill shall not exceed 6. 1010.3.4.1 Reinforced Soil Slope Structure backfill shall not exceed 20. Aggregate Angle of Internal Friction. The angle of internal friction for the panel and block MSE backfill material shall be no less than 34 degrees. The angle of internal friction for the reinforced soil slope structure backfill material shall be no less than 30 degrees. No testing will be required whenever 80 percent of the particle sizes are greater than ¾ inch or whenever the backfill material consists entirely of crushed limestone. When testing is required, testing shall be in accordance with one of the tests specified below. The angle of internal friction may be determined by the direct shear test in accordance with AASHTO T 236. This test shall be performed on the portion of the material finer than the No. 10 sieve, utilizing a sample of the material compacted to 95 percent of the maximum density as determined by AASHTO T 99, Methods C or D (with oversize correction, as outlined in Note 9 in AASHTO T 99) at optimum moisture content. The angle of internal friction may be determined by the triaxial compression test in accordance with AASHTO T 296. Reinforced Soil Slope Structure and Panel / Modular MSE Wall Aggregate Durability. The backfill material shall be, in the judgment of the Engineer, substantially free of organic materials, shale or other soft, poor durability particles and shall have either a magnesium or sodium sulfate soundness loss as follows: Requirement Property
Test Method
Soundness (MgSO4 - 4 cycles), percent loss Soundness (NaSO4 - 5 cycles), percent loss
AASHTO T 104 AASHTO T 104
Minimum
Maximum
-
30
-
15
The organic content of the backfill material shall be less than or equal to one percent and shall be measured in accordance with AASHTO T 267 for material finer than the No. 10 sieve. The use of salvaged material such as asphaltic concrete millings or Portland Cement Concrete rubble is not allowed.
9/1/2023
1010-3
Select Granular Backfill for Structural Systems and Box Culvert Bedding
Coefficient of Uniformity. Provide material with a coefficient of uniformity (D60/D10) of a minimum of 4 with concave downward grain size distributions as determined by ASTM D 2487. Electrochemical Requirements. The following electrochemical requirements shall apply to this backfill material whenever the material is used for mechanically stabilized earth wall or reinforced soil structure systems. Metallic Soil Reinforcement. When metallic soil reinforcements are used, the backfill material shall meet the electrochemical requirements as follows: Requirement Property
Test Method Minimum
Maximum
Minimum Resistivity, ohm-cm
AASHTO T 288
3000
-
Hydrogen-ion concentration (pH)
AASHTO T 289
5.0
10.0
Water-Soluble Chloride Ion Content, mg/kg1
AASHTO T 291
-
100
Water-Soluble Sulfate Ion Content, mg/kg1
AASHTO T 290
-
200
1
Indicate Method A or Method B in test report.
Whenever the resistivity of the backfill, material is greater than or equal to 5000 ohm-cm, the chlorides and sulfates requirements may be waived. Geosynthetic Soil Reinforcement. When geosynthetic soil reinforcements are used, the backfill material shall meet one of the following electrochemical criteria, depending on the base polymer: Requirement Base Polymer
Property
Test Method Minimum
Maximum
Polyester (PET)
Hydrogen-ion concentration (pH)
AASHTO T 289
3.0
9.0
Polyolefin (PP & HDPE)
Hydrogen-ion concentration (pH)
AASHTO T 289
3.0
-
9/1/2023
1010-4
Select Granular Backfill for Structural Systems and Box Culvert Bedding
Recycled Concrete Washout for Utility Trench Backfill. Recycled Concrete Washout will be allowed as fill material in a trench environment only. Recycled Concrete Washout as fill material shall consist of crushed stone, sand, gravel, and cement from reclaimed concrete washout. The aggregate shall not contain more than 15 percent deleterious rock and shale. The fraction passing the No. 40 sieve shall have a plasticity index not to exceed six. Any sand, silt and clay, and any deleterious rock and shale shall be uniformly distributed throughout the material. Recycled Concrete Washout shall be in accordance with the following gradation requirements: Sieve Percent by Weight Passing 1 1/2-inch
100
Passing1-inch
70-100
Passing No. 8
15-50
Passing no. 200
0-12
Certification and Acceptance. The Contractor shall furnish to the Engineer written certification that the backfill material provided complies with the applicable sections of this specification. Copies of all test results for tests, performed by an AASHTO accredited lab, to ensure compliance with this specification shall be furnished to the Engineer. Electrochemical and soundness tests performed on the material shall be valid for a period not to exceed two years from the date of testing. If a producer elects to produce material before Source Approval is granted, the producer is producing without approval and at risk of rejection. A representative sample shall be obtained from the gravel or sand deposit or quarry ledge or combination of quarry ledges. However, initial evaluation samples from the deposit or quarry will not be required provided plant produced material can be obtained meeting specification requirements, in which case the material may be submitted to the Engineer for Source Approval. An approved formation, ledge, combination of ledges or deposit may be re-sampled any time aggregate produced from the ledge or deposit has a significant change in color, texture, characteristics, or performance in the approved use. Either the producer or Engineer can request a new Initial Sample. If requested by the producer, the Engineer must concur. This sample is intended to serve as a quality check sample on material in the ledge. When sampling is performed, the same procedure as outlined for Initial Evaluation sampling is to be followed. Produced material previously approved prior to re-sampling and that produced during Approved Laboratory testing, shall be accepted. The sample record shall indicate reasons for re-sampling in the remarks. Acceptance will be based on the written certification, accompanying test reports, and any applicable tests performed as directed by the Engineer.
9/1/2023
1010-5
Select Granular Backfill for Structural Systems and Box Culvert Bedding
Section 1011
Geotextile
1011.1 Scope. This specification covers geotextile for use in subsurface drainage, sediment control, erosion control or as a permeable separator. 1011.2 Acceptance. Acceptance of the material will be based on the manufacturer's certification and upon the results of such tests as may be performed by the engineer. 1011.3 Material. Geotextiles shall be in accordance with the physical and chemical requirements of AASHTO M 288 for the specified application, except as modified in this specification. 1011.3.1 General. During shipment and storage, geocomposite material shall be protected from direct sunlight, ultra-violet rays, temperatures greater than 140°F, mud, dust and debris. 1011.3.2 Subsurface Drainage Geotextile. Subsurface drainage geotextile shall be used in subsurface drainage as a filter to protect drainage media from clogging with fines from adjacent soil. Typical applications will include lining of drainage trenches and wrapping drain pipes. 1011.3.2.1 The minimum permittivity shall be 1.0 sec-1. 1011.3.2.2 The material shall be AASHTO Class 2. 1011.3.3 Temporary Silt Fence Geotextile. Temporary silt fence geotextile shall be used in supported or non-supported sediment control fencing. 1011.3.4 Permanent Erosion Control Geotextile. Permanent erosion control geotextile shall be used when the erosion control measure will not be removed, such as erosion control of slopes and channels when placed under a rock blanket, rock ditch liner, etc. 1011.3.4.1 The minimum permittivity shall be 1.0 sec-1. 1011.3.4.2 The material shall be either AASHTO Class 1 or Class 2. 1011.3.5 Separation Geotextile. Separation geotextile shall be used as a separation material to prevent mixing of dissimilar material and to control migration of backfill material through joints in structural elements. 1011.3.5.1 The minimum permittivity shall be 1.0 sec-1. 1011.3.5.2 The material shall be either AASHTO Class 1 or Class 2.
12/9/2013
1011-1
Geotextile
1011.3.6 Erosion Control Blankets. Erosion control blankets shall be pre-qualified and categorized based on performance testing performed by the Texas Department of Transportation and the Texas Transportation Institute using the minimum standards cited in the Texas DOT Erosion Control Report "TXDOT / TTI Hydraulics and Erosion Control Laboratory Field Performance Testing of Selected Erosion Control Products Final Performance Analysis Through the Most Recent Evaluation Cycle". Erosion control blankets shall meet the following requirements.
Class 1, Slope Protection Type
Slope
Type of Slope
Maximum Sediment Loss
Minimum Vegetation Density
A
< 3:1
Clayey a
0.34
80%
B
< 3:1
Sandy b
12.20
70%
C
< 3:1
Clayey a
0.34
80%
D
< 3:1
Sandy b
26.84
70%
a
Clayey soil (AASHTO M 145, Type A-6 or A-7) is defined as soil having a minimum of 35 percent passing the No. 200 sieve and a minimum plasticity index of 11.
b
Sandy soil (AASHTO M 145, Type A-1 or A-3) is defined as soil having 100% passing the No. 10 sieve and a maximum plasticity index of 6.
Class 2, Flexible Channel Liner Type
Duration
Shear Stress
Maximum Sediment Loss
Minimum Vegetation Density
E
Short-term (< 2 yrs.)
0-2 lb/ft. [0-96 Pa]
1.15
70%
F
Short-term (< 2 yrs.)
0-4 lb/ft. [0-192 Pa]
1.00
70%
G
Long-term (> 2 yrs.)
0-6 lb/ft. [0-287 Pa]
1.00
70%
H
Long-term (> 2 yrs.)
0-8 lb/ft. [0-383 Pa]
0.80
70%
1011.3.6.1 Anchors. Anchors as recommended by the erosion control product manufacturer shall be used.
12/9/2013
1011-2
Geotextile
1011.3.6.2 Test Methods. Erosion control blankets shall be tested and evaluated by the Texas Department of Transportation and the Texas Transportation Institute in accordance with the Texas DOT Erosion Control Report. The blankets will also be evaluated on the basis of their performance in the field. 1011.3.6.3 Prequalification. Pre-qualified procedures may be obtained by writing to the Texas Department of Transportation, Director of Construction and Maintenance, 125 East 11th Street, Austin, TX 78701-2483. A list of qualified erosion control blankets will be maintained by Construction and Materials. Erosion control blankets will remain on the list as long as field performance is satisfactory. 1011.3.7 System A Geosynthetic Material. System A shall be a non-woven paving fabric composed of 85 percent or more polyolefin, polyester or polypropylene fibers. The paving fabric shall meet the following requirements:
Property
Test Method
Requirements a Minimum
Maximum
Grab Tensile Strength, pounds
ASTM D 4632
100
-
Ultimate Elongation, percent
ASTM D 4632
50
-
ASTM D 5261
4.0
-
ASTM D 6140
0.20
-
ASTM D 276
300
-
Weight per Unit Area, ounces per square yard Asphalt Retention b, c, gallons per square yard Melting Point, °F a
All numeric values shall represent Minimum Average Roll Values (MARV) in the weaker principle direction.
b
The asphalt binder retention value shall be the amount required to saturate the paving fabric only. Asphalt retention shall be provided in the manufacturer’s certification. Numerical value does not indicate the asphalt application rate required for construction.
c
Product asphalt retention property shall meet the specified MARV value.
1011.3.8 System B Geosynthetic Material. System B shall be a composite paving fabric consisting of paving fabric bonded to a reinforcement grid. The paving fabric shall be in accordance with Section 1011.3.7. The reinforcement grid shall be either an epoxy or elastomeric polymer coated glass fiber structural grid. The composite shall be in accordance with the following physical properties:
12/9/2013
1011-3
Geotextile
Properties
Requirement
Test Method
Minimum
Maximum
Grid Tensile Strength a, pounds per inch
ASTM D 6637
560
-
Ultimate Elongation, percent
ASTM D 6637
-
5
Grid Junction Strength b, pounds
GSI/GG-2
15
-
Grid Melting Point, °F
ASTM D 276
425
-
--
1.02/1.2
-
ASTM D 413
10
-
Aperture Size, Max., MD/XD c, inches Peel Strength, Fabric to Grid, pounds per foot a
All numeric values shall represent MARV in the weaker principle direction.
b
Tested with grid attached to the paving fabric.
c
Shall be centerline to centerline, where MD = machine direction and XD = cross-machine direction.
1011.3.9 System C Geosynthetic Material. System C shall be a geotextile paving mat composed of 50 percent or more fiberglass fibers. The paving mat shall meet the following requirements: Class 1 Properties
Test Method
Requirement a Minimum
Maximum
Tensile Strength, pounds / inch
ASTM D 5035
140
270
Elongation at Break, percent
ASTM D 5035
-
5
ASTM D 5261
4.0
6.9
ASTM D 6140
0.10
-
ASTM D 276
400°F
-
Weight Per Unit Area, ounces per square yard Asphalt Retention b, c, gallons per square yard Melting Point, Min. a b
c
All numeric values shall represent MARV in the weaker principle direction. The asphalt binder value shall be the amount required to saturate the paving fabric only. Asphalt retention shall be provided in the manufacturer’s certification. Numerical value does not indicate the asphalt application rate required for construction. Product asphalt retention property shall meet the specified MARV value.
12/9/2013
1011-4
Geotextile
Class 2 Properties
Test Method
Requirement a Minimum
Maximum
Breaking (Tensile) Strength, pounds / inch
ASTM D 5035
280
-
Ultimate Elongation, percent
ASTM D 5035
-
5
ASTM D 5261
7.0
-
ASTM D 6140
0.10
-
ASTM D 276
425°F
-
Weight Per Unit Area, ounces per square yard Asphalt Retention b, c, gallons per square yard Melting Point, Min. a b
c
All numeric values shall represent MARV in the weaker principle direction. The asphalt binder value shall be the amount required to saturate the paving fabric only. Asphalt retention shall be provided in the manufacturer’s certification. Numerical value does not indicate the asphalt application rate required for construction. Product asphalt retention property shall meet the specified MARV value.
1011.3.10 Prequalification. Prior to approval and use of this material, the manufacturer shall submit to Construction and Materials a certified test report showing specific test results from an independent laboratory in accordance with all requirements of these specifications. The certified test report shall contain the manufacturer's name, brand name of material, lot tested and date of manufacture. In addition, the manufacturer shall submit a one square yard sample for laboratory testing accompanied by a technical data sheet and an MSDS. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements specified. 1011.4 Certification. The contractor shall furnish a manufacturer's certification to the engineer for each lot of material furnished stating the name of the manufacturer, the chemical composition of the filaments or yarns and certifying that the material supplied is in accordance with this specification. The certification shall include or have attached typical results of tests from specific lots for all specified requirements. 1011.4.1 The manufacturer shall be responsible for establishing and maintaining a QC program to assure compliance with the requirements of this specification. Documentation describing the QC program shall be made available to the Engineer upon request. 1011.4.2 The manufacturer's certificate shall state that the furnished material meets MARV requirements as evaluated under the manufacturer's QC program. A person having legal authority to bind the manufacturer shall attest to the certificate.
12/9/2013
1011-5
Geotextile
(This Page Intentionally Left Blank)
12/9/2013
1011-6
Geotextile
Section 1012
Geocomposite Drainage Material
1012.1 Scope. This specification covers material for use as geocomposite drains. 1012.2 Acceptance. Acceptance of the material will be based on the manufacturer's certification and upon the results of such tests as may be performed by the Engineer. 1012.3 Material. 1012.3.1 General. During shipment and storage, geocomposite material shall be protected from direct sunlight, ultra-violet rays, temperatures greater than 140°F, mud, dust and debris. 1012.3.2 Edge Drain. Edge drain shall consist of a plastic core completely surrounded by geotextile. 1012.3.2.1 The edge drain shall have nominal dimensions of 1 to 1½ inches in thickness by 12 inches in height. 1012.3.2.2 The edge drain shall have a minimum flow capacity of 15 gal/min/ft. of width as determined by ASTM D 4716 when tested under a confining stress of 10 psi or more at a gradient of 0.1 or less. 1012.3.2.3 The edge drain shall have a minimum compressive strength of either 7,000 psf at a maximum deformation of 10% of the original thickness when tested in accordance with ASTM D 1621 or 8,000 psf at a maximum deformation of 20% when tested in accordance with ASTM D 695. 1012.3.2.4 The core shall provide a minimum of 10% open area to facilitate water entry or cross flow and shall be composed of plastic, which is physically and chemically stable under a normal range of service conditions. 1012.3.2.5 Geotextile shall be in accordance with Section 1011 for subsurface drainage geotextile. 1012.3.3 Vertical Drain at End Bents. The vertical drain shall consist of a plastic core with a geotextile attached to one or both sides. 1012.3.3.1 The vertical drain shall be no less than ⅜ inch or no greater than 1 inch in thickness. 1012.3.3.2 The vertical drain shall have a minimum flow capacity of 5 gal/min/ft. of width in either principal direction. 1012.3.3.3 The vertical drain shall have a minimum compressive strength of 6,000 psf at a maximum deformation of 10% of the original thickness, when tested in accordance with ASTM D 1621.
1/31/2007
1012-1
Geocomposite Drainage Material
1012.3.3.4 The core shall be composed of plastic which is physically and chemically stable under a normal range of service conditions. 1012.3.3.5 Geotextile shall be in accordance with Section 1011 for subsurface drainage geotextile. 1012.4 Certification. The Contractor shall furnish a manufacturer's certification to the Engineer for each lot of material furnished stating the name of the manufacturer and certifying that the material supplied is in accordance with this specification. The certification shall include or have attached typical results of tests from specific lots for all specified requirements, including the geotextile.
1/31/2007
1012-2
Geocomposite Drainage Material
Section 1013
Miscellaneous Drainage Material
1013.1 Scope. This specification covers material requirements for various plastic pipes, and other miscellaneous items required to provide underdrainage and edge drainage as specified elsewhere. 1013.2 Acceptance. Acceptance of the materials will be based on visual examination and results of such test required by the Engineer. 1013.3 Material. Pipe material shall be polypropylene (PP), polyvinyl chloride (PVC), or high density polyethylene (HDPE). 1013.3.1 Plastic Pipe. 1013.3.1.1 The pipe material shall have a minimum pipe stiffness at 5% deflection of 46 psi. 1013.3.1.2 Corrugated PVC sewer pipe with a smooth interior and fittings shall be in accordance with ASTM F 949. 1013.3.1.3 Smooth wall PVC underdrain pipe and fittings shall be in accordance with ASTM D 3034. 1013.3.1.4 Corrugated HDPE pipe with a smooth interior and fittings shall be in accordance with AASHTO M 252 Type S or SP. 1013.3.1.5 Schedule 40 PVC pipe shall be in accordance with ASTM D 1785. 1013.3.1.6 Corrugated double wall PP sewer pipe with a smooth interior and fittings shall be in accordance with ASTM F 2736. 1013.3.1.7 Corrugated triple wall PP sewer pipe with a smooth exterior and interior, and fittings shall be in accordance with ASTM F 2764. 1013.3.2 Rodent Screens. Rodent screen shall be press formed of 3 or 4 mesh, 21 gauge or heavier, stainless steel or hot-dipped galvanized wire screen or approved equivalent to provide a cup-shaped screen which will provide a friction tight fit when inserted into the drain outlet. 1013.4 Certification. The Contractor shall furnish a manufacturer's certification to the Engineer, for each lot of plastic pipe material furnished, stating the name of the manufacturer and certifying that the material supplied be in accordance with this specification.
2/3/2014
1013-1
Miscellaneous Drainage Material
(This Page Intentionally Left Blank)
2/3/2014
1013-2
Miscellaneous Drainage Material
Section 1015
Bituminous Material
1015.1 General. This specification covers bituminous material to be used in highway construction. Suppliers of emulsified asphalt, cutback asphalt or asphalt binders shall be as shown as per MoDOT's "Qualified Bituminous Material Sources". 1015.1.1 Approval of Source. The Contractor shall obtain approval of the source of bituminous material from the Engineer before any shipments to the work are made. 1015.1.2 Sampling, Testing and Acceptance Procedures. The supplier shall certify that bituminous material complies with the specification requirements. 1015.1.2.1 Certification. The supplier shall furnish the truck driver a copy of the bill of lading, manifest or truck ticket that is to be available to the Engineer at destination prior to unloading. The Engineer at the source shall be furnished a copy. The bill of lading, manifest or truck ticket shall provide the following manufacturer information regarding the shipment: type and grade of material; specific gravity at 60°F; temperature and net gallons of material; consignee; weight of truck before and after loading; destination; date and time loaded; name and location of the source; lot number, if applicable; if polymer modified the mixing and compaction temperatures; and a complete certification of analysis. The hauler shall supply the identification of hauling unit; the material type, grade and source of last delivery and volume of material remaining in the tank at the time of loading. The certification statement shall be signed by an authorized representative of the supplier and shall be substantially as follows: "This certifies that the bituminous material in this shipment complies with St. Louis County Missouri specifications for the grade specified and the weights shown hereon were obtained on MoDOT approved and calibrated scales and are correct within the specified scale requirements." 1015.1.2.2 Certificate of Analysis/Compliance. A semi-final inspection shall not be conducted until the Engineer completes all testing and the Contractor receives all test reports. The report formats shall be as follows: 1015.1.2.2.1 The Contractor shall provide material certification and quality control test results for each batch of binder, cutback or emulsion used on the project. A bill of lading shall be supplied for each tanker load. All material certifications and quality control test results representing each new batch shall include: 1) Supplier name; 2) Plant location; 3) Federal job number when applicable; 4) County project name and number; 5) Binder / cutback / emulsion grade;
2/1/2017
1015-1
Bituminous Material
6) Batch number; 7) For GTR: weight of GTR in the binder, percent; 8) For emulsions: residual asphalt content, percent; 9) Minimum polymer modifier content, percent; 10) The laboratory certificate of analysis that must meet all requirements of this specification. 1015.1.2.3 Sampling and Testing. The Engineer will, at random, observe the sampling and testing of truck shipments and tanks and will select representative samples of the material being supplied for testing in the field or in the Materials Testing Laboratory. Sampling of emulsified asphalt and asphalt binder shall be in accordance with AASHTO T 40 unless specified otherwise. When test results certified by the supplier are not representative of the material being shipped, the source approval will be withdrawn. A source may be reinstated when proof is furnished that the deficiency has been corrected and adequate controls are in effect to guarantee delivery of material meeting specifications. Emulsified Asphalt tests shall be in accordance with AASHTO T 59. For anionic emulsions, testing shall take place within 30 days of delivery, and provided separation has not been caused by freezing, the emulsified asphalt shall be homogeneous after thorough mixing. For cationic and polymer-modified emulsions, testing shall take place within 15 days of delivery, and provided separation has not been caused by freezing, the emulsified asphalt shall be homogeneous after thorough mixing. Sampling and test methods for cutback and performance grade asphalt shall be as follows: Property
2/1/2017
Method
MC
PG
Sampling
AASHTO T 40
X
X
Water
ASTM D 95
X
X
Flash Point (Tag Open Cup)
AASHTO T 79
X
Flash Point (Cleveland Open Cup)
AASHTO T 48
X
Viscosity, Centistokes
AASHTO T 201
X
Distillation
AASHTO T 78
X
Penetration
AASHTO T 49
X
Ductility
AASHTO T 51
X
Solubility in Trichloroethylene
AASHTO T 44
X
X
Specific Gravity
AASHTO T 228
X
X
Flash Point
AASHTO T 44
X
Viscosity (Rotational)
ASTM D 4402
X
Dynamic Shear
AASHTO T 315
X
Rolling Thin Film Oven Test
AASHTO T 240
X
Pressure Aging Test
AASHTO R 28
X
Creep Stiffness
AASHTO T 313
X
1015-2
Bituminous Material
1015.1.2.3 Sampling Equipment. The supplier shall furnish the required sampling equipment and shall sample the truck under the direction of the Engineer. The supplier shall be responsible for keeping all sampling containers and equipment clean, dry, free of all contaminants, and in good condition. Sampling devices on truck transports will be approved provided that an adequately insulated valve is used with a pipe or nipple inserted a suitable distance into the tank. Sample container material, size and type shall be as follows: Container
Material
Size
Type
Cutback Asphalt
1 quart
Screw Top Can
Emulsified Asphalt
2 quart
Plastic Container1
1 quart
Friction Top Can
Asphalt Binder 1
See ASTM D 140 for container type
To ensure a representative sample when using the drain cock method, allow sufficient material (approximately 1 gallon) to flow through the drain cock and discard before the sample is taken. Do not submerge the filled sample container. Use new sample containers that have not been washed, rinsed, or wiped with an oily cloth. During production, the Engineer will sample binder storage tanks at the hot mix manufacturing plant and emulsions from the distributor or spray paver daily. 1015.1.2.4 Truck Log. Each truck transport shall carry a log showing types of material and the dates hauled with respect to previous shipments, or the supplier shall furnish to the Engineer such information with respect to the previous load. 1015.1.2.5 Intermediate Storage. Intermediate storage tanks for storage and transfer of material between the refinery or terminal and the point of acceptance shall be equipped for sealing and shall be reserved exclusively for St. Louis County work. Use of any material from unsealed tanks will be subject to delay until material can be sampled, tested, and approved. 1015.1.2.6 Other Transportation. At sources from which liquid bituminous material is being accepted by certification, the applicable requirements of the foregoing sections shall be followed for shipments of material in transportation units other than trucks. The certification and all information regarding each shipment shall be furnished to the Engineer at the source. 1015.1.2.7 Railroad Shipments. For railroad shipments from refineries where the County does not maintain inspection, the supplier shall sample each carload at the source and submit the sample promptly to the Materials Testing Laboratory. A bill of lading or identification sheet shall accompany each sample and contain the following information: car number; type and grade of material; quantity represented including gross gallons; temperature; net gallons at 60°F; destination of shipment; purchase order or project number; and consignee. A certification statement similar to that as specified in
2/1/2017
1015-3
Bituminous Material
Section 1015.1.2.1 shall accompany each sample. Approval of the source may be withdrawn if samples submitted are not representative of the material shipped in the car. 1015.1.3 Proportioning and Blending Bituminous Material Constituents. All materials shall be properly proportioned and thoroughly blended in suitable tanks prior to delivery to transportation equipment, or material may be proportioned and blended by use of automatic proportioning equipment. All automatic-proportioning blenders shall meet the approval of the Engineer and shall be equipped with precision instruments, including electrically interlocked motors and automatic meters. Blending quantities of less than 8,000 gallons in tanks, or in tank trucks, will not be permitted. 1015.2 Application Temperatures for Bituminous Material. Bituminous Material Asphalt Bindera
Temperature, Degrees Fahrenheit Spraying
Mixing
Min
Max
Min
Max
PG 46-28
260
325
-
-
All Other Grades
285
350
275
350
30
70
150
50
110
70
100
180
90
140
250
150
220
130
170
800
180
260
170
210
3000
210
290
200
240
SS-1, SS-1h
125
160
70
160
SS-1vh
160
180
140
160
CRS-1
125
185
-
-
CRS-2
150
185
-
-
CSS-1, CSS-1h
125
160
70
160
CPEM-1, CRS-2P
130
180
-
-
Liquid Asphalt RC-MC (Grade)
Asphalt Emulsions
a
2/1/2017
The minimum mixing temperature shall be lowered to 200°F when a warm mix technology, as approved by the Engineer, is used.
1015-4
Bituminous Material
1015.2.1 Application. Temperatures of other grades of emulsions shall be as specified in the contract. 1015.2.2 The spraying temperature for non-modified PG 46-28 asphalt binder shall be 260°F to 325°F, and for all other higher temperature non-modified performance grades, the spraying temperature shall be 285°F to 350°F. The mixing and compaction temperatures for performance graded asphalt binder shall be determined by rotational viscosity testing as defined in ASTM D 4402. 1015.2.3 When material to be applied by pressure distributor is, due to refining or blending procedures, delivered at a temperature above the specified limits, the material may be applied at the higher temperature provided satisfactory application can be obtained at the specified rate and provided sufficient precaution is exercised with respect to the fire hazard. 1015.3 Measurement of Bituminous Material. Field weight or field volumetric determinations of the material actually incorporated into the work will be used for measurement of the quantity of bituminous material for payment. The volume of material supplied from intermediate storage tanks will be determined from the net weight of the material. The net weight will be determined from the gross weight of the loaded transport vehicle used to deliver the material to the project less the empty transport vehicle weight. The volume correction methods specified below will be used for determining the volume of bituminous material. Scales for determining the weight of bituminous material shall be in accordance with Section 310. 1015.4 Performance Graded Asphalt Binder. Performance Graded (PG) and Multiple Stress Creep Recovery (MSCR) asphalt binder shall be an asphalt-based binder produced from petroleum residue either with or without the addition of non-particulate organic modifiers. The grade shall be as specified in the contract. The manufacturer shall provide material handling and storage procedures for each asphalt binder grade certified. 1015.4.1 Basis of Acceptance. Suppliers furnishing PG and MSCR asphalt binders to St. Louis County projects by certification shall be in accordance with AASHTO R 26, except as noted herein. Materials shall be pre-qualified with MoDOT's "Construction and Materials. Changes" in formulation, base stock or methods of manufacture of qualified performance graded binders shall be noted and may require requalification. All PG and MSCR binders must meet specifications after the introduction of any liquid anti-strip or warm mix additives. If the results of any test do not conform to the requirements of this specification, retest to determine conformity.
2/1/2017
1015-5
Bituminous Material
1015.4.2 Characteristics. PG asphalt binder shall be in accordance with AASHTO M 320, Table 2 for the grade specified, except as follows. AASHTO T 111, "Inorganic Matter or Ash in Bituminous Materials", may be substituted for AASHTO T 44, "Solubility of Bituminous Materials", at the specification value indicated prior to the addition of ground tire rubber (GTR). All blends containing GTR shall include a minimum of 4.5 percent transpolyoctenamer rubber (TOR) by weight of the GTR, and the direct tension test will be waived. The following additional requirements will apply: Binder Characteristics Absolute Temperature Spread Between Upper and Lower Temperature for PG Binder Grade a
Elastic Recovery,b Percent, Minimum, AASHTO T 301
Separation Test,c Percent Difference, Maximum, ASTM D 5976
86°C
-
-
92°C
55%
10%
98°C
65%
10%
104°C
75%
10%
a
Temperature Spread = Upper PG Temperature minus Lower PG Temperature. Elastic recovery test to be performed on the residue from the Rolling Thin Film Oven Test at 25°C and 10 cm elongation. c Separation test to be performed in accordance with ASTM D 5976 except test upper and lower portions as original binder for G* value according to AASHTO T 315. b
1015.4.3 MSCR Binder Identification. In lieu of AASHTO M 320, Table 2, AASHTO M 332, Table 1 may be substituted, eliminating the elastic recovery requirement. The equivalent grading will PG 64-22 (see table below), Grade S for PG 64-22, PG 64-22 Grade H for PG 70-22 and PG 64-22 Grade V or E for PG 76-22. Specialty grades will be tested at the grade temperature for the desired characteristics, i.e. PG 58-28 for RAP/RAS mixtures. Binder grade may be changed by the Engineer and be paid for in accordance with Section 109. Production binder materials shall not be "air-blown or acid modified" to achieve the performance grade. Binders with fibers or other discrete particles larger than No. 60 sieve are not allowed. Specialty grades will be tested at the grade temperature for the desired characteristics in accordance with Section 413. The contractor shall indicate the MSCR binder grade on their mix design submittal. Suppliers shall furnish binder technical data with the Contractor's job mix design. The traffic grades of asphalt binder shall conform to the tables below for PG 64-22, PG 58-22, or AASHTO M 332 - Table 1.
2/1/2017
1015-6
Bituminous Material
Tests
Method
Traffic Grade
PG 64-22
S
H
V
E
Min
Max
Original Binder Flash point temp, C
AASHTO T 48
X
X
X
X
230
-
Viscosity @ 135°C, Pa·s
AASHTO T 316
X
X
X
X
-
3
Dynamic shear, 64°C @ 10 rad/s, G*/sinδ, kPa
AASHTO T 315
X
X
X
X
1.00
-
Solubility, percent
AASHTO T 44
X
X
X
X
99.0
-
X
X
X
X
-
1.00
-
4.0
-
2.0
-
1.0
X
-
0.5
X
-
75.0
-
5,000
Rolling Thin-Film Oven Residue (AASHTO T 240) Mass change, max, percent
AASHTO T 350
Average non-recoverable creep compliance Jnr3.2, @ 64°C, kPa-1
AASHTO T 350
Jnr3.2, @ 64°C, kPa-1
AASHTO T 350
Jnr3.2, @ 64°C, kPa-1
AASHTO T 350
Jnr3.2, @ 64°C, kPa-1
AASHTO T 350
X X X
Percent difference in the non-recoverable creep compliance Jnrdiff, @ 64°C, percent
AASHTO T 350
X
X
X
Pressurized Aging Vessel Residue (AASHTO R 28) Dynamic shear, 25°C @ 10 rad/s, G* sinδ, kPa Dynamic shear, 25°C @ 10 rad/s, G* sinδ, kPa Creep stiffness,-12°C @ 60 s, C Stiffness, MPa m-value Direct tension, failure at strain, 12°C @ 1.0 mm/min., percent
2/1/2017
AASHTO T 315
X
AASHTO T 315
X
X
X
-
6,000
AASHTO T 313
X
X
X
X
0.300
300 -
AASHTO T 314
X
X
X
X
1.0
-
1015-7
Bituminous Material
Tests
Method
Traffic Grade
PG 58-28
S
H
V
E
Min
Max
Original Binder Flash point temp, C
AASHTO T 48
X
X
X
X
230
-
Viscosity @ 135°C, Pa·s Dynamic shear, 58°C @ 10 rad/s, G*/sinδ, kPa Solubility, percent
AASHTO T 316
X
X
X
X
-
3
AASHTO T 315
X
X
X
X
1.00
-
AASHTO T 44
X
X
X
X
99.0
-
X
X
X
X
-
1.00
-
4.0
-
2.0
-
1.0
X
-
0.5
X
-
75.0
-
5,000
Rolling Thin-Film Oven Residue (AASHTO T 240) Mass change, max, percent
AASHTO T 350
Average Non-Recoverable Creep Compliance Jnr3.2, @ 58°C, kPa-1
AASHTO T 350
Jnr3.2, @ 58°C, kPa-1
AASHTO T 350
-1
Jnr3.2, @ 58°C, kPa
AASHTO T 350
Jnr3.2, @ 58°C, kPa-1
AASHTO T 350
X X X
Percent Difference in the Non-Recoverable Creep Compliance Jnrdiff, @ 58°C, percent
AASHTO T 350
Pressurized Aging Vessel Residue (AASHTO R 28) Dynamic shear, 19°C @ 10 rad/s, AASHTO T 315 G* sinδ, kPa Dynamic shear, 19°C @ 10 rad/s, AASHTO T 315 G* sinδ, kPa Creep stiffness,-18°C @ 60 s, Stiffness, MPa AASHTO T 313 m-value Direct tension, failure at strain, AASHTO T 314 -18°C @ 1.0 mm/min, percent
X
X
X
X X
X
X
-
6,000
X
X
X
X
0.300
300 -
X
X
X
X
1.0
-
1015.4.4 Characteristics for GTR. Ground tire rubber shall be ambient ground, free of wire or other contaminating materials and not contain more than 0.1 percent fabric. Cryogenically ground rubber may be used by demonstrating that the GTR is satisfactorily suspended during all phases of production and storage. The gradation of the GTR shall be as follows:
2/1/2017
1015-8
Bituminous Material
Ground Tire Rubber Sieve Size
Percent Passing by Weight Minimum
Maximum
No. 8
100
-
No. 16
96
100
No. 30
90
100
No. 50
20
-
1015.4.4.1 Modification Process. The percentage by weight of GTR in the binder shall be included with each lot of material. Ground tire rubber modified asphalt binder shall be tested and certified in accordance with Section 1015.4.1 and may be incorporated by any of the following methods: 1015.4.4.1.1 Blending at HMA Plant. All sampling and testing shall be performed in accordance the requirements for terminal blending including high and low temperature testing. 1015.4.4.1.2 Terminal Blending. Blending and certification shall be in accordance with Section 1015. 1015.4.5 Storage. PG, MSCR or GTR asphalt binder shall be furnished as a uniform mixture shipped directly to the project site from the asphalt binder supplier's permanent plant address or intermediate being stored facility, suitable for direct use. Asphalt binder shall be capable of storage at the project site without separation or settling. Automatic blending will be allowed, except no intermediate blending of asphalt binder and any other modifiers will be allowed at the project site. PG, MSCR or GTR asphalt binder shall be stored at no less than as recommended by the manufacturer. 1015.5 Liquid Bituminous Materials. 1015.5.1 Basis of Acceptance. Suppliers furnishing liquid bituminous materials shall comply with the following. All truck shipments shall be loaded from approved storage tanks, which have been sampled, tested, and certified by the supplier to the Engineer. If automatic blending equipment is used, blender material will be approved for use provided the finished product complies with specifications. At least one complete test shall be conducted every 2 weeks on each grade of material furnished for County work from the blender. A certified copy of the test results shall be furnished to the Engineer. Sampling and testing for certification purposes shall be conducted prior to shipping material to County work. After loading, the supplier shall sample and make identifying tests on a sufficient number of truck shipments of material consigned to a construction project to ensure that proper quality control is being maintained and that all such shipments comply with the specification requirements. The identifying test is viscosity for liquid bituminous material. For all liquid
2/1/2017
1015-9
Bituminous Material
bituminous material, AASHTO T 111, "Inorganic Matter or Ash in Bituminous Materials", may be substituted for AASHTO T 44, "Solubility of Bituminous Materials", at the specification value indicated. 1015.5.2 Type MC Liquid Asphalt. Type MC liquid asphalt shall be produced by fluxing an asphaltic base with suitable petroleum distillates. The material shall free from water, show no separation or curdling prior to use and shall not foam when heated to the application temperature. The material shall be in accordance with AASHTO M 82 Table 1, invoking Note b using penetration in lieu of viscosity for the grade specified in the contract. MC liquid asphalt shall be stored at no less than as recommended by the manufacturer. 1015.5.3 Emulsified Asphalt. This emulsified asphalt material shall be in accordance with AASHTO M 140 (Anionic), AASHTO M 208 (Cationic), or AASHTO M 316 (PolymerModified Cationic) for the type and grade specified in the contract. For anionic emulsified asphalt, demulsibility testing shall be performed within 30 days from the date of shipment and a maximum value of 0.30 is acceptable for the sieve tests for samples taken at the point of use. For cationic and polymer-modified emulsified asphalt, demulsibility testing shall be performed within 15 days from the date of shipment and a maximum value of 0.30 is acceptable for the sieve tests for samples taken at the point of use. Store all emulsion samples in a cool environment, and do not allow samples to roll around or to be shaken during transportation. Emulsion shall be stored at no less than 40°F or as recommended by the manufacturer. Emulsion shall be diluted only by the manufacturer. The residual rate shall be identified on the delivery ticket. 1015.5.3.1 Polymer Modified Asphalt Emulsion for Chip Seals. The cationic emulsified asphalt material polymer-modified with styrene-butadiene (SB) or styrenebutadiene-styrene (SBS) polymer shall comply with the requirements of the following tables:
2/1/2017
1015-10
Bituminous Material
CRS-2P
Tests a
Minimum
Polymer Type
Maximum
SB or SBS
Polymer solids content, percent
3.0
-
Viscosity, SSF @ 50°C,s
100
400
Storage Stability Test b, 24 hour, percent
-
1
Classification Test
Pass
Particle Charge Test
Positive
Sieve Test, 850 µm mesh, percent
-
0.3
Demulsibility, 0.02 N CaCl2, percent
-
-
Distillation: Oil distillate by volume of emulsion, percent Residue from distillation c, percent
65
3 -
Tests on Residue from Distillation: Penetration, 25°C, 100 g, 5 sec, 0.1 mm Ductility, 4°C, 5 cm/minute, cm Ash d , percent
100 30 -
200 1
Elastic recovery e, percent
58
-
a
All tests shall be performed in accordance with AASHTO T 59 except as noted. Polymer content as determined by TxDOT Test Method 533 C b In addition to AASHTO T 59, upon examination of the test cylinder, and after standing undisturbed for 24 hours, the surface shall show no appreciable white, milky colored substance and shall be a homogeneous brown color throughout. c AASHTO T 59 shall be modified to maintain a 399°F ± 10°F maximum temperature for 15 minutes. d Percent ash shall be determined in accordance with AASHTO T 111, “Ash in Bituminous Material”. e Elastic recovery shall be determined as follows. Condition the ductilometer and samples to be treated at 50°F. Prepare the brass plate, mold and briquet specimen in accordance with AASHTO T 51. Keep the specimen at the specified test temperature of 50°F for 85 to 95 minutes. Immediately after conditioning, place the specimen in the ductilometer and proceed to elongate the sample to 20 cm at a rate of pull of 5 cm/min. After the 20 cm elongation has been reached, stop the ductilometer and hold the sample in the elongated position for 5 minutes. After 5 minutes, clip the sample approximately in half by means of scissors or other suitable cutting devices. Let the sample remain in the ductilometer in an undisturbed condition for one hour. At the end of this time period, retract the half sample specimen until the two broken ends touch. At this point note the elongation (x) in cm. Calculate the percent recovery by the following formula: Percent Recovery = (20 - X) x 100 20
2/1/2017
1015-11
Bituminous Material
Polymer Modified Asphalt Emulsion CHFRS-2P
Test a
Minimum
Maximum
Viscosity, SFS @ 50 C
100
400
Storage Stability Test, 24 hour, percent
---
1.0
Demulsibility, 35 ml 0.8% dioctyl sodium sulfosuccinate, percent
60
---
Sieve Test, percent
---
0.10
Particle Charge Test
Positive
Distillationb Oil Distillate, by volume of emulsion, percent Residue from distillation, percent
--65
0.5 ---
3.0 54 1800 80 1300 95 65
---
Test on Residue from Distillation: Polymer content, weight, percent (solid based) Softening Point, C Float Test at 60 C, s Penetration, 25 C, 100 g, 5 s Viscosity @ 60 C, Poise Solubility in Trichloroethylene, percent Elastic Recovery c @ 10 C, percent
--130 -------
a
All tests shall be performed in accordance with AASHTO T-59 except as noted.
b
AASHTO T-59 shall be modified to maintain a 177 ± 5°C maximum temperature to be held for 20 minutes. Complete the total distillation in 60 ± 5 minutes from the first application of heat.
c
Elastic recovery shall be determined as follows. Condition the ductilometer and samples to be treated at 10°C. Prepare the brass plate, mold, and briquet specimen in accordance with AASHTO T 51. Keep the specimen at the specified temperature of 10°C for 85 to 95 minutes. Immediately after conditioning, place the specimen in the ductilometer and proceed to elongate the sample to 20 cm at a rate of pull of 5 cm/min. After the 20 cm elongation has been reached, stop the ductilometer and hold the sample in the elongated position for 5 minutes. After the 5 minutes, clip the sample approximately in half by means of scissors or other suitable cutting devices. Let the sample remain in the ductilometer in an undisturbed condition for one hour. At the end of this time period, retract the half sample specimen until the two broken ends touch. At this point note the elongation recovery (X) in cm. Calculate the percent recovery by the following formula:
% Recovery =
2/1/2017
1015-12
20 – X x 100 20
Bituminous Material
1015.5.3.2 Asphalt Emulsion for Micro Surfacing. Bituminous material for micro surfacing shall be a natural latex polymer modified asphalt emulsion and shall be a grade CQS-1h and comply with the requirements of the following table. The bituminous material shall show no separation after mixing. A minimum of 3.0 percent polymer content, by weight, of an approved polymer shall be milled into the asphalt emulsion at the time of manufacture of the emulsion. The emulsion shall be sampled in accordance with AASHTO T 40. Tests
Test Method
MSE-1 Min
Max
Specification for Cationic Emulsion
AASHTO M 208
As Tested
Viscosity, Saybolt Furol at 77°F, s
AASHTO T 59
20
100
Storage stability test, 24 hr., percent
AASHTO T 59
-
1a
Particle charge test
AASHTO T 59
Sieve test, percent on No. 20 mesh Sieve
AASHTO T 59
-
0.50
Residue, percent
AASHTO T 59
62 c
-
Penetration, 77°F, 100 g, 5 s,
AASHTO T 49
40
90
Ductility, 25°C, 5 cm/min, cm
AASHTO T 51
40
-
Solubility in Trichloroethylene, percent
AASHTO T 44
97.50
-
positive b
Tests on Residue from Distillation
a
The storage stability test may be waived provided the asphalt emulsion storage tank at the project site has adequate provisions for circulating the entire contents of the tank, and provided satisfactory field results are obtained. b If the particle charge test is inconclusive, material having a maximum pH value of 6.7 will be acceptable. c The temperature for this test shall not exceed 177°C
1015.5.3.3 Cationic Polymer Modified Emulsion Membrane (CPEM-1) for Ultrathin Bonded Wearing Course. The emulsion shall be a cationic polymer modified emulsion. The Cationic Polymer Modified Emulsion Membrane shall be a styrene butadiene rubber (SBR) polymer modified asphalt emulsion. Polymer modification shall be completed so that SBR is added inline into asphalt and surfactant mix ahead of mill head during emulsification. The appropriate SBR polymer compatible with the hot mix binder and aggregate shall be used. 1015.5.3.3.1 Polymer Modifier. The approved SBR polymer modifier shall be milled or blended into the asphalt or emulsifier solution during the emulsification process and prior to storage. The range of SBR solids content shall be from 3.0 percent to 5.0 percent polymer solids by weight of binder (asphalt) within the emulsion. The laboratory performing the mix design shall determine the minimum amount of SBR polymer required within that range. The asphaltic emulsion
2/1/2017
1015-13
Bituminous Material
manufacturer shall certify that each load of the emulsion contains the amount of SBR solids specified in the mix design. 1015.5.3.3.2 The cationic emulsified asphalt (CPEM-1) shall comply with following requirements when sampled in accordance with AASHTO T 40 and shall comply with the following requirements when tested in accordance with the specified test methods: Cationic Polymer Modified Emulsion Membrane Requirements Tests on Emulsion Method AASHTO M 208
Description
Min.
Specifications for Cationic Emulsion
Max.
As tested
Polymer Type
SBR
AASHTO T 59
Viscosity, Saybolt Furol at 122°F SSF, Seconds
25
125
AASHTO T 59
Storage Stability Test (24 hours) a, percent
-
1.0
AASHTO T 59
Particle Charge Test
AASHTO T 59
Sieve Test b, Percent retained on No. 20 Mesh Sieve
-
0.30
AASHTO T 59
Distillation: Percent Residue after Distillation c
63
-
AASHTO T 59
Oil Distillate, Percent by volume of emulsion
-
2
AASHTO T 59
Demulsibility, Percent d
60
-
Positive
a
After standing undisturbed for 24 hours, the surface shall show no white, milky colored substance, but shall be a smooth homogeneous color throughout. b The sieve test is waived if successful application of the material has been achieved in the field. c AASHTO T 59 with modifications to include a 400°F ± 10°F maximum temperature to be held for a period of 15 minutes. d 35 ml, 0.8 percent dioctyl sodium sulfosuccinate.
Tests on Residue from Distillation Method
Description
Min.
Max.
As Approved by Engineer
Polymer solids content, percent
3.0
5.0
AASHTO T 49
Penetration, 77°F, 3.5 oz., 5 seconds
90
150
AASHTO T 301
Elastic Recovery, 77°F, 20 cm elongation, percent
60
-
2/1/2017
1015-14
Bituminous Material
1015.5.3.3.3 The distillation residue of the CPEM-1 shall contain 3.0 to 5.0 percent polymer solids by mass of asphalt, as determined by an analytical method approved by the Engineer. The CPEM-1 polymer content submitted shall be considered the minimum. 1015.5.3.3.4 Each tanker load of CPEM-1 shall be accompanied with a Certificate of Analysis/Compliance and be submitted to the Engineer prior to use. 1015.5.3.3.5 Hard Penetration Asphalt Emulsions (SS-1vh). penetration asphalt emulsions shall be in accordance with the following:
The hard
Emulsion Properties of Hard Penetration Asphalt Emulsions (SS-1vh) Test on Emulsion
Min
Max
Viscosity, Saybolt Furol at 77°F, s
AASHTO T 59
20
100
Storage stability test, 24 hr., percent
AASHTO T 59
-
1.0 a
Sieve test, percent on No. 20 mesh Sieve
AASHTO T 59
-
0.30
Residue by Distillation, percent
AASHTO T 59
50
-
Oil Distillate by Distillation, percent
AASHTO T 59
-
1
Softening Point, ˚F
AASHTO T 53
149
200
Penetration, 77°F, 100 g, 5 s,
AASHTO T 49
-
40
G* / sin delta @ 76º C - 10 rad/sec, kPa
AASHTO T 315
1.0
-
Solubility in Trichloroethyleneb, %
AASHTO T 44
97.50
-
Tests on Residue from Distillation
a
In addition to AASHT O T 59, upon examination of the test cylinder, and after standing undisturbed for 24 hours, the surface shall show no appreciable white, milky colored substance and shall be homogeneous brown color throughout. The storage stability test may be waved provided the asphalt emulsion storage tank at the project site has adequate provisions for circulating the entire contents of the tank, provided satisfactory field results are obtained. b In lieu of performing AASHTO T 44, AASHTO T 111, Ash in Bituminous Material, may be performed with a maximum allowable percent ash of 1.0 percent.
1015.6 Measurement of Bituminous Material. Field weight or field volumetric determinations of the material actually incorporated into the work will be used for measurement of the quantity of bituminous material for payment. The volume of material supplied from intermediate storage tanks will be determined from the net weight of the material. The net weight will be determined from the gross weight of the loaded transport vehicle used to deliver the material to the project less the empty transport vehicle weight. The volume correction methods specified below will be used for determining the volume of bituminous material. Scales for determining the weight of bituminous material shall comply with the requirements of Section 310.
2/1/2017
1015-15
Bituminous Material
1015.6.1 Liquid Bituminous Material and Asphalt Binder - Volumetric Determination. Measurement of the material will be based on the volume at 60°F. The volume correction factors of ASTM D 1250, Table 24b, will be used for converting the material from the volume at the observed temperature to the volume at 60°F. The factors are divided into three groups: 0, 1, and 2 depending upon the API gravity degrees of the material in question (see table below to select proper group): Group
API Gravity
Specific Gravity
0
0 – 14.9
1.0760 – 0.9665
1
15.0 – 34.9
0.9659 – 0.8504
2
35.0 – 50.9
0.8498 – 0.7758
The volume of uncalibrated distributors and tank trucks will be determined from the net weight of the material. The net weight will be determined from the gross weight of the loaded delivery vehicle less the empty delivery vehicle weight. For computing the volume in gallons from weight, the following formula will be used:
G =
W SG x 8.328
Where: G = Volume in gallons at 60°F. W = Weight of material in pounds. SG = Specific Gravity of material at 60°F. 1015.6.2 Emulsified Asphalt. Water is not to be included in payment of emulsified asphalt. Measurement of the material will be based on the volume at 60°F using the tables below for converting the material from the volume at the observed temperature to the volume at 60°F. The Conversion Table has been taken from the Asphalt Institute Manual Series No. 19 (MS-19) and is to be used to correct the volume of hot emulsified asphalt to its volume at 60°F. The MS-19 table can be used for temperatures not listed below. Reduction of water from the emulsion can be used to determine binder volume in gallons then converted to tons or pounds. For asphaltic emulsion determined from volumetric measurements, the measured volume is reduced to the volume the material would occupy at 60°F before converting the volume to weight using the values in the table titled "Conversion Table". Convert volume to weight using the factors shown in the following table: Average Weight and Volume of Asphaltic Emulsion Type of Asphaltic Emulsion
Gallons/Ton at 60°F
Pounds/Gallon 60°F
All types
240
8.33
2/1/2017
1015-16
Bituminous Material
Conversion Table t
M
t
M
t
M
t
M
60
1.00000
87
0.99325
114
0.98650
141
0.97975
61
0.99975
88
0.99300
115
0.98625
142
0.97950
62
0.99950
89
0.99275
116
0.98600
143
0.97925
63
0.99925
90
0.99250
117
0.98575
144
0.97900
64
0.99900
91
0.99225
118
0.98550
145
0.97875
65
0.99875
92
0.99200
119
0.98525
146
0.97850
66
0.99850
93
0.99175
120
0.98500
147
0.97825
67
0.99825
94
0.99150
121
0.98475
148
0.97800
68
0.99800
95
0.99125
122
0.98450
149
0.97775
69
0.99775
96
0.99100
123
0.98425
150
0.97750
70
0.99750
97
0.99075
124
0.98400
151
0.97725
71
0.99725
98
0.99050
125
0.98375
152
0.97700
72
0.99700
99
0.99025
126
0.98350
153
0.97675
73
0.99675
100
0.99000
127
0.98325
154
0.97650
74
0.99650
101
0.98975
128
0.98300
155
0.97625
75
0.99625
102
0.98950
129
0.98275
156
0.97600
76
0.99600
103
0.98925
130
0.98250
157
0.97575
77
0.99575
104
0.98900
131
0.98225
158
0.97550
78
0.99550
105
0.98875
132
0.98200
159
0.97525
79
0.99525
106
0.98850
133
0.98175
160
0.97500
80
0.99500
107
0.98825
134
0.98150
161
0.97475
81
0.99475
108
0.98800
135
0.98125
162
0.97450
82
0.99450
109
0.98775
136
0.98100
163
0.97425
83
0.99425
110
0.98750
137
0.98075
164
0.97400
84
0.99400
111
0.98725
138
0.98050
165
0.97375
85
0.99375
112
0.98700
139
0.98025
166
0.97350
86
0.99350
113
0.98675
140
0.98000
167
0.97325
t = observed temperature in degrees Fahrenheit M = multiplier for reducing volumes to the basis of 60°F
For computing the volume of emulsion binder in gallons, the following formula will be used: G = VxMxE G = Volume of binder in gallons at 60°F. V = Measured Volume of delivered emulsion material in gallons at observed emulsion temperature t in degrees F. E = Residual Rate (i.e., the amount of residual binder left after distillation in decimal form; a typical residual rate = 0.67)
2/1/2017
1015-17
Bituminous Material
(This Page Intentionally Left Blank)
2/1/2017
1015-18
Bituminous Material
Section 1016
Silica Fume (Microsilica)
1016.1 Scope. This specification covers silica fume, or microsilica, which is suitable for use as an admixture for Portland cement concrete. Silica fume is a by-product resulting from the reduction of high purity quartz with coal in electric arc furnaces in the manufacture of elemental silicon or ferro silicon alloys. 1016.2 General. Silica fume shall be approved prior to use and be in accordance with ASTM C 1240, except as noted herein. If dry compacted form, the admixture shall be 100 percent silica fume with no admixtures. Silica fume slurries may contain other approved admixtures, such as water reducers or retarders, if the admixtures are included by the manufacturer of the silica fume admixture. 1016.2.1 Manufacturer Certification. The contractor shall furnish to the engineer a manufacturer's certification along with the brand name, batch identification, quantity represented, percent solids and the type, name and quantity of any admixtures, which are provided in the silica fume admixture. 1016.2.2 Silica Fume Test Results. The manufacturer's certification shall contain results of recent tests conducted on samples of the silica fume material taken during production or transfer and indicating conformance with Tables 1 and 3 of ASTM C 1240 for reactivity with cement alkalis and sulfate resistance expansion (high resistance), and this specification. The supplier shall further certify that the material being furnished is in accordance with this specification. 1016.2.3 Silica Fume Approval. Material under this specification may be obtained from a source identified on the MoDOT PAL designated for this specification. If the manufacturer is different from the source supplying the material, the manufacturer shall also be listed. 1016.2.4 Silica Fume Slurry. Liquid silica fume admixture shall be protected from freezing at all times. 1016.2.5 Admixture Compatibility. All admixtures used shall be compatible with the silica fume admixture and shall be recommended or approved in writing by the manufacturer of the silica fume admixture. 1016.2.6 The mixing of different sources of silica fume will not be permitted. 1016.2.7 The term "manufacturer", as used in this specification, is the company grinding the granulated blast furnace slag to produce silica fume. The term "marketing entity", as used in this specification, is the supplier or broker of the silica fume. The marketing entity shall be responsible for complying with these specifications. 1016.2.8 Portland cement used by the marketing entity for testing silica fume shall be in accordance with AASHTO M 85. 1016.2.9 All tests shall be performed in a MoDOT approved laboratory.
2/13/2013
1016-1
Silica Fume (Microsilica)
1016.3 Sampling, Testing Shipping and Storage. All marketing entities, independent laboratories and terminals testing or furnishing silica fume to St. Louis County projects shall be MoDOT qualified. 1016.3.1 Storage. All silica fume intended for use shall be sampled, tested and placed in designated silos or bins, or buildings that are weather-tight that will protect the silica fume from dampness and minimize quality deterioration. All silos, bins or buildings shall be completely empty and clean before silica fume is deposited therein. Silica fume that is delivered in packages shall have the classification of the silica fume, the name and brand of manufacturer, and the mass of the silica fume contained therein plainly marked on each package. Similar information is to be provided in the shipping documents. No silica fume stored by the contractor over the winter shall be used until retested by a contractor's independent laboratory. 1016.3.2 Shipping. Silica fume continually sampled and tested via autosamplers at a location, frequency and duration acceptable to MoDOT, may be continuously shipped direct from a marketing entity. All silica fume manually sampled and tested shall be held in the silo or bin until such time as the test results are completed prior to shipping. Conveyances for bulk shipment shall have the compartments completely empty and clean before any silica fume is loaded therein. 1016.4 Basis of Acceptance. The marketing entity shall certify that the material complies with the MoDOT specification requirements. When a qualified marketing entity or terminal is shipping silica fume for, or purchasing silica fume from, another qualified marketing entity, the bill of lading or delivery receipt shall be from the shipping company. The certification statement showing the actual manufacturer shall be prominently placed on the bill of lading or delivery receipt. A copy of the bill of lading or delivery receipt shall accompany each shipment and shall be furnished to St. Louis County at the shipping and destination points. 1016.4.1 Certification. The bill of lading or delivery receipt for each shipment to St. Louis County projects shall carry the following certification statement: "This is to certify this silica fume originated from a MoDOT qualified manufacturer, has been maintained to meet MoDOT specifications and was loaded from silo number ________."
__________________________________ Name and Location of Manufacturer
__________________________________ Name and Location of Shipping Facility
By________________________________ Signature and Name of Marketing Entity
2/13/2013
1016-2
Silica Fume (Microsilica)
Section 1017
Ground Granulated Blast Furnace Slag
1017.1 Scope. This specification covers one grade of finely ground granulated blast-furnace slag (GGBFS) for use as a cementitious material in concrete and mortar. 1017.2 General. All GGBFS shall be in accordance with AASHTO M 302, Grade 100 or 120, except as herein specified. Only GGBFS from sources qualified in accordance with these specifications will be permitted. 1017.2.1 GGBFS may only be used with AASHTO M 85 Type I or Type II Portland cement unless otherwise directed by the Engineer. 1017.2.2 The mixing of different grades and sources of GGBFS will not be permitted. 1017.2.3 The term "manufacturer", as used in this specification, is the company grinding the granulated blast furnace slag to produce GGBFS. The term "marketing entity", as used in this specification, is the supplier or broker of the GGBFS. The marketing entity shall be responsible for complying with these specifications. 1017.2.4 Cement used by the marketing entity for testing GGBFS shall be in accordance with AASHTO M 85. 1017.2.5 All tests shall be performed in a MoDOT approved laboratory. 1017.3 Sampling, Testing Shipping and Storage. All marketing entities, independent laboratories and terminals testing or furnishing GGBFS to St. Louis County projects shall be MoDOT qualified. 1017.3.1 Storage. All GGBFS intended for use shall be sampled, tested and placed in designated silos or bins, or buildings that are weather-tight that will protect the GGBFS from dampness and minimize quality deterioration. All silos, bins or buildings shall be completely empty and clean before GGBFS is deposited therein. GGBFS that is delivered in packages shall have the classification of the GGBFS, the name and brand of manufacturer, and the mass of the GGBFS contained therein plainly marked on each package. Similar information is to be provided in the shipping documents. No GGBFS stored by the contractor over the winter shall be used until retested by a contractor's independent laboratory. 1017.3.2 Shipping. GGBFS continually sampled and tested via autosamplers at a location, frequency and duration acceptable to MoDOT, may be continuously shipped direct from a marketing entity. All GGBFS manually sampled and tested shall be held in the silo or bin until such time as the test results are completed prior to shipping. Conveyances for bulk shipment shall have the compartments completely empty and clean before any GGBFS is loaded therein.
12/9/2013
1017-1
Ground Granulated Blast Furnace Slag
1017.4 Basis of Acceptance. The marketing entity shall certify that the material complies with the MoDOT specification requirements. When a qualified marketing entity or terminal is shipping GGBFS for, or purchasing GGBFS from, another qualified marketing entity, the bill of lading or delivery receipt shall be from the shipping company. The certification statement showing the actual manufacturer shall be prominently placed on the bill of lading or delivery receipt. A copy of the bill of lading or delivery receipt shall accompany each shipment and shall be furnished to St. Louis County at the shipping and destination points. 1017.4.1 Certification. The bill of lading or delivery receipt for each shipment to Department projects shall carry the following certification statement: "This is to certify this Grade 100/120 GGBFS originated from a MoDOT qualified manufacturer, has been maintained to meet MoDOT specifications and was loaded from silo number ________."
__________________________________ Name and Location of Manufacturer
__________________________________ Name and Location of Shipping Facility
By________________________________ Signature and Name of Marketing Entity
12/9/2013
1017-2
Ground Granulated Blast Furnace Slag
Section 1018
Fly Ash for Concrete
1018.1 Scope. This specification covers fly ash for use in Portland cement concrete. Fly ash is considered a finely divided residue that results from the combustion of ground or powdered coal and that is transported by flue gasses. Fly ash is collected by mechanical or electrical means and stored in stockpiles or bins. 1018.2 General. Only fly ash from sources qualified in accordance with these specifications will be permitted. The mixing of different classes and sources of fly ash will not be permitted. All fly ash shall be in accordance with AASHTO M 295, Class C (has pozzolanic and cementitious properties) or F (has pozzolanic properties), except as herein specified. Different classes of fly ash shall not be mixed nor shall different types be used in the same unit of construction. 1018.2.1 The percent each of silicon dioxide (SiO2), aluminum oxide (Al2O3) and iron oxide (Fe2O3) shall be reported in addition to the total of the three. Total of silicon dioxide, aluminum oxide and iron oxide Class
Range, percent Minimum Maximum
C
50
66
F
74
-
1018.2.2 Loss on ignition shall not exceed 1.5 percent. When used with Controlled Low Slump Material the loss on ignition requirements is waived. 1018.2.3 The available alkalies, as equivalent, as Na20, shall not exceed 1.5 percent. 1018.2.4 The term "manufacturer", as used in this specification, is the actual manufacturer of the fly ash. The term, "marketing entity", as used in this specification, is the supplier or broker of the fly ash. The marketing entity shall be responsible for complying with these specifications. 1018.2.5 Cement used by the marketing entity for testing fly ash shall be in accordance with AASHTO M 85. 1018.2.6 All tests shall be performed in a MoDOT approved laboratory. 1018.3 Sampling, Testing, Shipping and Storage. All marketing entities, independent laboratories and terminals testing and furnishing fly ash to St. Louis County projects shall be MoDOT qualified. 1018.3.1 Shipping. Fly ash shall be continually sampled and tested via autosamplers at a location, frequency, and duration acceptable to MoDOT, and may be continuously shipped direct from a marketing entity or generating station silo.
2/4/2011
1018-1
Fly Ash for Concrete
1018.3.2 Storage. All fly ash intended for use shall be sampled, tested, and placed in designated silos or bins. 1018.3.3 Coal Sources and Process. Fly ash from each coal source at each plant shall be qualified separately. Coals from different sources may be blended prior to burning, but the qualification shall be based on the blend. When the production procedure or fuel source is changed, or when any change is made by the manufacturer that alters the properties or characteristics of the qualified fly ash, requalification may be required. 1018.4 Acceptance. The marketing entity shall certify that the material complies with MoDOT specification requirements. When a qualified marketing entity or terminal is shipping fly ash for, or purchasing fly ash from, another qualified marketing entity, the bill of lading or delivery receipt shall be from the shipping company. The certification statement showing the actual manufacturer shall be prominently placed on the bill of lading or delivery receipt. A copy of the bill of lading or delivery receipt shall accompany each shipment and shall be furnished to St. Louis County at the shipping and destination points. 1018.4.1 Certification. The bill of lading or delivery receipt for each shipment to St. Louis County projects shall carry the following certification statement: "This is to certify this Class ___ fly ash originated from a MoDOT qualified manufacturer, has been maintained to meet MoDOT specifications and was loaded from silo number ________."
_________________________________ Name and Location of Manufacturer
__________________________________ Name and Location of Shipping Facility
By________________________________ Signature and Name of Marketing Entity
2/4/2011
1018-2
Fly Ash for Concrete
Section 1019
Cement
1019.1 Scope. This specification covers Portland cement (Types I, IA, II, IIA, II(MH), II(MH)A, III, IIIA, IV and V), hydraulic cement and blended hydraulic cement. 1019.2 General. All cement shall be in accordance with the following requirements. The basis of acceptance shall be as described in Section 1019.3. 1019.2.1 Portland Cement. All Portland cements shall be in accordance with AASHTO M 85 with the following modifications: a) Specific surface, fineness, for all Type I/II Portland cements shall not exceed 430 m2/kg using Air permeability test. Maximum fineness limits do not apply if the sum of C3S + 4.75C3A is less than or equal to 90. b) When slag cement is used as an inorganic processing addition, loss on ignition shall be corrected in accordance with ASTM C 114 and reported on mill test reports. c) Type I / II Portland cements shall have total alkali content not above 0.6 percent. 1019.2.2 Hydraulic Cement. All hydraulic cement shall be in accordance with ASTM C 1157, Type GU. 1019.2.3 Blended Hydraulic Cement. All blended hydraulic cement shall be in accordance with Type IP, IS, IL or IT of AASHTO M 240 with the following modification that chemical composition shall be provided and tolerances checked in accordance with Section 7.1.1 of AASHTO M 240 and allowable constituent amounts of Type IP, IS, IL and IT cements are within the specified limits listed below: a) Type IP (<25). Cement shall have a pozzolan constituent up to 25 percent by mass of the blended cement. Type IP cements, in which the pozzolan constituent is metakaolin or silica fume, shall be a maximum of 15 or 8 percent, respectively. b) Type IS (<25). Cement shall have a slag cement constituent up to 25 percent by mass of the blended cement. c) Type IL (<15). Cement shall have a limestone constituent up to 15 percent by mass of blended cement. Type IL cements shall have alkali content not above 0.6 percent. d) Type IT (X) (Y). X and Y represent the constituent (S, L, or P) followed by the whole percent number by mass of the final blended product. The Type IT cement shall have a slag cement, limestone, and pozzolan constituent up to 40 percent by mass of the ternary blended cement. The maximum constituent requirements shall be in accordance with Section 1019.2.3, a), b), and c) in some combination up to 40 percent.
12/9/2013
1019-1
Cement
1019.2.4 Other Cements. White Portland cement shall meet the requirements for Type I. Air-entraining Portland cement shall be used only when specified in the contract. Different types of cement shall not be mixed nor shall different types be used in the same unit of construction. 1019.2.5 Sack or Bag. A sack or bag of cement will be considered to be 94 pounds net. 1019.2.6 All tests shall be performed in a MoDOT approved laboratory. 1019.3 Sampling, Testing, Packaging and Storage. All manufacturers and terminals furnishing cement to St. Louis County projects shall be MoDOT qualified. 1019.3.1 Foreign Cement. All tests on foreign cement shall be performed by a qualified domestic manufacturer's independent laboratory. 1019.3.2 Packaging and Storage. All cement intended for use shall be sampled, tested, and placed in designated silos, bins, or buildings that are weather-tight that will protect the cement from dampness and minimize warehouse set. Cement that is delivered in packages shall have the words "Portland Cement", the type of cement, the name and brand of manufacturer, and the mass of cement contained therein plainly marked on each package. When the cement is an air-entraining type, the words “air-entraining” shall be plainly marked on each package. Similar information is to be provided in the shipping documents. 1019.4 Acceptance. The supplier shall certify that the material complies with MoDOT specification requirements. When a qualified manufacturer or terminal is shipping cement for, or purchasing cement from, another qualified manufacturer, the bill of lading or delivery receipt shall be from the shipping company. The certification statement showing the actual manufacturer shall be prominently placed on the bill of lading or delivery receipt. A copy of the bill of lading or delivery receipt shall accompany each shipment and shall be furnished to St. Louis County at the shipping and destination points. 1019.4.1 Certification. The bill of lading or delivery receipt for each shipment to St. Louis County projects shall carry the following certification statement: "This is to certify this Type ___ cement originated from a MoDOT qualified manufacturer, has been maintained to meet MoDOT specifications and was loaded from silo number ________."
__________________________________ Name and Location of Manufacturer
__________________________________ Name and Location of Shipping Facility
By________________________________ Signature and Name of Marketing Entity
12/9/2013
1019-2
Cement
Section 1020
Corrugated Metallic Coated Steel Culvert Pipe, Pipe Arches and End Sections
1020.1 Scope. These specifications cover corrugated steel pipe, pipe-arches and flared end sections intended to be used for the construction of culverts and similar uses. The steel used in fabrication shall have a protective metallic coating of zinc (galvanizing) or aluminum. 1020.2 Basis of Acceptance. Unless otherwise specified, the basis of acceptance will be in accordance with AASHTO M 36. Pipe shall be from an approved qualified plant and will be accepted based on certification, manufacturer quality control documentation, and tests on samples as required by the Engineer. 1020.3 Material. 1020.3.1 Steel. Steel sheet shall be certifiable in accordance with AASHTO M 218 or AASHTO M 274. Finished steel sheet shall be free from injurious defects such as blisters, flux, and uncoated spots. 1020.3.2 Zinc Coating. Zinc for coating (galvanizing) shall be prime western grade or better. Zinc-coated steel shall have a weight (mass) of zinc coating not less than 2.00 oz./ft2 of double exposed surface. If the average weight of zinc coating as determined from the required samples is less than 2.00 oz./ft2 or if any one specimen has less than 1.80 oz. of zinc per ft2 of double exposed surface, the lot sampled will be rejected or resampled as determined by the Engineer. If a retest is made, the weight of zinc coating of all the original samples and the samples for retest shall average at least 2.00 oz./ft2 of double exposed surface and no specimen shall have less than 1.80 oz./ft2 or the entire lot sampled will be rejected. Adherence of coating shall be such that no peeling occurs while the material is being corrugated or formed into pipe. 1020.3.3 Aluminum Coating. Aluminum for coating shall be commercially pure aluminum. The bath analysis shall be in accordance with the Aluminum Bath Analysis table shown in AASHTO M 274.. Aluminum-coated steel shall have a weight of aluminum coating no less than 1.00 oz./ft.2 of double exposed surface. If the average weight of aluminum coating, as determined from the required samples, is less than 1.00 oz./ft.2 or if any one specimen has less than 0.90 oz. of aluminum per ft.2 of double exposed surface, the lot sampled will be rejected or resampled, as determined by the engineer. If a retest is made, the weight of aluminum coating of all the original samples and the samples for retest shall average at least 1.00 oz./ft.2 of double exposed surface and no specimen shall have less than 0.90 oz./ft.2 or the entire lot sampled will be rejected. 1020.3.4 Documentation. 1020.3.4.1 Sheet Manufacturer's Certified Analysis. The manufacturer of each brand shall file with Construction and Materials a certificate setting forth the name or brand of metal to be furnished, the specified chemical composition and a typical or average analysis showing the percent of carbon, phosphorus, manganese, sulfur and silicon. The certificate shall be sworn to, for the manufacturer, by a person having legal authority to bind the company. 1/31/2007
1020-1
Corrugated Metallic Coated Steel Culvert Pipe, Pipe Arches and End Sections
1020.3.4.2 Sheet Manufacturer's Guarantee. The manufacturer of the steel sheet shall submit with the certified analysis a guarantee providing that all metal furnished is in accordance with the specification requirements, shall bear a suitable identification brand or mark, and shall be replaced without cost to the County when not in accordance with the specified analysis, sheet thickness, or coating. The guarantee shall be so worded as to remain in effect as long as the manufacturer continues to furnish material. The manufacturer shall make such tests and measurements as necessary to ensure that the material produced is in accordance with all specification requirements. These tests and measurements shall be identified by the identification symbols or code used on the sheet in a manner which will permit the manufacturer to produce specific reports showing test results representative of specific lots of steel sheet. Copies of reports of these tests shall be kept on file and shall be submitted to the engineer upon request. The brand shall be removed or obliterated by the manufacturer on all material where control tests, as outlined herein, do not show conformance to this specification. 1020.4 Fabrication. 1020.4.1 Riveted Seams. A longitudinal seam will not be allowed on the corner radius or invert of pipe-arch. 1020.4.2 Resistance Spot Welded Seams. A longitudinal seam will not be allowed on the corner radius or invert of pipe arch. 1020.4.3 Shop Elongation. If round pipe is required to be shop elongated, the vertical axis shall be 5% greater than the nominal diameter. A tolerance of one percentage point in elongation will be permitted. Approximately 2 feet at each end of an installation may be left round to accommodate connecting end treatments or extensions. A paint mark to indicate the top of pipe shall be placed on each piece of shop elongated pipe, and round ends on an elongated pipe shall be clearly marked "Outside End-Round". 1020.4.4 Beveled Ends. Corrugated metal pipe requiring beveled ends to conform to the adjacent roadway slope shall be cut in such a manner as to leave smooth edges without damage to the coating away from the cut edge. Cut edges shall be completely covered with two coats of single component inorganic zinc or organic zinc rich paint meeting the approval of the engineer. No other end finish will be required for pipe with beveled ends. 1020.4.5 End Sections. Metal end sections shall be in accordance with the requirements for base metal, coating, fabrication, sampling, accepted brands of metal, sheet manufacturer's certified analysis, sheet manufacturer's guarantee, sheet thickness, workmanship, and repair of coating. The sections shall conform to the shape, dimensions, and sheet thicknesses shown on the plans. The sections shall be manufactured as integral units or so the sections may be readily assembled in place. 1020.4.6 Bands. Formed bands may be used on pipe with annular corrugations and helically corrugated pipe with reformed ends. The bands shall be formed with a minimum of two corrugations matching the profile of the pipe being joined together. The corrugations shall be spaced to provide seating in the second corrugation of each pipe and without creating more than ½ inch annular space between the pipe ends when joined together.
1/31/2007
1020-2
Corrugated Metallic Coated Steel Culvert Pipe, Pipe Arches and End Sections
1020.4.6.1 Circumferentially corrugated bands, bands with projections and helically corrugated bands shall be so constructed as to lap on an equal portion of each of the culvert sections and shall be connected at the ends by galvanized angles having minimum dimensions of 2 inch x 2 inch x 3/16 inch, fastened with galvanized bolts of ½ inch minimum diameter. Formed bands shall be fastened together by two ½ inch bolts through a bar and strap welded to the band. Angles shall be secured to the coupling bands by riveting, welding, resistance spot welding or a method approved by the engineer at each corrugation. Rivets shall be placed such that the head of the rivet will be on the inside of the band. Welds, except for resistance spot welds, shall be painted with one coat of zinc dust, zinc oxide, or zinc-rich paint meeting the approval of the engineer. The 7 inch and 10½ inch bands shall have at least two fastening bolts, the 12 inch and 14 inch bands shall have at least three fastening bolts and the 16¼ inch or greater bands shall have at least four fastening bolts. Alternate methods of fastening the ends of coupling bands may be used if approved by the engineer. Coupling bands for pipe arch and shop elongated pipe shall be shaped to fit the structure. 1020.4.6.2 As an alternate to coupling bands, a bell and spigot joint system may be used as approved by Construction and Materials. 1020.4.7 Special Fittings. Special fittings, angles, and tees shown on the plans shall be fabricated by welding in such a manner as to avoid excessive damage to the coating away from the welded area. The welded area and adjacent damaged coating shall be repaired in accordance with Section 1020.6. 1020.5 Sampling, Testing and Acceptance Procedures. All fabrication plants furnishing pipe to St. Louis County projects shall be MoDOT qualified. 1020.5.6 Sampling of Material. Random sampling of the pipe or material used in the production of pipe will be conducted by the Engineer to verify if the pipe and material is in accordance with the applicable specifications. Sampling size and frequency will be at the discretion of the Engineer. In the event pipe material certified by the manufacturer are not in accordance with Section 1020 as determined by random sampling, testing and inspection, all pipe incorporating that material will be rejected. 1020.5.7 Mill and Factory Inspection. The Engineer may have the material inspected and sampled in the rolling mill or in the shop where fabricated. The engineer may require from the mill the chemical analysis of any heat number. The inspection, either in the mill or in the shop, shall be under the direction of the Engineer. The Engineer shall have free access to the mill or shop for inspection and every facility shall be extended for the purpose of inspection. Any material or pipe which has been previously rejected at the mill or shop and included in a later lot will be considered sufficient cause for rejection of the entire lot. 1020.5.8 Inspection. Inspection by the Engineer will include an examination of the pipe for deficiency in specified diameter, net length of finished pipe and any evidence of poor workmanship. The inspection may include taking samples for chemical analysis, mechanical properties, and determination of weight of coating. The pipe making up the shipment shall meet all requirements of these specifications. If 25% of the pipe in any lot fails to meet these requirements, the entire lot may be rejected.
1/31/2007
1020-3
Corrugated Metallic Coated Steel Culvert Pipe, Pipe Arches and End Sections
1020.5.9 Sampling of Coated Steel. Samples of coated steel sheet may be obtained from coils, flat or corrugated cut lengths or fabricated culverts. Samples shall be taken at a frequency determined by the manufacturer's QC Plan or as required by the Engineer. 1020.5.9.1 For testing weight of coating of flat or corrugated cut lengths before fabrication, three specimens, each not less than 2¼ inches square or of an equivalent area, shall be taken from each test sheet selected to represent the lot. The specimens shall be so taken that no part includes metal closer than 2 inches from an edge or 4 inches from an end of the cut length. These specimens shall be obtained in any one of the following patterns: 1) One specimen shall be obtained from the center of the cut length and the other two in a straight line diagonally at the opposite corners. 2) Specimens shall be taken in a straight line from one end of the cut length, one from the middle portion and one from near each edge. 1020.5.9.2 For testing weight of coating of coils before fabrication, three specimens, each not less than 2¼ inches square or of an equivalent area, shall be taken, one from the middle of the width and one from each side. No specimen shall be taken closer than 2 inches from an edge or 4 inches from an end of the coil. 1020.5.9.3 For testing weight of coating of fabricated pipe or pipe-arch, at least one specimen 2¼ inches square or of equivalent area, shall be selected for each 20 pieces of pipe within a given lot selected to be tested, provided that not less than three specimens, each from a different piece, shall represent any one lot. The three specimens shall constitute one sample and shall be in accordance with Section 1020.3. 1020.5.9.4 For chemical analysis of the base metal of flat or corrugated cut lengths before fabrication, a specimen, not less than 2¼ inches square or of an equivalent area, shall be taken from each of three different cut lengths for lots weighing 5 tons or less, from four cut lengths for lots weighing more than 5 tons and less than 10 tons and from five cut lengths for lots weighing 10 tons or more. Drillings or chips from the specimens shall be thoroughly mixed for analysis. 1020.5.9.5 For chemical analysis of the base metal of coils, three specimens, each not less than 2¼ inches square or of an equivalent area, shall be taken from across the width of the coil, or if more than one mill lift or coil is involved, three specimens shall be selected from each of at least two different coils. Drillings or chips from the specimens shall be thoroughly mixed for analysis. 1020.5.9.6 When chemical analysis of base metal of fabricated pipe or pipe arch is required, the analysis shall be performed on the same specimens taken for determination of weight of coating. 1020.5.9.7 For testing mechanical properties of the base metal, two specimens, each 4 inches x 14 inches, shall be taken from one end of a cut length or coil. The 14 inch dimension shall be in the longitudinal direction of the steel sheet. No specimen shall be taken closer than 2 inches from an edge or 4 inches from an end of a sheet.
1/31/2007
1020-4
Corrugated Metallic Coated Steel Culvert Pipe, Pipe Arches and End Sections
1020.5.9.8 Samples for retest of weight of coating on cut lengths shall be taken in accordance with pattern 1 of Section 1020.5.9.1. Samples for retest of mechanical properties or chemical composition of any base metal or retest of weight of coating on coils or fabricated pipe or pipe arch shall be taken in the same manner as for the original test. 1020.5.10 Testing of Metallic-Coated Steel. Tests for weight of coating, chemical composition, and mechanical properties of metallic-coated steel sheets shall be as herein specified. 1020.5.10.1 Test specimen size and method of test for determining weight of coating shall be in accordance with AASHTO T 65 for zinc coatings and AASHTO T 213 for aluminum coatings. At the option of the Engineer, material may be accepted on the basis of magnetic gauge determinations made in accordance with ASTM E 376. 1020.5.10.2 The method of test for chemical analysis shall be in accordance with ASTM E 30-68, exclusive of any later revisions or additions. 1020.5.10.3 Test specimen size and method of test for determining tensile strength, yield strength, and elongation shall be in accordance with ASTM A 370 for sheet steel. 1020.5.11 Acceptance of Metallic-Coated Steel Sheet. Acceptance of metallic coated steel sheet will be based upon a satisfactory sheet manufacturers certified analysis and guarantee and sheet identification markings, upon tests on samples of the material or upon both. The frequency of sampling will be determined by the engineer. The fabricator shall provide the equipment and personnel required to obtain the samples as directed by the Engineer. 1020.5.12 Accepted Brands of Metal. No metal will be accepted under these specifications until the sheet manufacturer's certified analysis and manufacturer's guarantee have been approved by the Engineer. Misbranding or other misrepresentation and nonuniformity of product, will each be considered a sufficient reason to discontinue the acceptance of any brand under these specifications, and notice sent to the sheet manufacturer of the discontinuance of acceptance of any brand will be considered to be notice to all culvert companies which handle that particular brand. 1020.5.13 Sampling and Testing of Continuous Lock Seam. Sampling and testing for continuous lock seam quality control shall be in accordance with AASHTO T 249. 1020.5.13.1 The pipe manufacturer or plant shall cut, log and retain quality control samples. The samples shall be retained for two years. Visual examination samples for quality control shall be cut during production. The manufacturer or plant shall sample a minimum of one lock per coil when the same diameter of pipe is being produced. The samples shall be taken from the beginning of the coil. If diameters are changed within a coil, at least one lock per diameter shall be taken. Quality control tension test specimens shall be taken from pipe representing each sheet thickness and diameter the first time that sheet thickness and diameter is produced. In addition, each sheet thickness thereafter shall be sampled on a monthly basis during production for tension testing of the seam. The manufacturer or plant shall record all tension test results and retain those records for two years. 1/31/2007
1020-5
Corrugated Metallic Coated Steel Culvert Pipe, Pipe Arches and End Sections
1020.5.13.2 Inspection by the Engineer will include random visual examination samples and tension test samples taken in the presence of the engineer. If visual examination samples indicate nonconformance, that length of the pipe will be rejected, and a resample will be taken from a different length of pipe of the same sheet thickness of the same diameter. If the resample fails, each shipment of that sheet thickness thereafter shall be sampled for visual examination and tension testing until the engineer determines that satisfactory quality control is established. Pipe from which tension test specimens have been taken may be cut and the undamaged portion accepted for use. 1020.6 Repair of Damaged Coating. Damaged coating on pipe shall be repaired in accordance with AASHTO M 36, except as follows. Coating damaged in the field shall be repaired by recoating by the hot dip process or by the metallizing process except that in instances of minor damage to areas in the upper two-thirds of the perimeter as installed, the engineer may permit repair in the same manner as specified for repair during fabrication. The fabricated unit shall be thoroughly cleaned prior to recoating. The hot-dip process shall be in accordance with Section 1020.3. 1020.7 Marking. Each section of pipe to be used on St. Louis County projects shall be marked with an approved manufacturer's identification marking prior to shipment. The marking shall be permanent and located within 12 inches of the downstream end of the pipe. 1020.8 Handling. All pipe shall be handled with care to avoid damage. Pipe having damaged coating, any localized bends in excess of 5% of the specified pipe diameter or any dent in excess of ½ inch will be rejected at the site of the work regardless of previous approvals. Rejected damaged pipe may be used if repaired to the satisfaction of the Engineer. 1020.9 Bill of Lading. A bill of lading or delivery receipt for each shipment of pipe shall be furnished to the Engineer at the shipping and destination points, shall contain an itemized statement of the sizes and lengths of pipe, and shall carry a certified statement. The certified statement shall be signed by an authorized representative of the manufacturer and shall state the following: "This certifies that the pipe, bands and end sections in this shipment are in accordance with MoDOT specifications, were fabricated at an approved plant and were fabricated from the following brand names:"
1/31/2007
1020-6
Corrugated Metallic Coated Steel Culvert Pipe, Pipe Arches and End Sections
Section 1021
Bituminous Coated Corrugated Metal Culvert Pipe and Pipe Arches
1021.1 Scope. This specification covers bituminous coated corrugated metal culvert pipe and pipe arches to be used for the construction of culverts. 1021.2 Basis of Acceptance. Basis of acceptance for pipe and pipe arches will be in accordance with Section 1020.2, Section 1020.5 and as specified herein. The basis of acceptance for bituminous material will be in accordance with AASHTO M 190, except acceptance may be based on samples obtained from storage or from the dipping tanks. 1021.3 Material. The pipe shall be in accordance, as applicable, with Sections 1020 or 1024. The bituminous material shall be in accordance with AASHTO M 190. 1021.3.1 Types of Coated Pipe. The coated pipe shall be one of the following types as specified in the contract: Type A ...................................................................................Fully Bituminous Coated Type B .............................................................. Half Bituminous Coated, Paved-invert Type C............................................................. Fully Bituminous Coated, Paved-invert Type D................... Fully Bituminous Coated, Paved-invert and 100% Paved or Lined 1021.4 Lift Hooks or Loops. Lift hooks or loops, if agreed upon by the engineer and manufacturer, may be attached to pipe and pipe arches to facilitate handling. 1021.5 Repair of Damaged Bituminous Coating. Bituminous coating damaged or displaced during delivery or installation shall be repaired as directed by the engineer by application of hot bituminous material of the same type as that originally used. Care shall be taken to avoid damage to the bituminous material during heating.
1/31/2007
1021-1
Bituminous Coated Corrugated Metal Culvert Pipe and Pipe Arches
(This Page Intentionally Left Blank)
1/31/2007
1021-2
Bituminous Coated Corrugated Metal Culvert Pipe and Pipe Arches
Section 1022
Corrugated Metallic Coated Steel Pipe Underdrain
1022.1 Scope. This specification covers corrugated metallic-coated steel pipe underdrain. 1022.2 Basis of Acceptance. Basis of acceptance will be in accordance with Section 1020.2, Section 1020.5, and as specified herein. 1022.3 Material. Corrugated metallic-coated steel underdrain shall be in accordance with Section 1020 and AASHTO M 36, Type III pipe for zinc-coated or aluminum-coated, with the following modifications. 1022.3.1 Pipe 6 inches in diameter shall be fabricated of steel no less than 0.052 inch, 18 gage, specified thickness. Pipe with diameters 8 to 21 inches, inclusive, shall be fabricated of steel no less than 0.064 inch, 16 gage, of the specified thickness. 1022.3.2 Coupling bands shall be of the same base metal as the pipe. Bolts, nuts, washers, and all other hardware items used with coupling bands shall be galvanized in accordance with AASHTO M 232 (ASTM A 153) or mechanically galvanized in accordance with ASTM B 695 Class 50. Coupling bands with projections are not acceptable. 1022.3.3 Mechanical requirements of the base metal shall not apply. 1022.3.4 Samples for determination of coating thickness may be taken from fabricated pipe. In the repair of damaged coating on elbows, pipe, and special fittings which are fabricated by methods which damage their coating, both the interior and exterior surfaces of the damaged area shall be thoroughly cleaned and all traces of welding flux and weld spatter shall be removed. The cleaned area shall then be painted with zinc-rich or aluminum asphalt paint at the fabricating plant. 1022.4 Perforations. Unless otherwise specified, all pipe shall be perforated in accordance with the requirements for Class 1 perforations AASHTO M 36. The minimum number of longitudinal rows of perforations shall be specified in AASHTO M 36, Table 12. 1022.4.1 When fine aggregate backfill is used, perforations shall have a nominal diameter of 3/16 inch.
10/1/2012
1022-1
Corrugated Metallic Coated Steel Pipe Underdrain
(This Page Intentionally Left Blank)
10/1/2012
1022-2
Corrugated Metallic Coated Steel Pipe Underdrain
Section 1023
Structural Plate Pipe and Pipe Arches
1023.1 Scope. This specification covers corrugated galvanized steel structural plates intended for use in construction of pipe and pipe arches. The plates shall consist of corrugated galvanized metal and shall be curved such that the plates can be bolted together to form a structure of the specified shape and size. 1023.2 Basis of Acceptance. The basis of acceptance will be in accordance with Section 1020.2, Section 1020.5 and as specified herein. 1023.3 Material. Corrugated galvanized steel structural plate for structural plate pipe and pipe arches shall be in accordance with AASHTO M 167, with the following modifications. 1023.3.1 Corrugations. The radii of curvature of the corrugations shall be at least one-half the depth of the corrugations. The corrugations shall have a depth of 2 inches and a pitch of 6 inches. The depth of corrugations shall not underrun the specified depth by more than 5%, and the pitch of the corrugations shall not deviate from the specified depth by more than ¼ inch. 1023.3.2 Spelter Coating. The spelter coating shall be free from injurious defects such as blisters, flux, and uncoated spots. For testing the weight of spelter coating and for chemical analysis, if required, the manufacturer shall take two samples for each 100 plates of each thickness of a shipment or fraction thereof. The samples may be obtained from a piece approximately 3 inches square, cut from a corner of a plate or from a coupon approximately 6 inches square attached to the center of one edge of the plate prior to galvanizing. The coupon shall be of the same thickness and base metal as the plate to which the coupon is attached. If the result of a test for weight of coating for any sample is not in accordance with AASHTO M 167, an additional sample shall be cut for tests from each of two other plates in the lot represented by the nonconforming sample. All original samples and samples for retest shall be in accordance with AASHTO M 167 or the entire shipment will be rejected. At the option of the Engineer, the material may be accepted or rejected on the basis of magnetic gauge results, except at the request of the Contractor or manufacturer, plates rejected by magnetic gauge results will be sampled as specified above. 1023.3.3 Accepted Brands of Metal. No metal will be accepted under these specifications until after the manufacturer's certificate and guarantee have been approved by the Engineer. 1023.3.3.1 Manufacturer's Certificate. The manufacturer of the structural plate identified by the manufacturer's mark shall file with Construction and Materials, a certificate setting forth the name of the manufacturer, the base metal manufacturer, the specified chemical composition and a typical or average analysis showing the percent of sulfur, copper and any other elements specified in Table I of AASHTO M 167. The certificate shall be sworn to for the manufacturer by a person having legal authority to bind the company. Mismarking or other misrepresentation by the manufacturer will be considered a sufficient reason to discontinue acceptance under these specifications. Notice sent to the manufacturer of the discontinuance of acceptance will be considered to be notice to all companies handling that particular manufacturer's product.
1/31/2007
1023-1
Structural Plate Pipe and Pipe Arches
1023.3.3.2 Manufacturer's Guarantee. The manufacturer of the structural plate shall submit with the certificate a guarantee providing that all structural plate furnished is in accordance with the specifications, shall bear the manufacturer's identification mark and shall be replaced without cost when not in accordance with the specified analysis, sheet thickness, or spelter coating. The guarantee shall be so worded as to remain in effect as long as the manufacturer continues to furnish the material. 1023.3.4 Bolts and Nuts for Connecting Plates. 1023.3.4.1 Bolts for connecting plates shall be ¾ inch in diameter and shall be in accordance with ASTM A 449. Nuts shall be in accordance with ASTM A 563, Grade C. Bolts, nuts and washers shall be galvanized in accordance with AASHTO M 232, or the bolts, nuts and washers may be mechanically galvanized. If mechanically galvanized, the coating thickness, adherence, and quality requirements shall be in accordance with AASHTO M 232, Class C. Except as specified herein, bolts and nuts shall meet the dimension requirements of ANSI B18.2.1 for heavy hex bolts and ANSI B18.2.2 for heavy hex nuts. The bearing surface of both bolts and nuts shall be symmetrically shaped to a 1 inch radius spherical surface. The maximum height of the wrench flats on bolts and thickness of nuts shall be within the limits specified in ANSI B18.2.1 and ANSI B18.2.2, respectively. Bolt lengths shall be such as to result in at least "full nuts" when tightened in place. The bolts and nuts may be sampled and tested before erection, or the bolts, nuts and washers may be accepted on certified mill tests by the manufacturer. 1023.3.4.2 Other fasteners may be used if the fasteners: 1) Meet the chemical and mechanical requirements of those specified in Section 1023.10.1. 2) Have body diameter and bearing areas no less than those specified in Section 1023.10.1. 3) Provide a comparable fit with the corrugations. 1023.4 Manufacture. The plates shall be connected by bolts at longitudinal and circumferential seams. Joints shall be staggered such that no more than three plates come together at any one point. Plates shall be furnished in standard sizes to permit structure length increments of 2 feet. The size and shape of the plates shall be such that the finished structure will have the dimensions shown on the plans or as specified herein and such that the circumferential or peripheral transverse seams will be staggered at least 1 foot, except that the Engineer may permit the seams in adjacent plates used for construction of beveled or skewed ends to be continuous. At least four bolts shall be used per foot of longitudinal seam, unless a greater number is specified on the plans, staggered in two rows, 2 inches apart, with one row in the valleys and one row on the crests of the corrugations. Bolts along circumferential seams shall be spaced not more than 10 inches apart. The distance from the center of bolt hole to the edge of the plate shall not be less than 1¾ times the diameter of the bolt. The diameter of the bolt holes for the longitudinal seams, except holes at corners of plates, shall not exceed the diameter of the bolts by more than ¼ inch. The major axis of the holes for transverse seams, including the holes at the corners of the plates, shall not exceed the diameter of the bolt by more than ½ inch and the average of the major and minor axis shall not exceed the diameter of the bolt by more than ¼ inch.
1/31/2007
1023-2
Structural Plate Pipe and Pipe Arches
1023.4.1 Circular Pipe. A manufacturing tolerance of 3 inches will be permitted in the diameter of the pipe. The thickness of metal to be used for each structure will be specified in the contract. The plates shall be prominently marked to show the position in which they are to be placed in the structure. 1023.4.2 Pipe-Arch. Plates for a pipe-arch shall form a cross section made up of four circular arcs tangent to each other at the arcs' junctions and symmetrical about the vertical axis. The top shall be an arc of no more than 180 degrees or no less than 155 degrees. The bottom shall be an arc of no more than 50 degrees or no less than 10 degrees. The top shall be joined at each end to the bottom by an arc of no more than 87½ degrees or no less than 75 degrees. The radius of corner arcs shall be between 16 inches and 21 inches for Type C-29 and smaller sizes, and between 29 inches and 33 inches for Type C-30 and larger sizes. The dimensions of structural plate pipe-arch shall be as specified in Table I, subject to a manufacturing tolerance of 2% plus 1 inch. The thickness of metal to be used for each structure will be specified in the contract. 1023.4.4 Beveled Ends. When specified on the plans, end plates for forming beveled ends shall be shaped to produce the specified slope in the finished structure. Burnt edges shall be free from oxide and burrs and shall present a workmanlike finish. Any edges cut after galvanizing shall be completely covered with two coats of single component inorganic zinc or organic zinc-rich paint, meeting the approval of the Engineer. Legible identification marks shall be placed on each part plate to designate the plate’s proper position in the structure. 1023.5 Workmanship. All plates shall show careful and finished workmanship. Among others, the following defects are specified as constituting poor workmanship, and the presence of any or all of these defects in an individual plate or in general in any shipment, will constitute sufficient cause for rejection: 1) Improper shape. 2) Ragged edges. 3) Unevenly lined or spaced bolt holes. 4) Illegible brands. 5) Bruised, scaled, or broken spelter coating. 6) Dents in the metal. 7) Bends in the metal not specified. 1023.6 Assembly Instructions and Drawings. The Contractor shall provide the Engineer with detailed assembly instructions and drawings for each structural plate pipe or pipe-arch prior to the installation of these structures.
1/31/2007
1023-3
Structural Plate Pipe and Pipe Arches
1023.7 Repair of Galvanizing. Spelter coating damaged in the field shall be repaired by hotdip galvanizing, the metallizing process as specified in Section 1020 or by the zinc alloy stick method in accordance with Section 712.14, except that in instances of minor damage, the Engineer may permit repair by painting with two coats of single component inorganic zinc or organic zinc-rich paint. The paint and application shall meet the approval of the Engineer. TABLE I Structural Plate Pipe-Arch ENGLISH Type
Area, Sq. Ft.
Span, Ft.-In.
Height, Ft.-In.
Type
Area, Sq. Ft.
Span, Ft.-In.
Height, Ft.-In.
C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11 C-12 C-13 C-14 C-15 C-16 C-17 C-18 C-19 C-20 C-21 C-22 C-23 C-24 C-25 C-26 C-27
22 24 26 28 31 33 35 38 40 43 46 49 52 55 58 61 64 67 71 74 78 81 85 89 93 97 101
6-1 6-4 6-9 7-0 7-3 7-8 7-11 8-2 8-7 8-10 9-4 9-6 9-9 10-3 10-8 10-11 11-5 11-7 11-10 12-4 12-6 12-8 12-10 13-5 13-11 14-1 14-3
4-7 4-9 4-11 5-1 5-3 5-5 5-7 5-9 5-11 6-1 6-3 6-5 6-7 6-9 6-11 7-1 7-3 7-5 7-7 7-9 7-11 8-1 8-4 8-5 8-7 8-9 8-11
C-28 C-29 C-30 C-31 C-32 C-33 C-34 C-35 C-36 C-37 C-38 C-39 C-40 C-41 C-42 C-43 C-44 C-45 C-46 C-47 C-48 C-49 C-50 C-51 C-52 C-53 ….
105 109 98 102 106 110 115 119 124 129 133 138 143 148 153 158 163 168 174 179 185 190 196 202 208 214 ….
14-10 15-4 13-3 13-6 14-0 14-2 14-5 14-11 15-4 15-7 15-10 16-3 16-6 17-0 17-2 17-5 17-11 18-1 18-7 18-9 19-3 19-6 19-8 19-11 20-5 20-7 ….
9-1 9-3 9-4 9-6 9-8 9-10 10-0 10-2 10-4 10-6 10-8 10-10 11-0 11-2 11-4 11-6 11-8 11-10 12-0 12-2 12-4 12-6 12-8 12-10 13-0 13-2 ….
1/31/2007
1023-4
Structural Plate Pipe and Pipe Arches
Section 1024
Corrugated Aluminum Alloy Culvert Pipe and Corrugated Aluminum Alloy Structural Plate
1024.1 Scope. This specification covers corrugated aluminum alloy culvert pipe and corrugated aluminum alloy structural plate intended for use in construction of pipe and pipe arches. 1024.2 Basis of Acceptance. The basis of acceptance will be in accordance with Section 1020.2, Section 1020.5 and as specified herein. 1024.3 Material. 1024.3.1 Corrugated Aluminum Alloy Culvert Pipe. This pipe shall be in accordance with AASHTO M 196, Type I. 1024.3.2 Corrugated Aluminum Alloy Structural Plate. Plates, shapes, and fasteners for aluminum alloy field bolted pipe and pipe-arch shall be in accordance with AASHTO M 219. The minimum required thickness shall be in accordance with the design criteria in AASHTO's Standard Specification for Highways Bridges, or as specified in the contract documents.
1/31/2007
1024-1
Corrugated Aluminum Alloy Culvert Pipe and Corrugated Aluminum Alloy Structural Plate
(This Page Intentionally Left Blank)
1/31/2007
1024-2
Corrugated Aluminum Alloy Culvert Pipe and Corrugated Aluminum Alloy Structural Plate
Section 1025
Corrugated Aluminum Alloy Pipe Underdrains
1025.1 Scope. This specification covers corrugated aluminum alloy pipe underdrains. 1025.2 Basis of Acceptance. The basis of acceptance will be in accordance with Section 1020.2, Section 1020.5, and as specified herein. 1025.3 Material. Pipe for corrugated aluminum alloy pipe underdrain shall be in accordance with AASHTO M 196, Type III, with the following modifications: 1025.3.1 Pipe 6 inches in diameter shall be fabricated of metal not less than 0.048 inch, 18 gage, specified thickness. Pipe with diameters 8 inches to 21 inches, inclusive, shall be fabricated of metal no less than 0.060 inch, 16 gage, specified thickness. 1025.3.2 Coupling bands shall be of the same aluminum alloy and corrugation type as the pipe. Bands with projections, smooth sleeve-type couplers and flat bands shall not be used. 1025.3.3 In the repair of damaged coating on elbows, pipe, and special fittings which are fabricated by methods which damage their coating, both the interior and exterior surfaces of the damaged area shall be thoroughly cleaned and all traces of welding flux and weld spatter shall be removed. The cleaned area shall then be painted with zinc-rich paint at the fabricating plant. 1025.4 Perforations. Unless otherwise specified, all pipe shall be perforated in accordance with the requirements for Class 1 perforations AASHTO M 196. The minimum number of longitudinal rows of perforations shall be specified in AASHTO M 196, Table 9. 1022.4.1 When fine aggregate backfill is used, perforations shall have a nominal diameter of 3/16 inch.
2/4/2011
1025-1
Corrugated Aluminum Alloy Pipe Underdrains
(This Page Intentionally Left Blank)
2/4/2011
1025-2
Corrugated Aluminum Alloy Pipe Underdrains
Section 1026
Reinforced Concrete Culvert, Storm Drain and Sewer Pipe
1026.1 Scope. These specifications cover reinforced concrete pipe to be used for the conveyance of sewage, industrial wastes, and storm water, and for the construction of culverts. 1026.2 Basis of Acceptance. 1026.2.1 The basis of acceptance shall be in accordance with AASHTO M 170, unless otherwise specified. Pipe shall be from an approved qualified plant and accepted based on certification, manufacturer quality control documentation, and tests on samples as required by the Engineer. 1026.2.2 The Contractor for quality control purposes and the Engineer for quality assurance purposes may select and apply the basis of acceptance in accordance with either Sections 5.1.1 or 5.1.2 in AASHTO M 170. 1026.2.2.1 If cylinders are tested, the cylinders shall be tested in accordance with AASHTO T 22. The average compressive strength of all cylinders tested shall be equal to or greater than the design concrete strength. 1026.2.2.2 If cores are cut from the wall of the pipe and tested, the cores shall be cut and tested in accordance with AASHTO T 280. If the compressive strength of each core tested is equal to or greater than the design concrete strength, the compressive strength of the concrete for the lot will be acceptable. 1026.2.2.2.1 If the compressive strength of a core tested is less than the design concrete strength, two additional cores shall be taken from that pipe section and tested. Concrete represented by these core tests will be considered acceptable if the average of the three cores is equal to or greater than the specified strength and no single core is less than 85 percent of the specified strength. 1026.2.2.2.2 If the compressive strength of the three cores does not meet the requirements of Section 1026.2.2.2.1, the pipe section from which the core was taken will be rejected. Two pipe sections from the remainder of the lot shall be selected at random and shall be tested for conformance with either Section 1026.2.2.2 or Section 1026.2.2.2.1. If both pipe sections meet the core strength requirements of either Section 1026.2.2.2 or Section 1026.2.2.2.1, the concrete compressive strength of the remainder of the lot will be accepted. If the compressive strength of either of the two pipe sections tested does not meet the requirements, the remainder of the lot will be either rejected or, at the option of the manufacturer, each pipe section of the remaining lot shall be cored and will be accepted individually. Any of the pipe sections that have a core not meeting the requirements of either Section 1026.2.2.2 or Section 1026.2.2.2.1 will be rejected.
1/31/2007
1026-1
Reinforced Concrete Culvert, Storm Drain and Sewer Pipe
1026.2.2.2.3 If the cores cut from a section of pipe meet the strength test requirements, the core holes shall be plugged and sealed by the manufacturer in a manner such that the pipe section will meet all of the requirements of these specifications. Pipe sections so sealed will be considered satisfactory for use. 1026.3 Material. Except as otherwise specified herein, reinforced concrete pipe shall be in accordance with AASHTO M 170. 1026.3.1 Reinforced Concrete. The reinforced concrete shall consist of a mixture of cement, mineral aggregates and water, in which steel has been embedded in such manner that the steel and the concrete act together. 1026.3.2 Cement. Cement shall be in accordance with Section 1019. Fly ash or GGBFS may be used to replace cement in accordance with Section 501, except approved Class C or Class F fly ash may be used to replace a maximum of 25% of Type I or II cement on an equivalent weight basis. Fly ash shall not exceed 25% by weight of the total cementitious material, i.e., microsilica, steel slag or other pozolanic material. 1026.3.3 Steel Reinforcement. All steel reinforcement shall be in accordance with Section 1036. 1026.3.4 Aggregates. Fine and coarse aggregates shall be in accordance with Section 1005, except that gradation requirements and percent passing the No. 200 sieve shall not apply. 1026.3.5 Concrete Mixture. The proportion of cementatious material in the mixture shall be no less than 470 pounds per cubic yard of concrete. 1026.3.6 Modified or Special Designs. The manufacturer may request approval of modified designs which differ from the designs in Section 7.1 AASHTO M 170; or special designs for sizes and loads beyond those shown in Tables I to V of AASHTO M 170; or special designs for pipe sizes that do not have steel reinforcement areas shown in Tables II to V of AASHTO M 170. Modified or special designs shall be in accordance with AASHTO M 242. 1026.3.7 Joints. If specified, joints shall be Type A rubber gaskets in accordance with AASHTO M 198. The manufacturer shall make tests in accordance with Section 8 of AASHTO M 198 to demonstrate adequate performance and shall furnish certification that the physical and chemical properties of the gasket are in accordance with this specification. 1026.3.8 Curing. A curing membrane in accordance with Section 1055 may be applied, and if used, shall be left intact until the strength requirements are met. 1026.3.9 Lift Holes. If agreed upon by the Engineer and the manufacturer, not more than two holes may be cast or drilled in the wall of each pipe for the purpose of handling at the construction site. The holes shall not be larger than 2½ inches in diameter for pipe 60 inches in diameter or less, and not larger than 3½ inches for pipe greater than 60 inches in diameter. The lift holes shall be carefully cast or drilled in a manner such that it is not necessary to cut, bend, or otherwise weaken the circumferential steel in the inner cage in pipe having two lines of reinforcement or any of the circumferential steel in pipe having one 1/31/2007
1026-2
Reinforced Concrete Culvert, Storm Drain and Sewer Pipe
line of reinforcement. Lift holes will be permitted for pipe specified with rubber gasketed joints only with the written approval of the Engineer. 1026.3.10 Marking. Each pipe shall be marked by the manufacturer with a "Q Cast" stamp to certify the pipe was produced by an ACPA certified plant. 1026.3.10.1 The following additional information shall be clearly marked on the inside of each section of pipe by indenting on the pipe section or by painting thereon with waterproof paint: 1) Pipe class. 2) Date of manufacture. 3) Name or trade-mark of the manufacturer. 1026.3.10.2 One end of each section of pipe with elliptical reinforcement shall be clearly marked, during the process of manufacturing or immediately thereafter, on the inside and the outside of opposite walls along the minor axis of the elliptical reinforcement with the word "Top" or "Bottom" to designate the proper position when laid. 1026.4 Sampling, Testing and Acceptance Procedures. All manufacturers furnishing pipe to St. Louis County projects shall be qualified as herein described. All pipe shall be subject to inspection by the Engineer at the source of manufacture, at an intermediate shipping terminal or at destination. The Engineer shall be allowed free access to all facilities and records as required to conduct inspection and sampling in accordance with Section 106. 1026.4.1 Application for Placement on Qualified List. To become qualified, a written request shall be sent by the manufacturer to Construction and Materials with the following information: 1) The manufacturer shall provide a statement certifying that the quality control procedures at the plant meet the requirements set forth by the American Concrete Pipe Association (ACPA) Compliance Audit and Certification Program. 2) Sources for each material to be used in the fabrication of pipe shall be provided. For aggregate sources, the ledge the material is being taken from shall also be included. 3) The manufacturer shall provide a guarantee that all material to be used in the fabrication of pipe will be in accordance with St. Louis County's specifications and pre-approval for any source of material will be received prior to use. 1026.4.2 Maintaining Qualification. To maintain qualification, the manufacturer shall perform and maintain a quality control program in accordance with the American Concrete Pipe Association (ACPA) Compliance Audit and Certification Program, with the following modifications: 1) The bill of lading for each shipment of material used in the production of pipe shall be kept on file for one year.
1/31/2007
1026-3
Reinforced Concrete Culvert, Storm Drain and Sewer Pipe
2) For all aggregates, the aggregate producer shall provide a certificate of compliance to applicable St. Louis County's specifications and identify what ledges the aggregate is being produced from. The certificate of compliance shall be kept as long as that material from that source and ledge is being used. 3) A sieve analysis for determination of the aggregate gradations used in each concrete mix shall be conducted once per month and when an aggregate source is changed. 4) The percentage of deleterious substance for each aggregate fraction shall be determined once a month. 5) Admixtures shall be from approved sources, and the manufacturer's certification that the material meets MoDOT specification shall be kept on file for one year. 6) Mill test reports for reinforcing steel shall be kept on file for one year. 7) Once a month, an absorption test shall be conducted for each mix used in the production of pipe. Test results shall be kept on file for one year. 8) For pipe with diameters of 66 inches or larger, three edge bearing tests shall be performed once per 100 pieces of pipe manufactured and at least once per year. Testing will not be required at plants where pipe of these diameters is not manufactured, nor will pipe of these diameters be required to be manufactured solely for the purpose of performing this testing. 1026.4.3 Plant Certification. Plants for concrete pipe production shall be certified by the American Concrete Pipe Association, and the certification shall be maintained current. 1026.4.4 Disqualification of a Manufacturer. A manufacturer may be disqualified to provide pipe for use on St. Louis County's projects based on the discretion of Construction and Materials, for reasons including, but not limited to, not maintaining ACPA certification, failure of material to consistently meet specifications, falsification of any documentation, misbranding of pipe, unsatisfactory performance in the field or for other reasons indicating lack of consistent material quality. 1026.4.4.1 In a case where a manufacturer loses ACPA certification and was not disqualified for any other reason, reinstatement will be considered when the manufacturer is recertified by ACPA. 1026.4.4.2 A manufacturer will not be considered for reinstatement until after one year from the date of removal for falsification of documents. 1026.4.4.3 Three notices of failure to meet specification requirements will cause disqualification of the manufacturer for one year, effective from the date of the third notice. 1026.4.4.4 A manufacturer disqualified within one year of the end of a disqualification may be subject to permanent removal, with no application to be reinstated for a period of three years.
1/31/2007
1026-4
Reinforced Concrete Culvert, Storm Drain and Sewer Pipe
1026.4.6 Reinstatement of a Manufacturer. Consideration of reinstatement of a manufacturer once disqualified will be no sooner than specified in Section 1026.8.3, will require a written document from the manufacturer stating the reasons for disqualification and the action taken to correct those deficiencies, written concurrence from Construction and Materials that the problem has been suitably addressed, and followed by an application in accordance with Section 1026.4.1. 1026.4.7 Sampling of Material. Random sampling of the pipe or material used in the production of pipe will be conducted by the Engineer to verify the pipe and material are in compliance with applicable specifications. Sampling size and frequency will be at the discretion of the Engineer.
1/31/2007
1026-5
Reinforced Concrete Culvert, Storm Drain and Sewer Pipe
(This Page Intentionally Left Blank)
1/31/2007
1026-6
Reinforced Concrete Culvert, Storm Drain and Sewer Pipe
Section 1027
Polymer Coated Corrugated Metal Culvert Pipe and Pipe Arches
1027.1 Scope. This specification covers polymer coated corrugated metal culvert pipe and pipe-arches to be used for the construction of culverts and storm sewers. 1027.2 Basis of Acceptance. Basis of acceptance for pipe and pipe-arches will be in accordance with Section 1020.2 and the AASHTO specifications cited herein. The basis of acceptance for polymer material will be in accordance with AASHTO M 245. Pipe shall be from an approved qualified plant and will be accepted based on certification, manufacturer quality control documentation and results from tests on samples as required by the Engineer. 1027.3 Material. Polymer coated corrugated metal pipe and pipe-arches shall be in accordance with Section 1020 and AASHTO M 245.
1/31/2007
1027-1
Polymer Coated Corrugated Metal Culvert Pipe and Pipe Arches
(This Page Intentionally Left Blank)
1/31/2007
1027-2
Polymer Coated Corrugated Metal Culvert Pipe and Pipe Arches
Section 1028
Corrugated Poly Vinyl Chloride (PVC) Culvert Pipe
1028.1 Scope. This specification covers corrugated PVC culvert pipe intended to be used for the construction of culverts, sewers and similar uses. 1028.2 Basis of Acceptance. All pipe designated for installation within Metropolitan Sewer District (MSD) jurisdiction will meet MSD specifications. Acceptance of corrugated PVC culvert pipe will be based upon the pipe being in accordance with this specification. Pipe shall be provided from an approved manufacturer, and will be accepted based on certification, identification markings and results from tests required by the Engineer. 1028.3 Material. All corrugated PVC culvert pipe, couplings and fittings shall be in accordance with ASTM F 949, except as follows. 1028.3.1 The pipe shall not be perforated unless otherwise specified. 1028.3.2 Field joints of corrugated PVC pipe shall provide circumferential and longitudinal strength to maintain the pipe alignment, prevent separation of pipe and prevent infiltration of side fill material. Coupling bands, if used, shall be of the same base material as the pipe. Prior to use, the design of coupling bands and fastening devices shall be submitted to and approved by Construction Division Manager. Final acceptance of coupling bands and fastening devices will be based upon field performance. 1028.3.3 The manufacturer shall provide to the engineer an itemized statement of the sizes and lengths of pipe in each shipment. 1028.3.4 Each individual section of pipe shall be marked in accordance with ASTM F 949, and shall have ASTM F 949 and the manufacturer's name marked on the pipe. 1028.4 Sampling, Testing and Acceptance Procedures. Manufacturers furnishing pipe to St. Louis County projects shall be MoDOT qualified. All pipe shall be subject to inspection by the Engineer at the source of manufacture, at an intermediate shipping terminal or at the destination. The Engineer shall be allowed free access to all facilities and records as required to conduct inspection and sampling in accordance with Section 106. 1028.4.1 Disqualification of a Manufacturer. A manufacturer may be disqualified from providing pipe for use on St. Louis County projects based on the discretion of the Construction Division Manager for reasons including, but not limited to, failure of material to consistently meet specifications; falsification of any documentation; misbranding of the pipe; unsatisfactory performance in the field; or for other reasons indicating lack of consistent material quality. 1028.4.1.1 A manufacturer will not be considered for reinstatement until after one year from the date of removal for falsification of documents. 1028.4.1.2 Three warnings for failure to meet specification requirements will constitute disqualification of the manufacturer for one year.
1/31/2007
1028-1
Corrugated Poly Vinyl Chloride (PVC) Culvert Pipe
1028.4.1.3 A plant disqualified twice for any reason in any two-year period will be subject for permanent removal, with a minimal suspension of three years. 1028.4.5 Reinstatement of a Manufacturer or Plant. Consideration of reinstatement of a manufacturer once disqualified will be no sooner than specified in Section 1028.4.4, will require a written document from the manufacturer stating the reasons for disqualification and the action taken to correct those deficiencies, written concurrence from the Construction Division Manager that the problem has been suitably addressed, and followed by an application in accordance with Section 1028.4.1. 1028.4.6 Sampling of Material. Random sampling of the pipe will be conducted by the Engineer to verify if the pipe and material is in accordance with Section 1028. Samples of PVC pipe will be obtained from fabricated culvert sections in accordance with ASTM F 949 at a frequency determined by the Engineer. 1028.4.7 Inspection. Inspection will include an examination of the pipe for markings, deficiency in specified diameter, net length of fabricated pipe and any evidence of poor workmanship. The inspection may include taking samples. 1028.4.8 Testing. Specimen testing size and method of tests shall be in accordance with ASTM F 949. The contractor or manufacturer shall provide the equipment and personnel to cut a sample from a section of pipe. The sample shall include the markings or a record of the markings for that section of pipe. 1028.4.9 Rejection. 1028.4.9.1 Any individual section of pipe failing to meet the marking, diameter, length or workmanship requirements of these specifications will be rejected. If 10% of the pipe in any lot fails to meet these requirements, the entire shipment of that pipe size may be rejected. 1028.4.9.2 If a test specimen taken in accordance with Section 1028.4.8 fails to meet the requirements of ASTM F 949, the pipe sampled will be rejected and the lot will be resampled. A resample will be of the same size as the original sample. The resample shall be in accordance to these specifications or the entire shipment will be rejected. 1028.5 Bill of Lading. A bill of lading or delivery receipt for each shipment of pipe shall be furnished to the Engineer at the shipping and destination points, shall contain an itemized statement of the sizes and lengths of pipe, and shall carry a certified statement. The certified statement shall be signed by an authorized representative of the manufacturer and shall state the following: "This certifies that the pipe, bands and end section in this shipment are in accordance with MoDOT specifications and were fabricated at an approved plant."
1/31/2007
1028-2
Corrugated Poly Vinyl Chloride (PVC) Culvert Pipe
Section 1029
Prestressed Concrete Members for Bridges
1029.1 Scope. This specification covers the fabrication of prestressed concrete members for bridges. This specification covers both pretensioned and post-tensioned members. 1029.2 Acceptance. Unless otherwise specified in the contract, acceptance of prestressed units will be based on tests of the material and inspection of the completed product. Acceptability of all types of sections covered by these specifications will be determined by the material tests required in Section 1029.3, by compression tests on concrete cores or cured concrete cylinders and by inspections of the finished sections, including quantity and placement of reinforcement, and freedom from defect. 1029.3 Material. 1029.3.1 Cement. Cement shall be in accordance with Section 1019. 1029.3.2 Aggregates. Fine and coarse aggregate shall be in accordance with Section 1005, except that requirements for gradation and percent passing the No. 200 sieve will not apply. The coarse aggregate shall meet the requirements of Section 1005.1, Gradation E of these specifications. 1029.3.3 Steel Reinforcement. Reinforcement shall be in accordance with Section 1036. 1029.3.4 Steel Strand. Steel strand shall be in accordance with AASHTO M 203. 1029.3.5 Structural Steel. Structural steel shall be in accordance with ASTM A 36. Structural steel for anchorage plates shall be in accordance with AASHTO M 270, Grade 50. 1029.3.6 Wire and Parallel Lay Wire Cables. Wire and parallel lay wire cables shall be in accordance with AASHTO M 203. 1029.3.7 High-Strength Steel Bars. High-Strength Steel Bars shall be in accordance with AASHTO M 275. 1029.3.8 Enclosures. Enclosures for post-tensioning tendons shall be mortar tight, semirigid metal tubes with an internal diameter at least ¼ inch larger than the bar, cable, strand or wire group to be enclosed, and shall be provided with suitable entrance and discharge ports for grouting. 1029.3.9 Mortar. Mortar for grouting tendons in post-tensioned members shall consist of a mixture of cement and fine sand in the approximate proportions of one part cement to ¾ parts sand by volume, with sufficient water to form a grout having the consistency of heavy paint. 1029.3.10 Concrete Mixture. Concrete material, proportioning, air-entraining, mixing, slump, and transporting of concrete shall be in accordance with Section 501, except as noted herein. Concrete for prestressed members shall conform to all requirements of Class A-1 concrete, except as noted herein. The Contractor may use Type I, IP, I(PM), IS, I(SM), Type II or Type III cement. Alternate mix designs shall be submitted to Construction
1/31/2007
1029-1
Prestressed Concrete Members for Bridge
Division Manager for approval. Trial batches may be required. Independent Laboratory testing may be required. Submissions shall include all mix designs, testing and production detail. 1029.4 Documentation. All wire, strand, bars, and anchorage assemblies shall be assigned a lot number and tagged for identification. The Contractor shall furnish one copy of the certified mill test report giving the chemical analysis and results of physical tests on the material furnished, except chemical analysis will not be required for steel strand in accordance with AASHTO M 203. The Contractor shall also furnish one certified copy of the stress-strain curve representative of the lot to be used. 1029.5 Equipment. 1029.5.1 Prestressing. The Contractor shall provide all equipment necessary for the construction and the prestressing of concrete members. Prestressing shall be done with approved jacking equipment. If hydraulic jacks are used, the jacks shall be equipped with accurate pressure gauges. All gauges, load cells, dynamometers and other devices for measuring the stressing load shall have an accuracy within two percent. The combination of jack and gauge shall be calibrated by a testing laboratory meeting the approval of the Engineer. A certified graph or table showing the calibration shall be furnished to the Engineer. The total load as determined from the strand elongation shall check that indicated by the gauge within five percent of the total load required to achieve the designated elongation. If other types of jacks are used, proving rings or other devices calibrated by a testing laboratory meeting the approval of the Engineer shall be furnished such that the jacking forces may be accurately determined. Calibration shall be repeated at intervals not exceeding one year and after each overhaul. While work is in progress, if any jack or gauge appears, in the judgment of the Engineer, to be giving erratic results, or if gauge pressure and elongation indicate materially different stresses, recalibration may be required. The Contractor shall furnish means of accurately measuring the elongation of the tendons to within 1/16 inch. Elongation upon completion of stressing operations shall be within five percent of that specified. No tensioning of strands shall be done when strand temperatures are below 30°F. 1029.5.2 End Anchorages. End anchorages and stressing blocks for pretensioned members shall be adequately designed to withstand the forces incidental to prestressing and to maintain the tension in all prestressed tendons of any member until the concrete has been placed and attained its specified transfer strength. 1029.5.3 Concrete Testing Equipment. Equipment for field determination of compressive strength of concrete shall be furnished by the Contractor at the location of manufacture of prestressed concrete members. The testing machine may be of any mechanical or hydraulic type, shall be power operated in accordance with AASHTO T 22, Section 5.1.2.1, shall be capable of testing cylinders to failure, and shall comply with the accuracy tolerances and corrections specified in AASHTO T 67, Section 16.1 and Section 17. Approximately the last one-half of the load shall be applied at a rate of between 1,200 and 3,000 psi per minute. The Contractor shall furnish a sufficient number of 6 inch x 12 inch compression test cylinder molds and lids of a type meeting the approval of the Engineer. The Contractor shall furnish sufficient personnel for cleaning and preparing reusable molds. The Contractor shall, at the option of the Engineer, furnish technicians to assist the Engineer with concrete testing and the making of test cylinders during the placing of concrete.
1/31/2007
1029-2
Prestressed Concrete Members for Bridge
1029.5.4 Field Laboratory. When requested, a Type 1 Field Laboratory in accordance with Section 601 shall be furnished. 1029.6 Construction Requirements. 1029.6.1 Shop Drawings. Shop drawings showing in detail the type, size, number of units, location of tendons, enclosures, method and sequence of releasing the strands, anchorage details and details of proposed lifting loops and lifting procedure shall be submitted to the Engineer for approval. The Contractor may select the method of prestressing, provided an approved specific method is used and the total prestressing force and the center of gravity of the prestressing tendons as shown on the plans are maintained. The shop drawings shall show a tabulation of the design computations and the total prestress force, size and spacing of all reinforcing steel and concrete compressive strengths for strand release and design. No inspection will be conducted until the plant inspector has received a copy of the approved shop drawings. Prior to making shop drawings, the Contractor shall submit in writing for approval of the Engineer any proposed tack welding in lieu of tying of the reinforcing bars of prestressed members. If approved by the Engineer, the location of tack welding of reinforcing bars shall be shown on the shop drawings submitted for approval. No heat or welding will be permitted in the proximity of prestressing tendons in the members. 1029.6.2 Forms and Formwork. Forms and formwork, placing and tying of reinforcing bars, and placing and vibrating of concrete shall be in accordance with the applicable requirements of Section 703 and Section 706, with the following additions: 1) Clamps, bolts or other devices connecting the bulk-head to the side forms, inserts, and blockouts shall be capable of being removed or loosened before steam curing is applied. 2) The casting bed shall have a concrete deck on which the form grillage and soffit plates may be adequately centered, aligned, and leveled to the same plane. 3) Exterior forms for prestressed members shall be metal other than aluminum, mortartight and of adequate design to produce members within the tolerances specified. 4) The temperature of the mixed concrete when placed shall not be higher than 90°F. The forms and reinforcing steel shall be cooled by acceptable methods to an ambient temperature of 90°F or lower. 5) Fabricating plants with demonstrated facilities for protection of the concrete during cold weather may, with the approval of the Engineer, cast prestressed units when the ambient temperature is below 40°F. When the ambient temperature is below 40°F, the forms, or enclosures, and reinforcing steel shall be heated to attain and maintain a temperature of at least 40°F. No concrete shall be placed when the concrete temperature is below 60°F. 6) The concrete for girders shall be placed in a minimum of two continuous lifts. No more than 30 minutes shall elapse between the placing of contiguous lifts of concrete. The thickness of the first layer for I-girder beam sections shall be such that the top of the concrete is slightly above the top of the bottom fillet. The casting procedure shall be modified if the length of girders and placement conditions are
1/31/2007
1029-3
Prestressed Concrete Members for Bridge
such that an initial set of concrete may result if each lift is continued full length before another lift is placed. 1029.6.3 Prestressing Tendons. Prestressing tendons for pretensioned members, and metal enclosures for post-tensioned members, shall be accurately placed and securely held during the placing and curing of the concrete. Strand chucks for pretensioning shall anchor the strand positively without slippage after seating. Strand chuck components shall be cleaned and inspected between each use and lubricated as necessary. All strands shall be free of contaminants such as dirt, oil, paint, wax, corrosion, or other foreign material that may prevent a bond between the strands and the concrete. The use of prestressing strands having kinks, bends, nicks, or other defects will not be permitted. A light coating of rust will not be cause for rejection provided that the loose rust is removed and the surface of the strands is not visibly damaged. Tensioned strands shall be protected against excessive temperatures such as those produced by torches, welding equipment or sparks. Strands from more than one source shall not be used in any one tensioning operation. 1029.6.4 Strand Splices. One approved splice per strand will be permitted provided the splices are located outside of the prestressed member. For single strand tensioning, the number of strands per bed that may be spliced is not restricted. If multi-strand jacking is used, either all strands shall be spliced or no more than 10% of the strands shall be spliced. Spliced strands shall be similar in physical properties, from the same source, and have the same twist or lay. Previously tensioned strands may be reused one time provided the strands meet all of the requirements of these specifications. 1029.6.5 Wire Failures. Wire failures may be accepted provided no more than one wire in any strand is broken and the area of broken wires does not exceed 2% of the total area of the strands. 1029.6.6 Stressing Requirements. The Contractor shall provide a technician skilled in the use of the system of stressing to supervise the stressing operations. 1029.6.7 Elongation. The Contractor shall compute the required elongation. Two copies of the computations shall be submitted to the Engineer. The length of the strand to be used in calculating elongations shall be the actual length of the strand along the strand's trajectory between the fixed anchorage and the reference point at jacking end of the strand. Stress losses due to slippage of strand anchorages, splice chucks, and movement of anchorage abutments shall be included in the elongation computations. 1029.6.8 Pretensioned Members. Prestressing tendons shall be uncoated seven wire low relaxation strands in accordance with AASHTO M 203, Grade 270. Several pretensioned members may be cast in one continuous line. The time intervening between the casting of the first and last member on a bed shall not exceed four days unless otherwise permitted by the Engineer. When the temperature at the time of tensioning is such that correction must be made to compensate for change in strand stresses, all members on the bed shall be cast in a continuous pour. The tension in the strand as determined from the elongation at the time of placing concrete shall be within five percent of that specified. The stress to be given each strand shall be as shown on the plans. Pretensioning shall be by either the single strand or multi-strand jacking method. Each strand shall be brought to a uniform initial tension. The initial tension of each strand shall be accurately measured by a dynamometer or other approved means. The initial tension shall be within 50 pounds or two percent of that required, whichever is the larger. The same jack used for single strand tensioning may 1/31/2007
1029-4
Prestressed Concrete Members for Bridge
be used for initial tensioning provided the jack is equipped with a proper gauging system for measuring the initial tension. Measurement of elongation shall not begin until initial tensioning has been completed. Strands tensioned as a group shall have the same initial tension, be from the same source, and have essentially the same modulus of elasticity. Coil ties shall be held in place in the forms by setting studs projecting through the forms. Studs shall be left in place until girders are erected and then replaced by coil tie rods. Alternate methods may be used, provided acceptable results are achieved. Coil ties shall have a concrete pull-out strength of no less than 9,000 pounds in 3,000 psi concrete. 1029.6.9 Post-Tensioned Members. Post-tensioned members shall be stressed in such manner that the tension being applied and the elongation of the tendon may be measured at all times. The Contractor shall furnish a certified record of gauge pressures and elongations to the Engineer. Friction losses in the enclosures, elastic shortening, and anchorage set shall be included in the computations for the required elongation of the tendon. In cases of discrepancies between gauge readings and the stress indicated by the elongation of the tendon, the elongation method of stress determination shall govern. Loads shall not be applied to the concrete until the concrete has attained the design compressive strength shown on the plans. Tendons shall be stressed in a sequence to produce the least eccentricity of the load. Post-tensioning elements shall be placed in metal enclosures and after stressing shall be bonded by pressure grouting the space between the enclosure and the tendon. Enclosures shall be thoroughly cleaned of all foreign material prior to grouting. The discharge ports shall be closed after all air has been forced out of the enclosure, as evidenced by the steady discharge of grout at the grout’s proper consistency, and a pump pressure of at least 50 psi maintained on the grout for a sufficient length of time to ensure completely filling all voids in the enclosure. Post-tensioned members shall not be removed from their supports for at least 24 hours after grouting. 1029.6.10 Strand Release. Strands shall not be released until the concrete has attained the required compressive strength shown on the approved shop drawings. The compressive strength shall be determined by tests of standard cylinders made of concrete from the same batches and cured in the same manner as the members. The strands or prestressing elements shall be cut or released in a sequence that produces the least eccentricity of the load. If steam curing is used, strand release shall be performed while the members are still warm. Forms, hold down device, or other appurtenances which may restrict movement of the members shall be removed or loosened prior to strand release. The sequence of release for hold down devices and strands shall be indicated on the shop drawings. Release shall be in accordance with the approved shop drawings. 1029.6.11 Curing. Concrete members shall be kept continuously wet until the conclusion of the curing period. Curing shall be accomplished by covering with burlap or jute mats kept continuously wet by moist air, live steam or any combination of these methods. Other moist curing methods that will keep the member moist may be used provided the details of the proposed method are submitted to the Engineer and approved. As soon as the concrete has set sufficiently that no marring of the surface or distortion will result, wet burlap or jute mats shall be applied, covering the exposed surface. Curing shall be continued until the concrete has attained the design compressive strength shown on the plans. The concrete shall not be exposed to temperatures below freezing until the curing has been completed. 1029.6.11.1 Steam Curing. A preset period of no less than four hours shall be allowed before steam cure is applied. When the ambient temperature is below 50°F, steam shall be applied also during the preset period, but only at a rate sufficient to keep the air 1/31/2007
1029-5
Prestressed Concrete Members for Bridge
surrounding the member at a temperature between 50°F and 70°F. After the preset period, steam shall be applied at a rate that will not increase the temperature of the air surrounding the members more than 40°F per hour. The maximum curing temperature shall not exceed 160°F, and the difference in temperature adjacent to the concrete at different locations within the enclosure shall not exceed 30°F at any time. Fluctuations of the temperature adjacent to the concrete during the curing period at any one location shall vary no more than 30°F. The Contractor shall furnish and place, at the direction of the Engineer, a minimum of two portable recording thermometers and no less than one for each 150 feet of enclosure, for use in determining the magnitude and degree of uniformity of temperatures within the enclosure. The temperature recording system shall be capable of automatically producing a temperature record during the entire curing period. The temperature record shall show the temperature at each location at intervals of no more than 15 minutes and have a range of approximately 0°F to 200°F. The temperature recording system shall be accurate within plus or minus 5°F. Steam shall be applied from pipes with perforations at suitable intervals laid along each side of the member, or by other approved arrangements. Jets of steam will not be permitted to impinge directly against the member, forms or test specimens. Provisions shall be made for effective circulation of the steam around all portions of the members. The concrete shall be kept continuously moist during the steam curing period. Steam curing shall continue until the required strength for transfer of load has developed. Steam or other curing methods shall continue until the concrete has attained the design compressive strength shown on the plans. After the expiration of the steam curing period, the temperature inside the chamber shall be reduced at a rate of no more than 40°F per hour until a temperature has been reached approximately 40°F above the temperature of the air to which the concrete will be exposed. 1029.6.12 Form Removal. Forms shall not be stripped from prestressed concrete members sooner than 12 hours after casting. If strand release strength has then been attained, forms may be removed and members moved without unnecessary delay to a curing area. If forms are removed before the concrete has attained the strength which will permit the units to be moved or stressed, only the minimum area of the curing enclosure that is necessary to remove each individual form section shall be removed at any one time. The open area in the enclosure shall immediately be closed as each form section is removed. When the surrounding air temperature is below 30°F, no portion of the enclosure shall be removed before the unit has attained the required transfer strength. Forms of test specimens shall be stripped at the same time the forms are removed from the members. 1029.6.13 Handling. Handling and storage of prestressed members shall be performed with the members in an upright position and with points of support in approximately the same position as designated for the final position of the members in the structure. Members shall not be transported nor erected until the concrete has attained the design compressive strength shown on the plans. In storage, the members shall be fully supported across their width on battens that are no less than 4 inches wide. During transportation, the ends of Ibeams shall not extend a distance of more than the depth of the beam beyond the bolsters or other supports on the transporting vehicle. Other beams shall not extend more than 1½ times their depth beyond the supports on the transporting vehicle. During storage, the supports shall maintain the members in essentially a level position without twisting. Stacking of members in storage shall be done only with the approval of the Engineer. If such permission is granted, the supports of all members shall be in the same vertical planes and shall be of adequate thickness to prevent damage to the lifting devices.
1/31/2007
1029-6
Prestressed Concrete Members for Bridge
1029.6.14 Surface Finish, I-Girders. Surface finish shall be in accordance with the requirements of Section 703.3.5.8, except that no cracks of any kind in post-tensioned members shall be filled before the stressing is completed. The Engineer will determine the kind, type, and extent of cracks and surface defects, such as honeycomb and chipped edges or corners that will be tolerated. Repairs may be permitted with mortar in accordance with Section 703.3.2.9. Commercially available patching material shall be used only if approved by the Engineer. The top surface of members shall be scored transversely to a depth of approximately ¼ inch with a wire brush, stiff broom or other approved method. A 3 inch wide strip at each end and at ¼ points across the top flange of the member shall be smooth finished to accurate top flange depth. No laitance shall remain on surfaces to be embedded in concrete. After removal of hold-down devices, holes shall be plugged. If the method for plugging these holes is not shown on the shop drawings, written approval of the proposed method shall be obtained from the Engineer. Exposed reinforcing steel shall be thoroughly cleaned of all concrete before delivery of members. The portions of girders to be embedded in the diaphragms at supports shall be roughened by sandblasting or other approved methods to provide suitable bond between girder and diaphragm. Mechanical benders, without the use of heat, shall be used to bend the strands on girders. 1029.6.15 Surface Finish, Tee Girders. Surface finish shall be in accordance with Section 703.3.5.8, except that no cracks of any kind in post-tensioned members shall be filled before the stressing is completed. The Engineer will determine the kind, type, and extent of cracks and surface defects, such as honeycomb and chipped edges or corners, which will be tolerated. Repairs may be permitted with mortar in accordance with Section 703.3.2.9. Commercially available patching material may be used if approved by the Engineer. The top surface of members shall be scored transversely to a depth of approximately ⅛ inch. A 6 inch square area at each end and at ¼ points of girders, centered on each stem, shall be smooth finished to accurate top flange depth. Laitance on surfaces to be embedded in concrete shall be removed by sandblasting, waterblasting or other approved methods. After removal of hold down devices, holes shall be plugged. If the method for plugging these holes is not shown on the shop drawings, written approval of the proposed method shall be obtained from the Engineer. Exposed reinforcing steel shall be thoroughly cleaned of all concrete before delivery of members. The portion of girders to be embedded in the diaphragms at supports shall be roughened by sandblasting or other approved methods to provide suitable bond between girder and diaphragm. Mechanical benders, without the use of heat, shall be used to bend the strands on girders. 1029.6.16 Surface Finish, Deck Panels. The top surface of the panel shall be scored to facilitate bond with the cast-in-place deck. The scoring shall be perpendicular to the prestressing strands in the panel and shall be approximately ⅛ inch in depth. 1029.7 Dimensional Tolerances. The dimensional tolerances shall be as shown in Table I, II, or III. 1029.8 Marking. Each precast unit shall be identified with the date, manufacturer, and identification number. Markings may be indented on the unit or painted thereon with waterproof paint, and shall be located as shown on the plans or as specified by the Engineer.
1/31/2007
1029-7
Prestressed Concrete Members for Bridge
TABLE I DIMENSIONAL TOLERANCES - I-GIRDERS AND MISCELLANEOUS PRESTRESS UNITS Length of Beam
± ⅛ inch per 10 feet of beam length, but not greater than ¾ inch
Width (Flanges, Web and Fillets)
+ ⅜ inch, - ¼ inch
Depth (Flanges, Web and Fillets)
± ¼ inch
Depth (Overall)
+ ½ inch, - ¼ inch
Horizontal Alignment (Deviation from a straight line parallel to centerline of member)
½ inch max., to 40 foot lengths ¾ inch max., 40 to 60 foot lengths 1 inch max., 60 foot or greater lengths
Camber (Deviation from design camber within 7 days of strand release)
± ½ inch, to 80 foot lengths ± 1 inch, greater than 80 foot lengths
Stirrup Bars (Projection above top of beam)
± ¾ inch
Stirrup Bars (Longitudinal spacing)
± 2 inches
Tendon Position
± ¼ inch center of gravity of strand group and individual tendons
Position of Deflection Points for Deflected Strands
± 6 inches, longitudinal
Position of Lifting Devices
± 6 inches, longitudinal
Side Inserts (Centerline to centerline, and centerline to end)
± ½ inch
Coil Inserts (Centerline to centerline, and centerline to end)
± 2 inches horizontal, except must be 3 inches or more from end of beam and within reinforcement cage of bent, ± 1 inch vertical
Slab Drain Inserts
± ½ inch from designated location, Engineer may approve location ± 6 inches from design, multiple inserts for single drain must be within ± ½ inch of vertical line
Exposed Beam Ends (Deviation from square or designated skew)
± ¼ inch horizontal, ± ⅛ inch vertical per foot of beam height
Bearing Area (Deviation from plane)
± ⅛ inch
Bearing Plates (Centerline to centerline)
± ⅛ inch per 10 feet of beam length, but not greater than ¾ inch
Bearing Plates (Centerline to end of beam)
± ½ inch
Diaphragm Hole Location
± 1½ inches for centerline of group ± ½ inch within group
1/31/2007
1029-8
Prestressed Concrete Members for Bridge
TABLE II DIMENSIONAL TOLERANCES - TEE GIRDERS Length of Beam
± ⅛ inch per 10 feet of beam length, but not greater than ½ inch
Width (Overall)
± ¼ inch
Depth (Overall)
± ¼ inch
Flange Thickness and Stem Thickness
± ⅛ inch
Horizontal Alignment (Deviation from a straight line parallel to centerline of member)
¼ inch max., to 40 foot lengths ⅜ inch max., 40 to 60 foot lengths ½ inch max., 60 foot or greater lengths
Camber (Deviation from design camber within 7 days of strand release)
± ½ inch, to 80 foot lengths ± 1 inch, greater than 80 foot lengths
Stirrup Bars (Projection above top of beam)
± ¾ inch
Stirrup Bars (Longitudinal spacing)
± 2 inches
Tendon Position
± ⅛ inch center of gravity of strand group and individual tendons
Strand Projection
± 1 inch
Diagonal Tolerance
± ¼ inch
Position of Deflection Points for Deflected Strands
± 6 inches, longitudinal
Position of Lifting Devices
± 6 inches, longitudinal
Side Inserts (Centerline to centerline, and centerline to end)
± ½ inch
Coil Inserts (Centerline to centerline, and centerline to end)
± 2 inches horizontal, except must be 3 in. or more from end of beam and within reinforcement cage of bent, ± 1 in. vertical
Exposed Beam Ends (Deviation from square or designated skew)
± ¼ inch horizontal, ± ⅛ inch vertical per foot of beam height
Bearing Area (Deviation from plane)
± ⅛ inch
Bearing Plates (Centerline to centerline)
± ⅛ inch per 10 feet of beam length, but not greater than ¾ inch
Bearing Plates (Centerline to end of beam)
± ½ inch
Center of Stem to Outside Edge of Top Flange
± ⅛ inch
Center to Center Distance Between Stems
± ⅛ inch
Stem End to End of Top Flange
± ¼ inch
Diaphragm Hole Location
± 1½ inches for centerline of group ± ½ inch within group
1/31/2007
1029-9
Prestressed Concrete Members for Bridge
TABLE III DIMENSIONAL TOLERANCES – DECK PANELS Length
+ ⅛ inch, - ½ inch
Width
± ¼ inch
Depth
± ⅛ inch
Stirrup Bars (Projection above top of panel)
± ¼ inch
Stirrup Bars (Longitudinal spacing)
± 1 inch
Tendon Position
± ⅛ inch center of gravity of strand group and individual tendons
Strand Projection
± 1 inch
Diagonal Tolerance
± ¼ inch
Warpage of corner (one corner out of plane of other three)
Be 1/16 inch/foot times the distance from the nearest adjacent corner
Bowing or camber, concave or convex, of any part of a flat surface
Shall not exceed length of bow in inches divided by 360, with maximum of ¾ inch; and differential bowing or camber between the adjacent members of the same design shall not exceed ¼ inch
Scupper holes, blockouts and voids
Placed as close as possible to design location after reinforcement steel and strands are properly located
1/31/2007
1029-10 Prestressed Concrete Members for Bridge
Section 1030
Vitrified Clay Products
1030.1 Vitrified Clay Sewer and Culvert Pipe. These specifications cover one class of vitrified clay pipe (Extra Strength Clay Pipe) for the conveyance of sewage, industrial wastes, storm water, underdrainage, filter fields, leaching fields and similar subdrainage installations. Extra strength vitrified clay pipe shall conform to the requirements of ASTM C 700. 1030.1.1 Pipe used in conjunction with a Metropolitan Sewer District (MSD) project must satisfy the requirements of the Sewer District. 1030.1.2 Joints. Pipe shall be provided with compression joints conforming to the requirements of ASTM C 425. The contractor shall furnish a manufacturer's certification in triplicate showing typical chemical resistance results of the joint material and physical test results representative of the joint performance and certifying that the joints conform to all the requirements specified. 1030.2 Underdrain. 1030.2.1 Vitrified Clay Underdrain Pipe. These specifications cover two classes of vitrified clay underdrain pipe as follows: 1) Extra Strength Perforated Clay Pipe. This pipe shall conform to the requirements of ASTM C 700. This class may be supplied at no additional cost when Standard Strength is specified. 2) Cradle Invert Clay Pipe. This pipe shall conform to the requirements of ASTM C 700. 1030.2.2 Pipe may be glazed or unglazed at the option of the manufacturer. Tests for acid resistance will be made when specified in the contract. 1030.3 Drain Tile. 1030.3.1 Clay Drain Tile. This tile shall conform to the requirements of ASTM C-4. Unless otherwise specified in the contract, only Type II, Extra-Quality; or Type III, Heavy-Duty Drain Tile, shall be furnished.
1/31/2007
1030-1
Vitrified Clay Products
(This Page Intentionally Left Blank)
1/31/2007
1030-2
Vitrified Clay Products
Section 1032
Precast Concrete Flared End Sections
1032.1 Scope. These specifications cover reinforced precast concrete flared end sections for use at inlets and outlets of rigid pipe culverts. 1032.2 Material. All material shall be in accordance with Section 1026.3, except that marking required by Section 1026.3.10 will be limited to Section 1026.3.10.1. 1032.3 Basis of Acceptance. 1032.3.1 Acceptability of end sections for all diameters shall be determined by the results of such material tests as are required in Section 1026 by crushing tests on concrete cores or cured concrete cylinders, and by inspection of the finished end sections, including quantity and placement of reinforcement, to determine the conformance with the design and the freedom from defects. 1032.3.2 When allowed by the Engineer, end sections from approved plants will be accepted based on certification, manufacturer quality control documentation and tests on samples as required by the Engineer in accordance with Section 1026. 1032.3.3 Flared end sections shall be in accordance with Section 1026 for Class II pipe or higher classes of pipe.
1/31/2007
1032-1
Precast Concrete Flared End Sections
(This Page Intentionally Left Blank)
1/31/2007
1032-2
Precast Concrete Flared End Sections
Section 1033
Precast Drainage Units
1033.1 Scope. This specification covers precast reinforced concrete manhole and drop inlet sections and appurtenances, such as grade rings, tops, and special sections. 1033.2 Acceptance. All precast drainage units designated for installation within Metropolitan Sewer District (MSD) jurisdiction will meet MSD specifications. For all other precast drainage units, the basis for acceptance shall be in accordance with AASHTO M 199 (M 199M). If Class B or B-1 concrete is used, compressive tests and absorption test specimens will not be required. 1033.3 Material. 1033.3.1 Cement. Cement shall be in accordance with Section 1019. Fly ash or GGBFS may be substituted for cement in accordance with Section 501. 1033.3.2 Fly Ash. Fly ash shall be in accordance with Section 1018. 1033.3.3 Ground Granulated Blast Furnace Slag. GGBFS shall be in accordance with Section 1017. 1033.3.4 Aggregate. Fine and coarse aggregate shall be in accordance with Section 1005, except that requirements for gradation and percent passing the No. 200 sieve shall not apply. 1033.3.5 Steel Reinforcement. Reinforcement shall be in accordance with Section 1036. 1033.3.6 Concrete Mixture. The manufacturer may designate the mixture proportions, but in no case shall the proportion of cement in the mixture be less than 470 lb./yd3 of concrete. Admixtures or blends may be used with the approval of the Engineer. At the option of the manufacturer, Class B or B-1 concrete may be used. If Class B or B-1 concrete is used, material, proportioning, mixing, slump, and transporting of concrete shall be in accordance with Section 501. 1033.4 Design. 1033.4.1 Precast Drainage Units. The design of precast drainage units shall be in accordance with AASHTO M 199 with the following modifications. 1033.4.1.1 Wall thickness for rectangular drop inlets shall be as shown on the plans. 1033.4.1.2 The quantity of steel reinforcement for rectangular drop inlets shall be as shown on the plans. 1033.4.2 Modified or Special Designs. The manufacturer may request approval of designs, prior to manufacture, other than those specified in the contract documents. Special or modified designs shall be submitted to the Engineer, in writing, and shall fully describe any deviations from the contract documents. The description shall also include the wall thickness, all other dimensions, concrete compressive strength and the area, type,
1/31/2007
1033-1
Precast Drainage Units
placement and strength of the steel reinforcement. Such sections shall meet all of the test and performance requirements specified by the Engineer in accordance with Section 1033.2. 1033.4.3 Reinforcement in Rectangular Drop Inlets. rectangular drop inlets shall be as shown on the plans.
Placement of reinforcement in
1033.4.4 Manhole Risers and Conical Tops. Each line of circumferential reinforcement shall be assembled into a cage that shall contain sufficient spacer bars or members, extending through the wall of the manhole risers and conical tops, to maintain the reinforcement rigidly in shape and correct position within the form. The exposure of the ends of stirrups or spacers that have been used to position the cages during the placement of the concrete will not be cause for rejection. 1033.5 Joints. The reinforced concrete riser sections, except grade rings, shall be formed such that the risers and top when assembled will make a continuous and uniform structure compatible with the tolerances specified for risers in AASHTO M 199. The joints shall be designed to permit placement without appreciable irregularities in the interior wall surface. 1033.6 Manufacture. 1033.6.1 Placement of Concrete. The transporting and placing of concrete shall be by methods that will prevent the segregation of the concrete material and the displacement of the reinforcing steel from the proper position in the form. 1033.6.2 Curing. 1033.6.2.1 Precast units shall be cured in accordance with Section 1026. Precast sections shall not be transported or erected until the design compressive strength has been reached. 1033.6.2.2 If Class B or B-1 concrete is used, the sections shall be cured with wet burlap for 72 hours or by covering with transparent membrane applied in accordance with Sec 502. Precast units constructed with Class B or B-1 concrete shall not be transported or erected until at least seven days after casting. If forms are removed before the expiration of the curing period, the parts of the structure exposed shall be cured as directed by the Engineer. 1033.6.3 Lift Holes. Lift holes shall be in accordance with Section 1026. If approved by the Engineer, lifting hooks or bars may be cast into the sections. 1033.6.4 Forms. Forms shall be mortar-tight and of sound material adequate to prevent distortion during placing and curing of concrete. Forms shall be reasonably smooth and free of loose knots, holes and other defects. 1033.6.5 Cold Weather Concreting. Concrete placed in cold weather shall be protected from freezing during the curing period by the use of a heated, weatherproof enclosure. Concrete shall not be placed on or against reinforcing steel or other surfaces with temperatures lower than 35°F. No concrete shall be placed when the ambient temperature is below 35°F.
1/31/2007
1033-2
Precast Drainage Units
1033.7 Physical Test Requirements. 1033.7.1 Concrete Test Requirements. The basis for concrete test requirements shall be AASHTO M 199. The specified number of specimens required for the tests shall be furnished without charge by the manufacturer and shall be selected at random by the Engineer. The cores for compression tests shall be taken from manhole or drop inlet sections that would not otherwise be rejected under this specification. The selection shall be made at the point or points designated by the Engineer. 1033.7.2 Compression Tests. Compression tests for satisfying the design concrete strength requirement may be made on either standard rodded concrete cylinders or cylinders compacted and cured in a similar manner to the manhole or drop inlet sections or, at the option of the manufacturer, on cores drilled from the wall of the section. If compression test cylinders are being used, the manufacturer shall furnish a sufficient number of molds of a type meeting the approval of the Engineer. The compressive strength of each core tested shall be equal to or greater than the design strength of the concrete. If a core does not meet the required strength, another core from the same section may be tested. If this core does not meet the required strength, that section will be rejected. Additional tests shall be made on other sections to determine the acceptability of the lot. 1033.7.3 Absorption Test Requirements. The Engineer may require samples for absorption tests if concrete other than Class B or B-1 is used. Each sample shall be a piece broken from the wall or a core drilled from the wall, have a minimum area of 9 inch2 as measured on one surface of the wall, have a thickness equal to the wall and be free of visible cracks. 1033.8 Permissible Variations in Dimensions. 1033.8.1 The basis for permissible variations in dimensions shall be AASHTO M 199. 1033.8.2 The internal dimensions of precast units shall not vary more than one percent or ⅜ inch, whichever is greater. 1033.8.3 The vertical spacing and vertical alignment between adjacent manhole steps and horizontal distance from the inside wall to the centerline of a manhole step shall not vary more than 1 inch from the design dimensions. 1033.9 Steps. Steps for precast manholes and drop inlets shall be in accordance with Section 604 and as shown on the plans. 1033.10 Repairs. Filling of form tie cavities and repair of other defects shall be in accordance with Section 703. 1033.11 Inspection. The quality of material, the process of manufacture and the finished precast units shall be subject to inspection and approval by the Engineer. 1033.12 Rejection. Precast units shall be subject to rejection for failure to conform to any of the specified requirements in AASHTO M 199.
1/31/2007
1033-3
Precast Drainage Units
1033.13 Marking. Marking shall be indented into the section or shall be painted thereon with waterproof paint. The following information shall be clearly marked on the inside of each precast unit: 1) MH for manholes or DI for drop inlets. Other units do not need a designation. 2) Date of manufacture. 3) Name or trademark of the manufacturer.
1/31/2007
1033-4
Precast Drainage Units
Section 1034
Reinforced Concrete Elliptical Culvert, Storm Drain and Sewer Pipe
1034.1 Reinforced Concrete Elliptical Culvert, Storm Drain and Sewer Pipe. This pipe shall be in accordance with AASHTO M 207, except material shall meet the requirements in Section 1026. 1034.1.1 The class of the pipe and whether Horizontal Elliptical or Vertical Elliptical shall be as specified in the contract.
1/31/2007
1034-1
Reinforced Concrete Elliptical Culvert, Storm Drain and Sewer Pipe
(This Page Intentionally Left Blank)
1/31/2007
1034-2
Reinforced Concrete Elliptical Culvert, Storm Drain and Sewer Pipe
Section 1035
Reinforced Concrete Arch Culvert, Storm Drain and Sewer Pipe
1035.1 Reinforced Concrete Arch Culvert, Storm Drain and Sewer Pipe. This pipe shall be in accordance with AASHTO M 206, except material shall meet the requirements in Section 1026. 1035.1.1 The class and size of the arch pipe shall be as specified in the contract.
1/31/2007
1035-1
Reinforced Concrete Arch Culvert, Storm Drain and Sewer Pipe
(This Page Intentionally Left Blank)
1/31/2007
1035-2
Reinforced Concrete Arch Culvert, Storm Drain and Sewer Pipe
Section 1036
Reinforcing Steel for Concrete
1036.1 Scope. This specification covers reinforcing steel to be used in concrete. 1036.2 Acceptance. 1036.2.1 All material may be obtained from a source identified on the Missouri Department of Transportation's (MoDOT's) PAL designated for this specification. The source shall be listed on the MoDOT's PAL at the time the material is incorporated into the project. 1036.2.2 All material will be inspected and accepted in accordance with Section 106. 1036.2.3 AASHTO or ASTM specifications, when referenced, will control only the physical properties, chemical properties and handling and storage of the material, except as otherwise specified herein or shown on the plans. 1036.2.4 Recycled Content. Reinforcing steel manufactured with post-consumer or preconsumer material shall meet the AASHTO or ASTM requirements specified herein. When recycled materials are submitted for use, the recycled content shall be indicated in the certification documents and shall meet one of the following minimum requirements. 1036.2.4.1 Materials with recycled content such that the sum of post-consumer recycled content plus one-half of the pre-consumer content constitutes at least 10 percent (based on cost) of the total value of the material. 1036.2.4.2 Materials with recycled content such that the sum of post-consumer recycled content plus one-half of the pre-consumer content constitutes at least 20 percent of the total value of the material. 1036.2.5 Handling, Storage & Surface Condition of Reinforcement. Reinforcement shall be stored above the ground on platforms, skids, protective cribbing, or other supports that prevent sags in the bundles. Reinforcement shall be protected as far as practical from: oil, grease and dirt or other deleterious materials; mechanical injury and surface deterioration caused by exposure to conditions producing rust. Prior to placement of concrete, all reinforcement shall be free from dirt, loose rust or scale, mortar, paint, grease, oil, or other materials that might reduce bond. Reinforcement shall be free from cracks and laminations. Bonded rust, surface irregularities, or mill scale will not be cause for rejection, provided the minimum dimensions, cross sectional area, and tensile properties of the reinforcement specimen meet the physical requirements for the size and grade of steel specified. 1036.2.5.1 Epoxy-coated and galvanized reinforcement shall be handled and stored by methods that will not damage the coating. Bundles shall not be dropped or dragged. When stacking of bundles of coated reinforcement is required, separate the stacked bundles with timbers. Reinforcing steel shall be transported and stored in a manner that will not damage any applied coating. Schedule deliveries of epoxy coated bars to the job site to avoid the need for long term storage. When storage of epoxy coated reinforcement at the job-site exceeds 60 days, protect the epoxy-coated reinforcement from sunlight, salt spray, and weather exposure with opaque polyethylene sheeting or
4/8/2013
1036-1
Reinforcing Steel for Concrete
other suitable equivalent protective material. Make provisions for air circulation around the epoxy-coated reinforcement to minimize condensation under the protective covering. Since the epoxy coating is flammable, the coated reinforcement shall not be exposed to any fire or flame. Provide systems for handling coated bars which have padded contact areas, nylon slings, etc., all free of dirt and grit. Lift bundled coated bars with strong back, multiple supports, or platform bridge to prevent sagging and abrasion. Pad bundling bands where in contact with bars. Do not drop or drag bars or bundles. 1036.2.5.2 Prior to placement of concrete, all reinforcement shall be free from dirt, loose rust or scale, mortar, paint, grease, oil, or other materials that might reduce bond. Reinforcement shall be free from cracks and laminations. Bonded rust, surface irregularities, or mill scale will not be cause for rejection, provided the weight, minimum dimensions, height of deformations, cross sectional area, and tensile properties of the reinforcement specimen meet the physical requirements for the size and grade of steel specified by the applicable AASHTO or ASTM specification requirements. 1036.2.6 Identification of Reinforcing Steel. 1036.2.6.1 Bundles of reinforcing bars shall be tagged showing the quantity, grade, size, and suitable identification to allow for checking, sorting, and placing. 1036.2.6.2 Bundles of flat sheets of welded wire reinforcement shall be tagged showing the quantity, style designation, width, and length. 1036.3 Reinforcing Steel for Concrete Structures. 1036.3.1 Unless otherwise specified, steel reinforcing bars shall be deformed bars in accordance with either AASHTO M 31 (ASTM A 615), Grade 60 or 75; ASTM A 706 Grade 60; or AASHTO M 322 (ASTM A 996), Type A, Grade 60, unless specified otherwise. 1036.3.2 Spiral reinforcement shall be in accordance with Section 1036.3.1, except that the reinforcement may be plain or deformed, or shall be cold drawn steel wire in accordance with AASHTO M 32 (ASTM A 82) or deformed steel wire in accordance with AASHTO M 225 (ASTM A 496). 1036.3.3 Steel welded steel wire reinforcement, plain, shall be in accordance with ASTM A 1064. 1036.3.4 Prestressing reinforcement shall be ½ inch diameter for precast prestressed concrete piles and ½ inch or 0.6 inch diameter for pretensioned concrete girders, posttensioned segmental precast concrete girders, or cast-in-place prestressed concrete. Prestressing reinforcement shall be mill bright high tensile strength seven wire low relaxation strand conforming to the requirements of AASHTO M 203, Grade 270. 1036.3.5 Reinforcing Steel Bar Supports. Wire supports shall comply with standard type and classes of protection as specified in "CRSI Manual of Standard Practice", latest edition and as detailed in Standard Drawing C706.30, "Reinforcing Bar Supports". Wire supports shall be spaced to provide adequate support for slab reinforcing steel. For flat slab spans the lower layer of slab steel shall be supported by Beam Bolster (BB) bar supports with one row near each end of span and interior rows spaced approximately 24 inches on center. For beam spans, the lower layer of slab steel shall be supported by Beam Bolster (BB) bar 4/8/2013
1036-2
Reinforcing Steel for Concrete
supports approximately 36 inches on center with a minimum of three rows between longitudinal beams and one row on each overhang placed not more than 12 inches from edge of slab. BB bar supports shall have Class 1 maximum protection unless shown otherwise in the plans. Top reinforcing bars shall be supported by Continuous High Chairs Upper (CHCU) or Beam Bolster Upper bars (BBU) as shown on the plan details spaced a maximum of 30 inches on centers. The use of Standees is not permitted. Epoxy-coated, vinyl-coated, or plastic-coated wire bar supports shall have a minimum coating thickness of 5 mils. 1036.3.5.1 Plastic Bar Supports. Plastic bar supports may be used as an alternate to wire BB and BBU bar supports. Plastic supports shall not be spaced closer than 12 inches apart along a reinforcing bar. When used, plastic bar supports shall meet the following requirements: 1) Chairs and bolsters must be of adequate strength to resist a 300 pound concentrated load without permanent deformation or breakage. 2) The material from which plastic bar supports are manufactured shall be either resin or first generation recycled thermoplastic resin, be colored white, gray, or black, and be chemically inert in concrete. 3) Plastic reinforcing bar supports shall be molded in a configuration that does not restrict concrete flow and consolidation around and under the reinforcing bar support. 1036.3.5.2 Plain Concrete Blocks. Where concrete is to be placed directly on aggregate or soil, plain concrete blocks may be used to support reinforcing bars. The blocks for holding the lower reinforcing bars in position shall be cast to approved shape and dimension from concrete of the same materials and proportions as that to be used in the structure, and shall be properly cured. The blocks shall not be over 6 inches in length and shall be placed to permit their ends to be covered with concrete. The use of pebbles, pieces of broken stone or brick, metal pipe or wooden blocks, shall not be permitted. 1036.4 Reinforcement for Concrete Pavement. 1036.4.1 Steel Wire Material Properties. Welded steel wire reinforcement for concrete pavement shall be in accordance with ASTM A 1064 standard Specification for Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete with a minimum yield strength of 65 ksi for plain wire and 70 ksi for deformed wire. Epoxy-coated wire and welded wire shall be in accordance with ASTM A884. Galvanizing shall be in accordance with ASTM A 641, for cold-worked wire, or AASHTO M 111 (ASTM A123), for zinc (hotdipped galvanizing) coating of steel welded wire sheets/mats. The welded wire reinforcement shall be supplied in either flat sheets or hinged sheets of the size and design shown on the plans. Longitudinally hinged wire reinforcement for sheets of a required width of 8 feet or greater may be used. All steel welded wire reinforcement shall be free from dirt, paint, oil, grease, thick rust and other foreign substances. Thin powdery rust will be acceptable.
4/8/2013
1036-3
Reinforcing Steel for Concrete
1036.4.1.1 Wire Ordering, Spacing and Size. The quantity, wire spacing and sizes, width and length of sheets are to be specified in the order. For example, a typical order may be: 120 sheets, 6 x 12, W6.3 x W4, 11-foot width x 6-foot length. 120 is the number of sheets in the order. 6-inch is the spacing of the longitudinal wires. 12-inch is the spacing of the transverse wires. W6.3 is the size of the longitudinal wires. W4 is the size of the transverse wires. 11-foot width is the width of the wire fabric in the transverse wire direction. 6-foot length is the length of the wire fabric in the longitudinal direction. Sheet dimensions should be in 6 inch multiples, preferably to the nearest foot. Length is parallel to the roadway length. Typical sheet dimensions are 12 inches less than the repair size (i.e., a 12 foot wide lane repair requires 11 foot width mesh). Wire spacing and size for concrete pavement shall be ordered by the following criteria: 10-inch or less pavement thickness - 6 x 12 - W6.5 x W4 for plain fabric or 6 x 12 - D7 x D4 for deformed fabric. Greater than 10-inch pavement thickness - 6 x 12 - W8 x W4 for plain fabric or 6 x 12 - D8 x D4 for deformed fabric. 1036.4.1.2 For plain welded wire reinforcement the maximum allowable wire spacing is 12 inches in accordance with ACI 318 3.5.3.5. For material used in the fabrication of plain welded wire reinforcement the tension and yield strength properties shall conform to ASTM A 1064 and the following requirements: Size W1.2 and Larger
Smaller than Size W1.2
Tensile Strength, ksi
75
70
Yield Strength, ksi
65
56
Reduction of Area, min. percent
301
301
Property
1
For material with a tensile strength testing over 100 ksi, the reduction of the area shall be less than 25 percent.
1036.4.1.3 For deformed welded wire reinforcement the maximum allowable wire spacing is 16 inches in accordance with ACI 318 3.5.3.6. For material used in the fabrication of deformed welded wire reinforcement the tension and yield strength properties shall conform to ASTM A 1064 and the following requirements: Property
All Sizes
Tensile Strength, min, ksi
80
Yield Strength, min., ksi
70
1036.4.1.4 Wire Supports for Steel Wire Reinforcement. The spacing will depend upon the wire size and the wire spacing. Supports spacing for all wire reinforced concrete pavements shall be 30 ± 6 inches apart. Plastic or wire bar supports, such as chairs and bolsters, shall conform to industry practice as described in the WRI "WWR500, Manual of Standard Practice" or "TF 702 – Supporting WWR". All metal bolsters or chairs which bear against the forms for exposed surfaces shall be equipped with snug fitting, high density, polyethylene tips which provide ½ inch minimum clearance between
4/8/2013
1036-4
Reinforcing Steel for Concrete
the metal and any exposed surface. For epoxy-coated reinforcement, all wire / bar supports and bar clips shall be epoxy or plastic coated. For galvanized reinforcing, chair and bar supports shall be hot-dipped galvanized, after fabrication, in accordance with ASTM A123. The spacing of slab bolster rows and high chair rows for deck slabs shall be as noted in WRI's "Manual of Standard Practice, WWR-500" and "TF 702, Supporting WWR" unless otherwise directed by the Engineer. 1036.4.1.5 Repair of Coated Wire Reinforcement. 1036.4.1.5.1 Epoxy-Coated Reinforcement. In addition to the requirements of ASTM D 3963, all visible damage (i.e., scratches, nicks, cracks) to the epoxy coating of the reinforcement, caused during shipment, storage or placement shall be repaired by the Contractor at the job site with approved patching material. Ends of reinforcement that have been sheared sawed, or cut by other means shall be coated with approved patching material. The areas on the sheets / mats and tie down bars damaged by welding shall be repaired with approved patching material. Patching of damaged areas shall be performed in accordance with the patching material manufacturer's recommendations. Any damaged surface area (prior to repair with approved patching material) shall not exceed 10 percent of the total sheet surface area, unless otherwise directed by the Engineer. Should this limit be exceeded the sheet shall be removed and replaced with an acceptable sheet. All patching material shall be fully cured prior to placing concrete. The patching material shall be compatible with the epoxy coating, inert in concrete, and suitable for repairs in the field. The patching material shall be prequalified, as required for the coating material and shall either be identified on the container as meeting the requirements of Annex A1 of ASTM D 3963 - or shall be accompanied by a Materials Certificate certifying that the material meets or exceeds the requirements of said Annex A1. 1036.4.1.5.2 Galvanized Reinforcement. All visible damage (i.e., scratches, nicks, cracks) to the galvanized coating of the reinforcement, caused during shipment, storage or placement shall be repaired by the Contractor at the job site in accordance with appropriate AASHTO or ASTM specifications. Ends of reinforcement that have been sheared, sawed, or cut by other means shall be coated. The area on the sheets and tie down bars damaged by welding shall be repaired and properly coated. Field coating of damaged areas shall be performed in accordance with the coating manufacturer's recommendations. Zinc coating shall conform to ASTM B6 and shall be applied in accordance with ASTM A 780 to achieve a dry film equal to or exceeding that designated in the contract documents. All touchup paint shall be cured fully prior to placing concrete. 1036.4.1.5.3 Splicing of Wire Reinforcement. All reinforcement shall be furnished in the lengths indicated on the plans unless otherwise noted. Except for splices shown on the plans, splicing of sheets / mats will not be permitted without the approval of the engineer. A minimum of 50 percent of the wires shall be spliced at joints requiring load transfer. 1036.4.1.5.3.1 Lapped. Lapped splices shall be in accordance with ACI 318 and the minimum length shall be at least the length of one wire space plus 2 inches for plain wire or 8 inches for deformed wire. In contact lap splices, the sheets shall be placed in contact and tied together in such a manner as to maintain the minimum distance to the surface of the concrete as shown on the 4/8/2013
1036-5
Reinforcing Steel for Concrete
plans. In non-contact lap splices, the sheets / mats shall be placed as shown on the plans. They shall be properly supported and tied to adjacent sheets / mats to develop the full strength of the section and to maintain distance from the surface of the concrete as shown in the contract documents. 1036.4.1.5.3.2 Welded. Welded splices shall be used at the locations shown on the plans and as directed by the Engineer. Welding shall conform to AWS publication "Structural Welding Code, Reinforcing Steel, AWS D1.4" and applicable special provisions. 1036.4.1.5.3.3 Welding splices shall not be used on epoxy-coated or galvanized sheets. No welding shall be performed near epoxy-coated or galvanized sheets / mats that will cause damage to the coating. 1036.4.2 Substitutions. Substitutions of different sheet patterns, but equivalent sized sheets will be permitted when approved by the Engineer. The substituted sheets shall have equivalent or larger reinforcement areas than needed for design or as shown in the contract documents. 1036.4.3 Dowel Bars. Materials for dowel bars are in accordance with Section 1057.3. 1036.4.3.1 Expansion and Contraction Dowel Basket Assemblies. Expansion and Contraction dowel basket assemblies shall be an approved welded assembly possessing the rigidity to hold the dowel bars in place during the placing and compacting of the supplied concrete and conform to Standard Drawings C502.03, "Type AA Expansion Joint", and C502.11 "Supporting Units", respectively. Dowel basket assemblies shall be supplied to hold the dowels in a position parallel to the surface and centerline of the slab at mid-depth of the slab thickness. The assembly shall have two parallel spacer bars and two subgrade bearing members. An upright bar support of each end of each dowel bar shall be welded to both the spacer bar and the bearing member at appropriate points to hold the bars at the design height. Weld dowels (on one end only) into side frames, with welded ends alternating along length of assembly. The opposite end of each dowel shall be held securely in place by means of wire loops or metal tubes welded to the spacer bar. Suitable ties shall be provided to hold the contraction joint assembly in normal position during shipping, handling, and installation. Wire sizes shall be at least W7 (0.306 inch) for the outside spacer bars, bearing member, and upright supports. The tie wires used for securing the spacer bars shall be at least W3 (0.177 inch) wires. The finished assembly shall be manufactured so that the dowels are horizontal and parallel from each other and perpendicular to the basket to hold dowels to within ± ½ inch of half slab depth. The dowel supporting unit shall be factory assembled and capable of holding the dowels in their required positions. Six staking pins shall be provided per basket assembly to anchor the assembly to the subgrade. Staking pins shall be fabricated from a minimum W7 (0.306 inch) wire with a suitable hook and shall have a length of not less than 18 inches. Horizontal support wires and shipping braces are not required to be cut. A broken weld will be sufficient cause for the rejection of the length or section of the assembly in which it occurs.
4/8/2013
1036-6
Reinforcing Steel for Concrete
1036.4.3.2 Dowel Paving Staking Pins. Paving Staking pins shall be fabricated from a minimum W7 (0.306 inch) wire for the diameter of dowel bar specified. Pins shall have a standard grade stop of 6 inches and be supplied for the specified pavement thickness. Two paving staking pins per bar shall be required to maintain the bar to within ± ½ inch of half slab depth and so that the dowel bars are aligned according to the contract documents. 1036.4.4 Tie Bars. Materials for tie bars are in accordance with Section 1057.4. 1036.4.4.1 Tie Bar Paving Staking Pins. Paving Staking pins shall be fabricated from a minimum W7 (0.306 inch) wire for the diameter of tie bar specified. Pins shall have a standard grade stop of 6 inches and be supplied for the specified pavement thickness. Two paving staking pins per bar shall be required to maintain the bar to within ± ½ inch of half slab depth and so that the tie bars are aligned according to the contract documents. 1036.5 Mechanical Connectors for Reinforcing Bars Splice. Only steel in accordance with Section 1036.3.1 shall be used. 1036.5.1 Coated bars shall not be spliced except as shown in the contract documents. 1036.5.2 Mechanical connectors for use on epoxy coated reinforcing bars shall be epoxy coated. Mechanical connectors coated prior to installation shall be coated in conformance with the applicable requirements for epoxy coatings contained in Section 1036.5.4. Mechanical connectors coated after installation shall be coated with an epoxy repair material compatible with the reinforcing bar epoxy coating. 1036.5.3 Mechanical connectors shall be manufactured from ASTM A 615 Grade 60 deformed rebar material, free of external welding and machining. 1036.5.4 Mechanical connectors tensile strength of the splice shall be least 125 percent of the specified minimum yield strength of the reinforcing bar. Slippage of the coupler on the rebar is considered a failure. 1036.5.5 Organic coatings, other than epoxy, shall not be used. 1036.5.6 Patching or repair material shall be compatible with the coating, inert in concrete and in accordance with the epoxy resin manufacturer's recommendations. The material shall be epoxy and be suitable for application at the plant or in the field to uncoated areas and damaged areas of the coating. 1036.6 Coated Reinforcing Steel Bars. 1036.6.1 Epoxy. Epoxy coated reinforcing steel bars shall be in accordance with AASHTO M 284 (ASTM A 775) or ASTM 934 except as otherwise specified herein or shown on the plans. When required damaged epoxy coating shall be repaired with patching material conforming to ASTM A 775 or ASTM A 934 and performed in accordance with the patching material manufacturer's guidelines. Coating thickness after curing shall be within the following limits (average of 10 gage readings per bar sample):
4/8/2013
1036-7
Reinforcing Steel for Concrete
Coating Thickness Specification in mils
Bar Type
Bar Size
All
Nos. 3 to 5
7 to 12
All
Nos. 6 to 18
7 to 16
Straight
All
7 to 12
Bent
All
7 to 16
AASHTO M 284 (ASTM A 775)
ASTM A 934
1036.6.1.1 The maximum thickness of epoxy coating on spiral reinforcement, coated after fabrication, shall be 20 mils. 1036.6.1.2 Bars may be sheared (except dowels) or sawn to length after coating, provided end damage to coating does not extend more than ½ inch back and the cut end is patched before any visible oxidation appears. Flame cutting will not be permitted. 1036.6.1.3 In addition to the requirements of AASHTO M 284 and CRSI for continuity of coating, no more than eight of the holidays permitted shall be in any 1 foot length of bar. 1036.6.2 Zinc-Coated (Galvanized) Reinforcing Steel. Zinc-coated (galvanized) reinforcing steel shall bars be in accordance with ASTM A 767, Class I, except as otherwise specified herein or shown on the plans. When required damaged zinc coating shall be repaired with zinc-rich formulation patching material conforming to ASTM A 780 and performed in accordance with the patching material manufacturer’s guidelines. Minimum coating weight and thickness after curing shall be within the following limits (average of 5 gage readings per bar for each 3 bar sample): Minimum Coating Specification Bar Size
Weight of zinc coating (oz./ft2)
Thickness, mils
Nos. 3
3.00
5.10
Nos. 4 and Larger
3.50
5.95
1036.7 Tie Wire. 1036.7.1 Steel Tie Wire shall be 16 gauge or heavier, black annealed. 1036.7.2 Epoxy coated reinforcement shall be tied with plastic-coated or epoxy-coated steel tie wire.
4/8/2013
1036-8
Reinforcing Steel for Concrete
1036.7.3 Zinc-coated (galvanized) reinforcement shall be tied with zinc-coated (galvanized) steel tie wire manufactured in accordance with AASHTO M 232 (ASTM A 153), Class D or plastic coated with a material compatible with the galvanized coated bars. 1036.8 Weight. The diameter, area, and theoretical weight of reinforcing bars will be computed using AASHTO M 31 Table 2 or ASTM A 615 Table 1. The weight of reinforcing wire, welded wire fabric, and plain bar of sizes other than those listed in the tables referenced above, will be computed from tables of weight published by CRSI or computed using nominal dimensions and an assumed unit weight of 490 pounds per cubic foot. The cross-sectional area of wire in square inches will be assumed to be equal to its MW or MD-Size Number. If the weight per square unit of welded wire fabric is given on the plans, that weight will be used. 1036.8.1 The weight of reinforcement used in precast members, where payment for the reinforcement is included in the contract price for the member will not be measured. Threaded bars or dowels placed in the work and used to attach such members to cast-inplace concrete after the installation of precast members will be measured. 1036.8.2 No allowance shall be made for clips, wire, separators, wire chairs, and other material used in supporting, spacing, and fastening the reinforcement in place or for galvanizing such items. If bars are substituted upon the Contractors request and as a result more steel is used than specified, only the amount specified will be measured. 1036.8.3 The additional steel required for splices that is not shown on the plans but is authorized as provided herein, will not be measured. Mechanical couplers will not be measured, but shall be considered incidental to the furnishing of reinforcing steel. 1036.8.4 No allowance will be made for the weight of epoxy or galvanizing in computing the weight of reinforcing steel. 1036.9 Documentation. 1036.9.1 Documentation of uncoated steel shall include the steel manufacturer's certified mill test report showing complete chemical and physical test results for each heat. 1036.9.2 Documentation of coated steel shall include the coating applicator's certification that all material used, the preparation of the bars, coating and curing are in accordance with these specifications, and that no bar contains more than one holiday per linear foot. The certification shall include or have attached specific results of tests of coating thickness and flexibility of coating. 1036.10 Sampling and Testing. 1036.10.1 Reinforcing Bars. For bar sizes No. 3 to 11, inclusive, one tension test, and one bend test shall be made of the largest size rolled from each heat. For bar sizes Nos. 14 and 18, one tension test and one bend test shall be made of each size from each heat. For all bar sizes one set of dimensional property tests (including coating thickness when applicable) shall be made of each bar sized rolled from each heat. Each pair of bar samples submitted for testing shall be straight and a minimum 36 inches in length. Each heat is to be properly identified by the steel manufacturer by a means such as tagging bundles or bars of each heat with the heat number. Reinforcing bars that cannot be identified by heat number
4/8/2013
1036-9
Reinforcing Steel for Concrete
and source will not be inspected, tested, or accepted. Tags shall show the quantity, grade, size, and suitable identification. 1036.10.2 Plain and Welded Wire Reinforcement. Test specimens for testing tensile, bending and weld shear strength mechanical properties shall be obtained from cutting the finished welded wire reinforcement a full width section, of sufficient length to perform the physical testing specified. One test shall be made per project. The sample shall be submitted for testing shall have attached thereto a tag bearing the name of the manufacturer, description of the material, and the appropriate AASHTO or ASTM specification. Reinforcement that cannot be identified by wire spacing and source will not be inspected, tested, or accepted. 1036.10.3 Retests. If the results of the sample fail to meet the designated ASTM, AASHTO, or other contract-specific specification minimum requirements, the reinforcing material shall be retested in accordance with that governing specification.
4/8/2013
1036-10
Reinforcing Steel for Concrete
Section 1037
Shear Connectors
1037.1 Scope. This specification covers the requirements for stud-type shear connectors and weldability qualification. 1037.2 Material. Studs shall be in accordance with AASHTO M 169 for cold drawn carbon steel bars Grades 1015, 1017 or 1020, either semi or fully-killed. If flux retaining caps are used, the steel for the caps shall be of a low carbon grade suitable for welding and shall be in accordance with ASTM A 109. The flux for welding shall be self-contained either in the base of the stud or in the ferrule and automatically applied in the welding operation. A ferrule of heat resistant ceramic or other suitable material shall be used with each stud and the ferrule shall be composed of material which is not detrimental to the welds, does not cause excessive slag, and has sufficient strength to withstand thermal or structural shock. 1037.3 Qualification Procedure. The procedure for weldability tests to qualify shear connector studs for welding under shop or field conditions shall be as follows. Such tests may be performed by a university, independent laboratory or by other approved testing agencies. The tests shall be made on each type and size of stud. The agency performing the tests shall submit to the manufacturer of the stud a certified report giving procedures and results for all tests including the information listed under Section 1037.9. 1037.4 Duration of Qualification. Qualifications will be considered valid until the manufacturer makes a change in the base of the stud, the flux, or the arc shield, which affects the welding characteristics. 1037.5 Preparation of Specimens. 1037.5.1 Test specimens shall be prepared by welding representative studs to the center of square specimen plates, ½ inch to ¾ inch thick, be in accordance with ASTM A 36. At the option of the manufacturer, several studs may be welded to a large plate and the specimen plates cut of a size suitable for test equipment used. Studs shall be welded with power source, welding gun and control equipment as recommended by the manufacturer. Welding voltage, current and time shall be measured by suitable instrumentation and recorded for each specimen. Lift and plunge shall be at the optimum setting as recommended by the manufacturer. 1037.5.2 Studs shall be of uniform quality and condition, free from laps, fins, seams, cracks, twists, bends, or other injurious defects. The finish shall be as produced by cold drawing, cold rolling or machining. The overall height after welding will be shown on the plans. The size of studs with allowable tolerance shall be as follows.
1/31/2007
1037-1
Shear Connectors
Stud Size - Inches Shank Diameter
Shank Diameter Tolerances
Overall Height (Tolerance After Welding)
Head Diameter
Head Thickness, Min.
¾ inch
+ 0.000" - 0.010"
+ 0.062" - 0.125"
1¼" ± 1⁄64"
⅜"
⅞ inch
+ 0.000" - 0.010"
+ 0.062" - 0.125"
1⅜" ± 1⁄64"
⅜"
1037.5.3 Thirty test specimens shall be welded consecutively with optimum current and time. Optimum current and time shall be the mid-point of the range normally recommended by the manufacturer for production welding. 1037.5.4 Thirty test specimens shall be welded consecutively with time held constant at optimum but with current 10% below optimum. 1037.5.5 Thirty test specimens shall be welded consecutively with time held constant at optimum but with current 10% above optimum. 1037.6 Qualification Tests. 1037.6.1 Tensile Tests. Ten of the specimens welded in accordance with Section 1037.5.3, ten in accordance with Section 1037.5.4 and ten in accordance with Section 1037.5.5, shall be subjected to a tensile test. Tensile properties shall be determined in accordance with the applicable sections of AASHTO T 244. If a fracture occurs outside the middle half of the gage length, the test shall be repeated. A stud will be considered as qualified if all test specimens meet the following requirements:
Tensile Strength (min.)
60,000 psi
Yield Strength* (min.)
50,000 psi
Elongation (min.)
20% in 2 inches
Reduction of Area (min.)
50%
* As determined by a 0.2% offset method. 1037.6.2 Bend Tests. Twenty of the specimens welded in accordance with Section 1037.5.3, twenty in accordance with Section 1037.5.4 and twenty in accordance with Section 1037.5.5, shall be bent alternately 30 degrees in opposite directions until failure occurs. A stud will be considered as qualified if, on all test specimens, fracture occurs in the shank of the stud and not in the weld.
1/31/2007
1037-2
Shear Connectors
1037.7 Retests. If a weld failure occurs in any of the tensile or bend test groups, another test group may be prepared and tested. If weld failure repeats, the stud shall fail to qualify. 1037.8 Qualification. For a manufacturer's studs and arc shields to be qualified, each group of thirty studs shall, by test or retest, meet the requirements specified in Section 1037.6. 1037.9 Report of Tests. The report of the testing laboratory to the manufacturer shall include the following: 1) Drawings which show shapes and dimensions with tolerances of studs, arc shields, and flux. 2) A complete description of material used in the studs and arc shields, including the quantity and analysis of the flux. 3) A certification that the studs and arc shields described in the report are qualified in accordance with Section 1037.8. 1037.10 Certification. Prior to inspection, the Contractor shall submit to the Engineer the following information: 1) The name of the manufacturer. 2) A detailed description of the studs to be furnished. 3) A certification from the manufacturer that the studs delivered are qualified in accordance with Section 1037.8. 4) A copy of the qualification test results as certified by the testing laboratory unless the source and manufacturing process for these studs has been previously approved. 5) Certified copies of in-plant quality control test results.
1/31/2007
1037-3
Shear Connectors
(This Page Intentionally Left Blank)
1/31/2007
1037-4
Shear Connectors
Section 1038
Bearing Pads for Structures
1038.1 Scope. These specifications cover elastomeric bearing pads of neoprene, of rubber and fabric and of rubber and fiber. Elastomeric bearing pads shall include plain bearings, consisting of elastomer only, and laminated bearings, consisting of layers of elastomer restrained at their interfaces by bonded laminates. 1038.2 Acceptance. All material will be accepted on the basis of the required certification and testing required by the Engineer. 1038.3 Elastomeric Bearing Pads. 1038.3.1 Material. The elastomer shall be 100 percent virgin chloroprene (neoprene) compound meeting the requirements shown below. The pads shall be of the Durometer Grade specified on the plans. If test specimens are cut from the finished product, a 10 percent variation in "Physical Properties" will be allowed. Durometer Grade
ASTM Standard
50
60
70
D 2240
Hardness
50±5
60±5
70±5
D 412
Tensile Strength, psi (min.)
2500
2500
2500
D 412
Ultimate Elongation, percent (min.)
400
350
300
D 573 70 hours @ 212°F
Heat Resistance: Change in Durometer Hardness, Points (max.) Change in Tensile Strength, percent (max.) Change in Ultimate Elongation, percent (max.)
+15
+15
+15
-15
-15
-15
-40
-40
-40
D 395 Method B
Compressive Set: 22 hours at 212°F, percent (max.)
35
35
35
D 1149
Ozone: 100 pphm ozone in air by volume, 20 percent strain, 100°F ± 2°F, 100 hours, mounting procedure ASTM D 518 Procedure A
No Cracks
No Cracks
No Cracks
D 429 Method B
Adhesion: Bond made during vulcanization, lb./in.
40
40
40
D 746, Procedure B
Low Temperature Test Brittleness at -40°F
No Failure
No Failure
No Failure
1/31/2007
1038-1
Bearing Pads for Structures
1038.3.2 Laminates. Laminates shall be cold or hot rolled steel sheets in accordance with ASTM A 1008 and A 1011 with a minimum grade of 36. 1038.3.3 Manufacturing Requirements. Shop drawings for laminated neoprene bearings pad assemblies shall be prepared and submitted to Design Division, Bridge Section for approval in accordance with Section 1080.3.2. Shop drawings will not be required for plain neoprene bearing pads or laminated neoprene bearing pads without a steel sole plate. Cut edges shall be at least as smooth as ANSI 250 finish. Unless otherwise shown on the plans, all components of a laminated bearing shall be molded together into an integral unit, and all edges of the laminations shall be covered by a minimum of ⅛ inch of elastomer except at laminate restraining devices and around holes that will be entirely closed on the finished structure. The laminated neoprene bearings pad assembly steel sole plate shall be bonded by vulcanization to the laminated neoprene pad to provide a homogenous bond free of air and moisture pockets. The following values shall be met under laboratory testing conditions of full size bearings: 1) Compressive strain of any layer of an elastomeric bearing shall not exceed seven percent at 800 psi average unit pressure or at the design dead load plus live load pressure, if so indicated on the plans. 2) Shear resistance of the bearing shall not exceed 50 psi for 50 durometer, 75 psi for 60 durometer or 110 psi for 70 durometer compounds at 25% strain of the total effective elastomer thickness after an extended 4-day ambient temperature of -20°F. 1038.3.4 The manufacturer shall proof load each laminated neoprene bearing with a compressive load of 1,500 psi on the bearing area. The bulging pattern shall not indicate improper laminate placement or poor laminate bond. No more than two separate surface cracks with a width of 0.08 inch and a depth of 0.08 inch will be permitted. 1038.4 Type “N” Polytetrafluoroethylene (PTFE) Bearings. 1038.4.1 Type "N" PTFE bearings shall be either fixed units or expansion units having sliding surfaces of mirror stainless steel against PTFE material. Shop drawings for type "N" PTFE bearings shall be prepared and submitted to Design Division, Bridge Section for approval in accordance with Section 1080.3.2. The PTFE sliding bearings shall consist of a steel sole plate with a welded upper element of stainless steel bearing on a lower element consisting of a layer of PTFE material bonded to a stainless steel plate that shall be bonded to the neoprene elastomeric pad. The surface of the stainless steel plate shall be protected from weld splatter during the welding procedure. 1038.4.2 The stainless steel sheet for the top and bottom elements of sliding bearings shall be Type 304 in accordance with ASTM A 240. The finished stainless surface of the top element shall be a plane within a tolerance of 1⁄32 inch, shall be polished sufficiently to meet the friction requirement in Section 1038.4.6.1, and shall be comparable to a No. 8 mirror finish as established by the American Iron and Steel Institute Committee of Stainless Steel Producers "Finishes for Stainless Steel" at the completion of fabrication. 1038.4.3 Neoprene elastomeric pads shall be in accordance with Section 1038.3.
1/31/2007
1038-2
Bearing Pads for Structures
1038.4.4 The PTFE material shall be 100% virgin PTFE fluorocarbon resin, unfilled, or filled with fiberglass reinforcement to minimize the cold flow tendencies while maintaining the friction properties of the PTFE fluorocarbon resin. The amount of filler by weight of filled PTFE sheet shall be no more than 15%. The finished material shall exhibit the following physical properties:
Requirement
Test Method
Filled Value
Unfilled Value
Hardness at 78°F
ASTM D 2240, Shore "D"
50-60
50-65
Tensile Strength psi
ASTM D 4895
2000 (min.)
2800 (min.)
Elongation, Percent
ASTM D 4895
150 (min.)
200 (min.)
Deformation Under Load, Percent - 73.4°F - 2000 psi
ASTM D 621 Method A
10 (max.)
15 (max.)
Specific Gravity
ASTM D 4895
2.20 ± 0.03
2.16 ± 0.03
1038.4.5 The PTFE sheet shall be bonded to the stainless steel with epoxy bonding material designated by the manufacture as compatible with the PTFE sheet and stainless steel, and be able to withstand the temperatures of vulcanization. The stainless steel shall then be bonded by vulcanization to the neoprene elastomer to provide a homogenous bond free of air and moisture pockets. 1038.4.6 One load specimen from the sliding bearing, consisting of a bottom element and a compatible top element no less than the smaller of the bearing area or 7 inches x 7 inches, shall be tested by the manufacturer. 1038.4.6.1 The specimen shall be loaded to 800 psi compression at 68°F ± 2°F and subjected to 100 cycles of one inch of horizontal movement each way from center at a rate of 2.5 inches per minute. The breakaway friction coefficient shall be computed for each direction of each cycle, and the breakaway friction coefficient mean and standard deviation shall be computed for the sixth through twelfth cycles. The initial static breakaway coefficient of friction for the first cycle shall not exceed twice the design coefficient of friction. The maximum coefficient of friction for all subsequent cycles shall not exceed the design coefficient of friction. Failure of a single sample shall result in rejection of the entire lot. Following the test, the breakaway coefficient of friction shall be determined again and shall not exceed the initial value. The bearing shall show no signs of bond failure or other defect. 1038.4.6.2 A minimum of one test for sliding bearings shall be performed for each lot of bearings.
1/31/2007
1038-3
Bearing Pads for Structures
1038.5 Rubber and Fabric Pads. 1038.5.1 Rubber and fabric bearings pads shall be manufactured of new material and be composed of multiple layers of prestressed cotton duck material weighing no less than 8.1 oz./yd2. The duck warp count shall be 50 threads plus or minus one thread per inch and filing count 40 threads plus or minus two threads per inch, each with two yarns per thread. The finished pads shall have 64 plies per inch of thickness. The duck material shall be impregnated and bound with a high quality rubber compound containing rot and mildew inhibitors and anti-oxidants, compounded into resilient pads of uniform thickness. 1038.5.2 The pads shall withstand compressive loads perpendicular to the plane of laminations of no less than 10,000 psi without separation of bond or detrimental deformation. Load deflection properties, determined in accordance with procedures of Military Specifications MIL-C-882B, shall not exceed 10 percent of total pad thickness at 1000 psi and 15 percent of total pad thickness at 2000 psi. When loaded to 1500 psi, permanent set as load shall be removed in accordance with procedures of MIL-C-882B and shall be no more than 2.5 percent of the original "zero point" thickness. Type A Durometer hardness shall be 87 to 95. The ratio of lateral expansion to vertical deflection shall not exceed 0.25 when loaded to 1500 psi. The material shall not lose effectiveness throughout a temperature range of -65°F to 150°F. The thickness shall vary no more than five percent from that shown on the plans. There shall be no visible evidence of damage or deterioration resulting from environmental effects of sunshine, humidity, salt spray, fungus, or dust in accordance with MIL-E-5272. 1038.6 Rubber and Fiber Pads. 1038.6.1 Rubber and fiber bearing pads shall consist of a rubber body and fabric fibers for insulation under aluminum rail posts. The bearing pads shall be made from new unvulcanized rubber and unused fabric fibers. Fibers and rubber shall be in proper proportion to maintain specified strength and stability. 1038.6.2 Type A durometer surface hardness of the pads shall be 70 to 90. Pads of the specified thickness shall be capable of withstanding compressive loads of no less than 7000 psi without excessive extrusion or detrimental reduction in thickness.
1/31/2007
1038-4
Bearing Pads for Structures
1038.7 Tolerances. For both plain and laminated bearings, the permissible variation from the dimensions and configuration shown on the plans shall be as follows: Inch Overall Vertical Dimensions Average total thickness 1¼ inches or less Average total thickness over 1¼ inches
-0, +⅛" -0, +¼"
Overall Horizontal Dimensions 36 inches and less Over 36 inches
-0, +¼" -0, +½"
Thickness of Individual Layers of Elastomer (Laminated bearings only)
± ⅛"
Variation from a Plane Parallel to the Theoretical Surface (as determined by measurements at the edges of bearings) Top Sides Individual non-elastic laminates
⅛" ¼" ⅛"
Position of Exposed Connection Members
⅛"
Edge Cover of Embedded Laminates or Connection Members
-0, +⅛"
Size of Holes, Slots or Inserts
-0, +1/8 (-0, +3)
Position of Holes, Slots or Inserts
±1/8 (±3)
1038.8 Certification. The manufacturer shall furnish certification of all material. The certification shall indicate that the components are in accordance with this specification and shall include typical test results representative of the material, except for bearings meeting Section 1038.3 and Section 1038.4 which will require test results for the material actually used in the bearing. The certification shall indicate the results of the proof loading, when required.
1/31/2007
1038-5
Bearing Pads for Structures
(This Page Intentionally Left Blank)
1/31/2007
1038-6
Bearing Pads for Structures
Section 1039
Epoxy Resin Material
1039.10 Type II Epoxy. 1039.10.1 Scope. This specification covers two-component epoxy resin to be used to bond plastic concrete or mortar to hardened concrete or mortar. 1039.10.2 General Requirements. The epoxy shall be furnished as a two-component system in accordance with the requirements of AASHTO M235 (ASTM C 881), Type II, Grade 2, Class B or C, in accordance with the range of temperatures for which they are suitable. The temperature in question is that of the surface of the harden concrete to which the bonding system is to be applied. 1039.10.3 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the manufacturer shall submit to Construction Division Manager a certified test report showing specific test results from an independent laboratory in accordance with all requirements of these specifications. The certified test report shall contain the manufacturer's name, brand name of material, lot tested, date of manufacture and ratio of components. In addition, the manufacturer shall submit a one quart sample of each component, A and B, for laboratory testing accompanied by a technical data sheet and an MSDS. With approval by the Engineer of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer would be placed on a qualified list of concrete bonding compounds. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements herein specified. 1039.10.4 Acceptance. To obtain final acceptance of this material, the manufacturer shall furnish certification to the Engineer at the destination. The certification shall state that the material is supplied in accordance with all requirements specified and that the material is the same system, identically formulated to the material tested for manufacturer and brand name approval. 1039.20 Type III Epoxy. 1039.20.1 Scope. This specification covers two-component epoxy to be used in the grouting of dry cracks, in epoxy mortar for patching concrete, in epoxy mortar surface leveling and for use in bonding skid-resistant materials to harden concretes used on trafficbearing surfaces (or surfaces subject to thermal or mechanical movements). 1039.20.2 General Requirements. The epoxy shall be furnished as a two-component system in accordance with the requirements of AASHTO M235 (ASTM C 881), Type III, Grade 1, Class B or C, in accordance with the range of temperatures for which they are suitable. The temperature in question is that of the surface of the harden concrete to which the bonding system is to be applied.
1/31/2007
1039-1
Epoxy Resin Material
1039.20.3 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the manufacturer shall submit to Construction Division Manager a certified test report showing specific test results from an independent laboratory in accordance with all requirements of these specifications. The certified test report shall contain the manufacturer's name, brand name of material, lot tested, date of manufacture and ratio of components. In addition, the manufacturer shall submit a one quart sample of each component, A and B, for laboratory testing accompanied by a technical data sheet and an MSDS. With approval by the Engineer of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on a qualified list of concrete bonding compounds. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements herein specified. 1039.20.4 Acceptance. To obtain final acceptance of this material, the manufacturer shall furnish a certification to the Engineer at destination certifying that the material supplied is in accordance with all requirements specified and stating that the material is the same system and is identically formulated to the material tested for manufacturer and brand name approval. 1039.30 Epoxy or Polyester Bonding Agents for Dowels. 1039.30.1 Scope. This specification covers a two-component epoxy or polyester bonding agent to be used in anchoring epoxy coated dowel bars in concrete for pavement repair. 1039.30.2 General Requirements. Epoxy or polyester bonding agents for anchoring epoxy coated dowel bars shall be furnished as a two-component system. The system shall include automatic mixing, whether in cartridge or bulk form. The component ratios shall be shown on the label of each cartridge or bulk container. 1039.30.3 Properties. The epoxy or polyester bonding agent shall exhibit good bonding properties between the epoxy coated dowel bar and the existing concrete and shall cure in two hours or less. Bonding agents, when initially mixed, shall have a viscosity which prevents flow from a horizontal hole. When tested in accordance with MoDOT Test Method T 49, the minimum pull-out load shall be 8100 pounds. 1039.30.4 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the manufacturer shall submit to Construction Division Manager a certified test report from an independent laboratory showing specific test results in accordance with all requirements of this specification. The certified test report shall contain the manufacturer's name, brand name of material, lot tested, date of manufacture, ratio of components by volume and system tested. In addition, the manufacturer shall submit to Construction Division Manager a sample representing the system for laboratory testing accompanied by a technical data sheet, an MSDS and any special installation instructions relative to the system being submitted, including recommended curing time. With approval by the Engineer of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on a qualified list of bonding agents for dowels. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements herein specified. 1/31/2007
1039-2
Epoxy Resin Material
1039.30.5 Acceptance. To obtain final acceptance of this material, the manufacturer shall furnish certification to the engineer at the destination that the material supplied is in accordance with all requirements specified and stating that the material supplied is the same system and is identically formulated to the material tested for manufacturer and brand name approval. 1039.40 Epoxy Bonding Agents for Resin Anchor Systems. 1039.40.1 Scope. This specification covers a two component epoxy bonding agents to be used in anchoring steel components in concrete for structures. 1039.40.2 General Requirements. The epoxy shall be furnished as a system in accordance with the requirements of AASHTO M235 (ASTM C 881), Type IV, Grade 3, in accordance with the range of temperatures for which they are suitable. The temperature in question is that of the surface of the harden concrete to which the bonding system is to be applied and as described herein. 1039.40.3 Pull Test. The epoxy bonding agent shall exhibit good bonding properties between the anchored product and the existing concrete and shall cure in 24 hours or less. When tested in accordance with MoDOT Test Method T 74, the ultimate minimum pull-out load shall be in accordance with the following table:
Pull-Out Specification Requirements Diameter of Threaded Rod or Reinforcing Bar
Minimum Ultimate Pullout Strength
½ inch
9800 pounds
⅝ inch
15,500 pounds
¾ inch
20,400 pounds
⅞ inch
27,500 pounds
1 inch
33,600 pounds
1039.40.4 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the manufacturer shall submit to Construction Division Manager a certified test report from an independent laboratory showing specific test results in accordance with all requirements of this specification. The certified test report shall contain the manufacturer's name, brand name of material, lot tested, date of manufacture, bar or rod size tested, embedment depth and ratio of components. In addition, the manufacturer shall submit a one quart sample of each component, A and B, for laboratory testing accompanied by a technical data sheet and a material safety data sheet. With approval by the engineer of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on a qualified list of Epoxy Bonding Agents for Resin Anchor Systems. New certified test results and samples shall be submitted any time
1/31/2007
1039-3
Epoxy Resin Material
the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements herein specified. 1039.40.5 Acceptance. To obtain final acceptance of this material, the manufacturer shall furnish certification to the Engineer at the destination that the material supplied is in accordance with all requirements specified and stating that the material is the same system and is identically formulated to the material tested for manufacturer and brand name approval. 1039.50 Sand for Epoxy Mortar. 1039.50.1 Scope. This specification covers sand for use in epoxy mortar for the repairing of concrete surfaces. The epoxy material used in epoxy mortar shall be Type III epoxy in accordance with Section 1039.2. 1039.50.2 Properties. Sand for mortar shall be a quartzite sand, Ottawa sand or equal. The sand shall be clean and dust free. The maximum moisture content shall be 2 percent. The gradation shall be in accordance with the following requirements:
GRADATION REQUIREMENTS Sieve Size
Percent Passing by Weight
No. 16
100
No. 30
97-100
No. 50
5-35
No. 100
0-2
No. 200
0-0.4
1039.50.3 Acceptance. The manufacturer shall furnish certification to the Engineer at the destination that the material supplied is in accordance with all requirements of this specification and stating that the material is identically formulated to the material tested for manufacturer and brand name approval. Acceptance will be based on certification and testing.
1/31/2007
1039-4
Epoxy Resin Material
1039.60 Epoxy Polymer Concrete Overlay. 1039.60.1 Scope. This specification covers an epoxy concrete overlay system consisting of an epoxy resin material and aggregate for use on bridge deck surfaces. 1039.60.2 Epoxy Resin Materials. The infrared spectrum for each component of the epoxy-resin material shall essentially match that of the standard infrared spectrum for the particular component as specified in AASHTO T 237, Sections 4 and 5. The epoxide equivalent for Component A shall not exceed 270. The mixed epoxy shall meet the following requirements: EPOXY RESIN REQUIREMENTS Property
Specific Value
Pot life, 75°F, minutes
10 - 55
Tensile strength, 75°F, 7 Days, psi (min.)
1500
Tensile elongation, 75°F, percent (min.)
20
Water absorption, percent (max.)
0.8
Compressive strength, 4 hours, psi (min.)
1000
Compressive strength, 48 hours wet, psi (min.)
4000
Ash content, percent (max.)
0.5
Rotational Viscosity, 75°F, Spindle 3, 60 rpm, Poise
7 - 25
Volatile Content, percent (max.)
3.0 No shearing, shrinkage, expansion or scaling.
Thermal Shear
1039.60.2.1 Classes. Epoxy resin shall be formulated for use at specific temperatures as specified in ASTM C 881. The controlling temperature shall be that of the hardened concrete surface to which the overlay is applied. Where unusual curing rates are desired and upon the approval of the Engineer, a class of epoxy may be used at a temperature other than that for which the epoxy is normally intended.
1/31/2007
1039-5
Epoxy Resin Material
1039.60.2.2 Packaging. Containers shall be identified as "Component A-Contains Epoxy Resin" and "Component B-Contains Hardener" and shall show the type, class and mixing directions. Each container shall be marked with the name of the manufacturer, class, batch, or lot number, date of packaging, date of shelf life expiration, pigmentation, if any, manufacturer, and the quantity contained in pounds and gallons. 1039.60.3 Aggregate for Epoxy Polymer Concrete Overlay. Aggregate shall be bauxite, crushed porphyry, aluminum oxide, flint chat or other similarly hard, durable, dry aggregates with less than 0.2% moisture. Aggregate shall be in accordance with the following gradation: Aggregate Requirements Sieve Size
% Passing By Weight
# 4 (4.75 mm)
100
# 20 (850 µm)
0-5
# 200 (75 µm)
0-1.0
1039.60.3.1 Lead Content. Aggregate produced as a by-product from lead or zinc mining operations shall not have a total lead content greater than 4,500 ppm, as determined by EPA Method 3050A, "Acid Digestion of Sediments, Sludges and Soils (particle size reduced to 1 mm or less)". Suppliers of this aggregate shall provide certification to the Engineer for each shipment that the total lead content of the aggregate does not exceed this value, and attach a typical test report from the same source no older than 12 months prior to the shipment. 1039.60.3.2 Aggregate Recommendation. For each contract, the epoxy supplier shall supply a letter to the Engineer specifically recommending the use of a designated aggregate and source, which has been previously approved by Construction Division Manager. 1039.60.4 Overlay System. The overlay system shall not exhibit shearing, shrinkage, expansion or scaling.
1/31/2007
1039-6
Epoxy Resin Material
1039.60.5 methods:
Test Methods.
Tests will be performed in accordance with the following
TEST METHODS Rotational Viscosity
ASTM 2393 Model LVT Brookfield viscometer
Epoxy equivalent
MoDOT Test Method T 73
Volatile content a
ASTM D 1259, Method B, for mixed system
Filler content
MoDOT Test Method T 73
Ash content
ASTM D 482
Pot life
AASHTO T 237
Tensile strength
ASTM D 638
Compressive strength
AASHTO M235 (ASTM C 881)
Water absorption
ASTM D570
Thermal Shear
MoDOT Test Method T72
a
Sample cured 4 days at room temperature and weighed on a previously weighed metal foil.
1039.60.6 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the manufacturer shall submit to Construction Division Manager a certified test report showing specific test results in accordance with all requirements of this specification. The certified test report shall include the manufacturer's name, brand name of material, lot tested, date of manufacture, ratio of components by volume and system tested. In addition, the manufacturer shall submit to Construction Division Manager a sample representing the system for laboratory testing accompanied by a technical data sheet, a material safety data sheet and any special installation instructions relative to the system being submitted. Upon approval of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on a qualified list of epoxy resin materials for polymer concrete overlay. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates non-conformity with any of the requirements herein specified. 1039.60.7 Product History. The overlay system shall have a proven record of a minimum of two years on similar bridge decks within the United States and which can be inspected by the Engineer if so desired. A list including the location, the name of the agency involved with the project, and a name and phone number of a contact person with that agency, shall be provided for each location used as evidence of satisfactory use.
1/31/2007
1039-7
Epoxy Resin Material
1039.60.8 Acceptance. The manufacturer shall furnish certification to the engineer at the destination that the material supplied is in accordance with all requirements specified and stating that the material supplied is the same system and is identically formulated to the material tested for manufacturer and brand name approval. Acceptance will be based on certification and testing. 1039.70 Polymer Concrete. 1039.70.1 Scope. This specification covers polymer concrete consisting of a fast setting epoxy based solid that may contain aggregate for use at bridge expansion joints. 1039.70.2 General Requirements. The polymer concrete shall be resilient, self-adhering, water tight and shall withstand and remain bonded to the surrounding material under repeated impact and thermal cycling. The polymer concrete shall not flow or become tacky at temperatures up to 130°F, shall be resistant to ultraviolet radiation, petroleum products and abrasion, and shall be capable of curing at all temperatures above 50°F. Mixing and placement shall be in accordance with the manufacturer's recommendations. 1039.70.2.1 The combined liquid components with no aggregate added shall be in accordance with the following requirements: EPOXY REQUIREMENTS Property
Specific Value
Mixing Ratio, by Volume
1:1
Viscosity (ASTM D 2393), Poises, Spindle 2, 30 rpm, 25°C ± 2°C
9-20
Color
Black
Gel Time (AASHTO M-200-73), minutes
25-50
Elongation (ASTM D 638 a), percent
45-55
Tensile Strength (ASTM D 638 a), psi (min.)
900
Shore D Hardness (ASTM D 2240), 77°F
45-75
a
Test Method Type 1, Molded Specimens, 0.25 inches thickness
1/31/2007
1039-8
Epoxy Resin Material
1039.70.2.2 The cured polymer concrete including aggregate, which shall be supplied by the manufacturer, shall be in accordance with the following requirements:
POLYMER CONCRETE REQUIREMENTS Property
Specific Value
Compression strength (ASTM C 579), psi, minimum at 24 hours
2500
Bond Shear Strength (ASTM C 882), psi
700
Abrasion Resistance (ASTM C 501), Wear Index (Taber H-22) (max.)
1.0
Compressive Stress (OK/OHD L-6), psi
350
Resilience (OK/OHD L-6), percent
70
1039.70.3 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the manufacturer shall submit to Construction Division Manager a certified test report from an independent laboratory showing specific test results in accordance with all requirements of this specification. The certified test report shall contain the manufacturer's name, brand name of material, lot tested, date of manufacture and ratio of components. In addition, the manufacturer shall submit a one quart sample of each component, A and B, for laboratory testing accompanied by a technical data sheet and a material safety data sheet. With approval by the engineer of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on a qualified list of polymer concretes. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements herein specified. 1039.70.4 Acceptance. To obtain final acceptance of this material, the manufacturer shall furnish certification to the Engineer at destination certifying that the material supplied is in accordance with all requirements specified and stating that the material is identically formulated to the material tested for manufacturer and brand name approval.
1/31/2007
1039-9
Epoxy Resin Material
(This Page Intentionally Left Blank)
1/31/2007
1039-10
Epoxy Resin Material
Section 1040
Guardrail, End Terminals, One-Strand Access Restraint Cable and Three-Strand Guard Cable Material
1040.1 Scope. This specification covers guardrail, end terminals, one-strand access restraint cable, three-strand guard cable, end terminals and all appurtenances required for installation. 1040.2 Posts and Blocks. The same type of posts and blocks shall be used in a given run, except as shown on the plans or as approved by the engineer. 1040.2.1 Wood Posts and Blocks. Wood posts and blocks for guardrail and one-strand access restraint cable shall be in accordance with Section 1050. 1040.2.2 Steel Posts, Plates and Rails. Steel posts, anchor plates, bearing plates, soil plates, plate washers and channel rail shall be structural steel in accordance with AASHTO M 270, Grade 36, shall be of the dimensions and weights shown on the plans and shall be galvanized in accordance with AASHTO M 111. Bolts, nuts, and washers shall be in accordance with the dimensions shown on the plans and shall be galvanized in accordance with AASHTO M 232 or may be mechanically galvanized. If mechanically galvanized, the coating thickness, adherence and quality requirements shall be in accordance with AASHTO M 232, Class C. Any dimensional defects and structural discontinuities shall be cause for rejection. The material to be welded shall be preheated in accordance with good welding practice and welds shall be full section and sound throughout. All welds shall be mechanically cleaned before galvanizing. No punching, drilling, cutting, or welding will be permitted after galvanizing. 1040.2.3 Plastic Blocks. Plastic guardrail blocks shall meet the dimensional requirements shown on the standard plans. The blocks shall be a homogeneous product with a uniform texture and shall have no cracking, chipping, flaking, peeling, or splintering after fabrication. The blocks will not be considered homogeneous if there are more than five voids larger than ⅝ inch or any voids larger than ¾ inch on any cut face. The blocks shall be of new stock. The blocks shall meet all applicable requirements of National Cooperative Highway Research Program (NCHRP) Report 350 and meet approval by Construction Division Manager. 1040.2.3.1 Approval. Prior to approval and use of the plastic guardrail blocks, the manufacturer shall submit to Construction Division Manager, the manufacturers name, the product brand name or model number, a copy of the NCHRP Report 350 test results, a copy of the FHWA acceptance letter, an MSDS and a sample block. 1040.2.3.2 Acceptance. Acceptance of the material will be based on the manufacturer's certification and upon the results of such tests as may be performed by the Engineer. 1040.3 Steel Beam Guardrail. Guardrail beams shall be of the class and type shown on the plans. Guardrail beams shall be in accordance with AASHTO M180, Type 1 or Type 2, except as noted herein. Type 1 material shall be galvanized by the continuous method.
10/1/2012
1040-1
Guardrail, End Terminals, One-Strand Access Restraint, Cable and Three-Strand Guard Cable Material
1040.3.1 Test Specimens. Test specimens for mechanical properties shall be prepared and tested in accordance with ASTM A 653. 1040.3.2 End Sections. End sections and terminal connectors shall be of a class and type the same as or superior to that used for the beam to which the end sections and terminal connectors are attached. The physical properties shall be in accordance with AASHTO M 180. 1040.3.3 Fabrication. The beams, end sections, and terminal connectors shall be shaped and punched as shown on the plans. The beams, end sections, and terminal connectors shall be ready for assembly when delivered. Only drilling or cutting necessary for special connections and for sampling will be permitted in the field. Warped or deformed beams will be rejected. Beams to be erected on a radius of 150 feet or less shall be shop curved to the approximate curvature of the installation. 1040.3.4 Markings. 1040.3.4.1 Beams. Beam Markings shall be in accordance with AASHTO M 180, except the AASHTO specification number may be omitted if another designation for Class and Type is used. 1040.3.4.2 Transition Sections and Terminal Connectors. Transition sections and terminal connectors shall be marked in accordance with Section 1040.3.4.1, except as follows. Durable tags securely attached to each section or connector may be used. If the transition section or terminal connector is Class B, indicating the Class will not be required. If the transition section or terminal connector is Type 2, indicating the Type will not be required. Heat numbers and coating designations will not be required. 1040.3.4.3 End Sections. No markings or tags are required for end sections. 1040.3.4.4 Posts. Posts shall be marked such that the marking is exposed after installation, in such a manner as to indicate the manufacturer. 1040.3.5 Brand Registration and Guarantee. The manufacturer shall be on the current MoDOT qualified list of Guardrail Fabricators. For Type I coated material, the brand registration and guarantee shall certify the material as being produced by the continuous galvanizing method. 1040.3.6 Acceptance. Acceptance shall be by brand registration and guarantee and any sampling deemed necessary by the Engineer. The contractor or supplier shall provide equipment and personnel required to obtain samples as directed by the Engineer. 1040.4 Crashworthy End Terminals. Approval of crashworthy end terminal systems may be requested by submitting proof of equivalent crash test results as described in Section 606.30, shop drawings, certification and any additional required information to the Engineer. Approval shall be received prior to the fabrication and installation of any system.
10/1/2012
1040-2
Guardrail, End Terminals, One-Strand Access Restraint, Cable and Three-Strand Guard Cable Material
1040.5 End Anchors and Bridge Anchors. 1040.5.1 Steel Tube and Tube Block. Steel tubes for end anchors shall consist of structural steel tubing in accordance with ASTM A 500 Grade B or ASTM A 501 and shall be galvanized in accordance with AASHTO M 111. Structural steel tubing blocks for guardrail shall consist of steel tubing in accordance with ASTM A 500 Grade B and shall be galvanized in accordance with AASHTO M 111. 1040.5.2 Cable. Cable shall be ¾ inch in diameter, Type II, Class A in accordance with AASHTO M 30. 1040.5.3 Transition Cap Rail. The transition cap rail shall be in accordance with AASHTO M 270, Grade 36. 1040.5.4 Thrie Beam Rail and Transition Section. The thrie beam rail and transition section shall be galvanized in accordance with AASHTO M 180, Type 2. 1040.5.5 Approval. Cable assembly and anchor plate shall be subject to approval by the engineer and shall have a minimum breaking strength of 20 tons. 1040.5.6 Markings. Thrie beam rail and transition sections shall be marked in accordance with Section 1040.3.4. 1040.6 Cable and Fittings. 1040.6.1 One-Strand Access Restraint Cable. 1040.6.1.1 Cable. Cable shall be zinc coated steel wire strand; ½ inch in diameter; seven wire strand; Common, Siemens-Martin or High Strength grade; Class A coating; and be in accordance with ASTM A 475. 1040.6.1.2 Hardware. Eyebolts, turnbuckles, and clips for cable connections and end anchors shall be steel forgings in accordance with AASHTO M 102 or pearlitic malleable iron in accordance with ASTM A 220. All miscellaneous parts, comprising of cable connections, fasteners and end anchors, shall be galvanized in accordance with AASHTO M 232. 1040.6.2 Three-Strand Guard Cable. 1040.6.2.1 Cable and Connecting Hardware. The cable and connecting hardware shall be in accordance with AASHTO M 30 and AASHTO M 269. The wire rope shall be Type 1, ¾ inch diameter, 3 x 7 construction with a Class A coating. The rope, with connecting hardware, shall develop the breaking strength of a 25,000 pound single cable. Connecting hardware shall be galvanized in accordance with AASHTO M 232 or may be mechanically galvanized. If mechanically galvanized, the coating, thickness, adherence, and quality requirements shall be in accordance with AASHTO M 232, Class C. Cast Steel components shall be in accordance with AASHTO M 103, Grade 70-40, Class 1. Malleable iron castings shall be in accordance with ASTM A 47. Compensating devices shall have a spring constant of 0.46 pounds per inch, plus or minus 0.06 pounds per inch, and permit 6 inches of travel, plus or minus 1 inch. All threaded parts on compensating cable end assemblies shall be in accordance with 10/1/2012
1040-3
Guardrail, End Terminals, One-Strand Access Restraint, Cable and Three-Strand Guard Cable Material
ASTM F 568 Class 4.6, ¾ - 10 threads. Socket baskets shall be designed for use with the cable anchor wedge as shown on the plans. Guard cable anchor brackets shall be manufactured from an AASHTO M 270, Grade 250 steel plate, and zinc-coated in accordance with AASHTO M 111. Dimensional tolerances not shown on the plans shall be consistent with the proper functioning of the part, including the part's appearance and accepted manufacturing process. 1040.6.2.2 Cable Brackets. Steel used in the fabrication of the bracket shall be in accordance with ASTM A 36. The bracket shall be galvanized after fabrication in accordance with AASHTO M 111. All fittings, including splices, shall be designed to use the wedge detail and shall be of such section as to develop the full strength of the ¾ inch, 25,000 pound round cable. Designs for a combination or single-unit compensating device and turnbuckle assembly shall be submitted for approval. Compensating devices shall have a spring rate of 0.46 pounds per inch, plus or minus 0.03 pounds per inch, and permit 6 inches of travel, plus or minus 1 inch. All parts, except cable wedge, shall be hot-dip zinc coated in accordance with AASHTO M 232 or ASTM B 695. 1040.6.2.3 Hook Bolts, Hex Bolts, Nuts and Washers. Hook bolts, hex bolts, and washers shall be in accordance with ASTM A 307. Cable hook nuts shall be 5⁄16 - 18 threads and in accordance with ASTM A 563. Hook bolts, as installed, shall develop an ultimate pull open strength of 450 to 1,000 pounds applied in a direction normal to the axis of the post. Hooked anchor studs shall be in accordance with AASHTO M 314, except the threads and nominal diameter shall be ¾ - 10 and in accordance with ASTM 568 Class 4.6. All items shall be galvanized in accordance with AASHTO M 232 or may be mechanically galvanized in accordance with AASHTO M 232, Class C. 1040.7 Certification. The contractor shall furnish manufacturer's certification for all material governed by this specification. Specifically, the certifications shall indicate compliance with the requirements of each applicable section and as set forth in Table I. 1040.8 Repair of Galvanizing. Galvanized material shall be handled in a manner to avoid damage to the surface. No field punching, drilling, cutting or welding will be permitted after galvanizing. Any galvanized material on which the spelter coating has been damaged will be rejected or may be repaired in accordance with Section 712 with the approval of the Engineer.
10/1/2012
1040-4
Guardrail, End Terminals, One-Strand Access Restraint, Cable and Three-Strand Guard Cable Material
Table I Certification Requirements Item
Galvanizing Standard
Steel Grade
Other
Wood Post and Blocks
-
-
a
Steel Posts, Plates and Brackets
AASHTO M111
AASHTO M 270, Grade 36
b
Plastic Blocks
-
-
g
Guardrail Beam
Section 1040.3
Section 1040.3
b, c
Bolts, Nuts and Washers
AASHTO M 232
ASTM A 307
End Terminals Systems
-
-
f
AASHTO M 111 AASHTO M 111
ASTM A 500/ASTM A 501 AASHTO M 270, Grade 36
b b
AASHTO M 30 AASHTO M 232
AASHTO M 30 AASHTO M 102/ASTM A 220
b b
AASHTO M30 AASHTO M 232 AASHTO M 232 AASHTO M 232 AASHTO M 111 AASHTO M 111 AASHTO M 232 AASHTO M 232 AASHTO M 232
AASHTO M 30 & AASHTO M 269 AASHTO M 102/ASTM A 220 AASHTO M 103 ASTM A 47 AASHTO M 270 AASHTO M 270, Grade 36 ASTM A 307 ASTM A 563 AASHTO M 314
b d d d
End Anchors: - Tubes - Transition Cap Rail One-Strand Access Restraint Cable - Cable - Hardware Three Strand Guard Cable - Cable - Hardware - Cast Steel Components - Malleable Iron Castings - Anchor Brackets - Cable Brackets - Hook and Hex Bolts - Hook Nuts - Hooked Anchor Studs
e d
"Other" Key (Table l) a
Certification shall state that the material is in accordance with Section 1050 and shall include a listing of the materials supplied, and shall have a certified test report as detailed in Section 7.2 of AWPA Standard M2 attesting to complete compliance with this specification.
b
Certification shall include, or have attached, specific results of laboratory tests for physical and chemical properties from samples representative of the material.
c
Must have Brand Registration and Guarantee on file, including certification indicating the coating is either Type 1 by continuous galvanizing method or Type 2.
d
All threaded parts of compensating cable end assemblies and hooked anchor studs shall be in accordance with ASTM F 568.
e
All fittings for cable bracket, except the cable wedge, shall be in accordance with AASHTO M 232 or ASTM B 695.
f
Certification shall state the name of the manufacturer and that the units furnished are identical in materials and design as those tested for performance in accordance with Section 606.30.
g
Certification shall state that the materials furnished are identical in chemistry, mechanical properties, and geometry as those that passed the NCHRP 350 crash test, and as those that were approved by the Missouri Department of Transportation (MoDOT).
10/1/2012
1040-5
Guardrail, End Terminals, One-Strand Access Restraint, Cable and Three-Strand Guard Cable Material
(This Page Intentionally Left Blank)
10/1/2012
1040-6
Guardrail, End Terminals, One-Strand Access Restraint, Cable and Three-Strand Guard Cable Material
Section 1041
Polypropylene Culvert Pipe
1041.1 Scope. This specification covers double and triple wall polypropylene (PP) culvert pipe intended for use in the construction of culverts, sewers and similar uses. 1041.2 Basis of Acceptance. Acceptance of polypropylene culvert pipe will be based upon the pipe being in accordance with this specification. Pipe shall be provided from an approved manufacturer, and will be accepted based on certification, identification markings, and results from tests required by the engineer. 1041.3 Material. All polypropylene culvert pipe, couplings, and fittings shall be in accordance with ASTM F2736 for double wall and ASTM F2764 for triple wall, except as follows. 1041.3.1 Section properties shall be within the following limits: Minimum
Maximum
Pipe Wall Centroid to Inside Face yc (in.)
Pipe Wall Moment of Inertia I 4 (in. / in.)
Area Ratio a (Aeff / Ag)
Extreme Fiber Ratio b (yc / c)
Inside Diameter Di (in.)
Outside Diameter Do (in.)
12
0.168
0.445
0.0314
0.803
0.586
11.97
14.65
15
0.216
0.537
0.0538
0.821
0.687
14.85
17.81
18
0.217
0.569
0.0747
0.777
0.549
17.82
21.42
24
0.241
0.710
0.1318
0.723
0.558
23.85
28.34
30
0.248
0.882
0.2732
0.661
0.475
29.70
35.81
30
0.324
1.107
0.4416
0.676
0.681
29.70
35.81
36
0.315
1.363
0.4808
0.653
1.000
35.39
41.62
42
0.452
1.208
0.5554
0.817
0.797
41.38
47.72
48
0.348
1.535
0.9460
0.542
0.980
46.92
54.14
60
0.541
1.627
1.2088
0.739
0.812
58.65
67.17
Triple Wall
Double Wall
Nominal Size S (in.)
Effective Pipe Wall Area Aeff (in.2 / in.)
a b
2
Ag equals gross area of pipe wall per unit length of pipe (in /in.). c equals the distance from the pipe wall centroid to the outermost fiber (in.).
1041.3.2 The pipe shall not be perforated unless otherwise specified.
12/9/2013
1041-1
Polypropylene Culvert Pipe
1041.3.3 Field joints of polypropylene pipe shall provide circumferential and longitudinal strength to maintain the pipe alignment, prevent separation of pipe, and prevent infiltration of fill material. Coupling bands, if used, shall be of the same base material as the pipe. The design of coupling bands and fastening devices shall be pre-approved by MoDOT. Final acceptance of coupling bands and fastening devices will be based on field performance. 1041.3.4 The manufacturer shall provide to the engineer an itemized statement of the sizes, section properties, and lengths of pipe in each shipment. 1041.4 Sampling, Testing and Acceptance Procedures. Manufacturers furnishing pipe to Department projects shall be qualified as herein described. All pipe will be subject to inspection by the Engineer at the source of manufacture, at an intermediate shipping terminal or at the destination. The Engineer shall be permitted free access to all facilities and records as required to conduct inspection and sampling in accordance with Section 106. 1041.4.1 Sampling of Material. Random sampling of the pipe will be conducted by the Engineer to verify if the pipe and material are in accordance with these specifications. Samples of polypropylene pipe will be obtained from fabricated culvert sections in accordance with ASTM F2736 or ASTM F2764 at a frequency determined by the Engineer. 1041.4.2 Inspection. Inspection will include an examination of the pipe for markings, deficiency in specified diameter, net length of fabricated pipe and any evidence of poor workmanship. The inspection may include taking samples. 1041.4.3 Testing. Specimen testing size and method of tests shall be in accordance with ASTM F2736 or ASTM F2764. The contractor or manufacturer shall provide the equipment and personnel to cut a sample from a section of pipe. The sample shall include the markings or a record of the markings for that section of pipe. 1041.4.4 Unacceptable Material. 1041.4.4.1 Any individual section of pipe failing to meet the marking, diameter, length or workmanship requirements of these specifications will be unacceptable. If 10 percent of the pipe in any lot fails to meet these requirements, the entire shipment of that pipe size may be rejected. 1041.4.4.2 If a test specimen taken in accordance with Section 1041.4.3 fails to meet the requirements of ASTM F2736 or ASTM F2764, the pipe sampled will be rejected and the lot will be resampled. A resample will be of the same size as the original sample. The resample shall be in accordance with these specifications, or the entire shipment will be rejected. 1041.5 MoDOT Certification. When the pipe producer / supplier is to be considered for approval, the manufacturer's product will be listed on MoDOT's Pre-Accepted List (PAL) Polypropylene Pipe Field, Section 1041, Table 1, Prequalified Polypropylene Pipe Manufacturers, located at: www.modot.org/business/materials/pdf/main/TABLES.pdf
12/9/2013
1041-2
Polypropylene Culvert Pipe
1041.6 Storage and Handling. Polypropylene pipe are lightweight and easy to use. While no special care is needed in handling and installation, the contractor shall follow the following handling requirements: a) Follow all applicable safety regulations when handling pipe; b) The pipe shall not be dropped from the delivery truck into an open trench, or onto uneven surfaces; c) Avoid dragging or striking the pipe against another pipe or object; d) Avoid dragging the pipe across the ground; e) Do not drive over the pipe prior to installation; and f) Inspect the pipe and joining systems before installation. 1041.6.1 Stacking and Storage Height. Polypropylene drainage products are available palletized allowing for convenient transporting and orderly storage. If the products were not received on a pallet, the pipe should be carefully stacked. One method commonly used is to secure the bottom lengths of pipe together side-by-side, or use stop blocks, and then place additional pipe on top. Where pipe is stock piled, the total pile height shall not exceed 5 feet and the pipe must be adequately restrained to prevent pile collapse. Do not walk on stock piled pipe. 1041.6.2 Cold and Hot Weather Storage Protection. No significant handling or installation precautions required unless specified by the manufacturer. 1041.6.3 Protection from Ultraviolet Light. Ultraviolet (UV) Stabilizers shall be added to the polypropylene to protect against ultraviolet light. No additional protection is required unless specified by the manufacturer. 1041.7 Certification. A bill of lading or delivery receipt for each shipment of pipe shall be furnished to the engineer at the shipping and destination points. The bill of lading shall contain an itemized statement of the sizes and lengths of pipe for that shipment. The bill of lading shall contain a certified statement. The certified statement shall be signed by an authorized representative of the manufacturer and shall state the following: "This certifies that the pipe and bands in this shipment are in accordance with MoDOT specifications and were fabricated at an approved plant."
12/9/2013
1041-3
Polypropylene Culvert Pipe
(This Page Intentionally Left Blank)
12/9/2013
1041-4
Polypropylene Culvert Pipe
Section 1043
Fence Material
1043.1 Scope. These specifications cover the material required in the construction of chainlink fence and woven wire fence. 1043.2 Chain-Link Fence Material. Material used in the construction of fences and gates shall consist of chain-link fence fabric, posts, rails, ties, bands, bars, rods, tension wire and other fittings and hardware designed to support the fabric in a vertical, taut position. 1043.2.1 Zinc Coated Steel Fabric. Zinc coated steel fabric shall be in accordance with AASHTO M 181 Type 1, Class D, with the following exceptions. The weight of zinc coating shall be at least 2.0 ounces per square foot of uncoated wire surface, determined from the average of all specimens representing the lot and no less than 1.8 ounces per square foot on an individual specimen. Sections of fencing with excessive lumps, beads, and drops of zinc will be removed before determining weight of coating. 1043.2.2 Aluminum Coated Steel Fabric. Aluminum coated steel fabric shall be in accordance with AASHTO M 181 Type 2, with the following exceptions. An individual specimen shall have at least 0.30 ounce per square foot of uncoated wire surface on 0.148 inch or 0.192 inch specified diameter wire and no less than 0.25 ounce per square foot on 0.120 inch specified diameter wire. 1043.2.3 Vinyl Coated Steel Fabric. Vinyl coated steel fabric shall be in accordance with AASHTO M 181 Type IV, Class A or Class B. In addition to the referenced colors, brown will also be acceptable. 1043.2.4 Aluminum Alloy Fabric. AASHTO M 181 Type III.
Aluminum alloy fabric shall be in accordance with
1043.2.5 Posts, Braces, Rails and Gate Frames. These members shall be in accordance with AASHTO M 181 Grade 1 or Grade 2 of the shape and dimension shown on the plans. These members may be used with either Type I, Type II, Type III or Type IV fabric. 1043.2.5.1 Zinc Coated Steel Members. Zinc coated steel members shall be in accordance with ASTM F 1043, heavy industrial fence Group IA, with Type A interior and exterior coating, and the standard plans. 1043.2.5.2 Zinc Plus Organic Coated Steel Members. Zinc plus organic coated steel members shall be in accordance with ASTM F 1043, heavy industrial fence Group IC, with Type B or D interior coating and Type B exterior coating, and the standard plans. 1043.2.5.3 Aluminum Alloy Members. Aluminum alloy members shall be in accordance with ASTM F 1043, heavy industrial fence Group IB, and the standard plans.
1/31/2007
1043-1
Fence Material
1043.2.6 Tension Wire. Tension wire shall be in accordance with AASHTO M181 Type I, Class I. 1043.2.7 Fabric Fasteners. Fabric fasteners shall consist of wire ties, hog rings and Cclips. Fasteners for use with zinc or aluminum coated steel fabric shall be in accordance with Section 1043.2.8.1 or Section 1043.2.8.2; those for use with aluminum alloy fabric shall conform to Section 1043.2.8.2; and those for use with vinyl coated steel fabric shall conform to Section 1043.2.8.3. Fasteners shall be capable of withstanding a 180 degree bend over the fasteners own diameter without fracture of the wire or loss of adherence of coating. The wire shall have a finished or coated diameter of no less than 0.143 inch, except C-clips for attaching fabric to H section posts shall have a finished or coated diameter of no less than 0.187 inch. Aluminum alloy C-clips will not be permitted for fastening fabric to H section posts. 1043.2.7.1 Zinc or Aluminum Coated Fabric Fasteners. Wire shall be zinc coated at a rate of no less than 0.70 ounce per square foot or aluminum coated at a rate of no less than 0.30 ounce per square foot. 1043.2.7.2 Aluminum Alloy Fabric Fasteners. Wire shall be of aluminum alloy having a minimum tensile strength of 16,000 pounds per square inch. 1043.2.7.3 Vinyl Coated Fabric Fasteners. Wire may be of steel or aluminum alloy and shall be uniformly coated with the same vinyl material as used to coat the fence fabric. Vinyl coating thickness shall be a minimum of 0.010 inch. Aluminum alloy wire shall have a minimum tensile strength of 16,000 pounds per square inch. 1043.2.8 Miscellaneous Fittings and Hardware. Miscellaneous fittings and hardware shall be in accordance with AASHTO M 181. Aluminum alloy fittings shall not be used with zinc coated steel posts, rails, or gate frames. 1043.2.9 Gates. Frames shall be fastened at the corners by clamps and braces or by welding. If corners are to be welded, the ends of the vertical members shall be hemispherically notched to fit snugly to the horizontal members. The joint shall be uniformly and continuously fillet welded. The welded area and adjacent damaged coating shall be recoated by the hot-dip process or metallizing process; or covered with two coats of zincrich paint. The material for repair of welded areas and applications shall meet the approval of the Engineer. Each gate frame shall be cross braced with no less than two ⅜ inch adjustable truss rods. The filler for gates shall be chain-link fabric of the same kind used for the fence. This filler shall be attached to the frame with stretcher bars and wire ties or clamps. Gates 6 feet high or less shall be equipped with two hinges, and gates more than 6 feet high shall have three hinges. All gates, walk and drive, shall be equipped with a latch and locking attachment. Gatekeepers and center rests of an approved design shall be installed for double drive gates.
1/31/2007
1043-2
Fence Material
1043.2.10 Barbed Wire. Barbed wire for use with chain-link fence shall be zinc-coated steel, aluminum coated steel or aluminum alloy and shall be in accordance with AASHT0 M 280 with the following exceptions. Zinc coated barbed wire shall consist of two No. 12½, 13½ or 15½ gage line wires twisted with 4 point barbs uniformly spaced approximately 4 or 5 inches apart in accordance with and the minimum weight of coating shall be 0.80 ounce per square foot of uncoated wire surface for all gages. Aluminum coated barbed wire shall be in accordance with the requirements for zinc coated barbed wire, except that the coating shall be aluminum alloy. The weight of coating per square foot of surface shall not be less than 0.25 ounce for both line wires and barbs. However, barbs of suitable aluminum alloy will be permitted. Aluminum alloy barbed wire shall be aluminum alloy 5052-H38, ASTM B 211. Aluminum alloy barbed wire shall consist of two 0.110 inch line wires twisted with 4 point 0.080 inch diameter wire barbs spaced 5 inches apart. 1043.3 Woven Wire Fence Material. Woven wire fence shall be composed of woven wire, barbed wire, brace wire, posts, ties, fittings and hardware. 1043.3.1 Fabric. Fabric shall be made of zinc coated or aluminum coated steel wire. Zinc coated fabric shall be in accordance with AASHTO M 279, for Design Number 939-6-11, Grade 60 or 939-6-12.5, Grade 125. The minimum weight of zinc coating shall be Class 3 for all gages. Line wires shall have tension curves. Aluminum coated fabric shall be in accordance with the requirements for zinc coated fabric, except that the coating shall be aluminum alloy applied at the rate of no less than 0.25 ounce per square foot of uncoated wire surface. 1043.3.2 Barbed Wire. Barbed wire for use with zinc coated steel fabric or aluminum coated steel fabric shall be in accordance with Section 1043.2.9. 1043.3.3 Wood Posts. Wood posts and braces shall be in accordance with the requirements of Section 1050 1043.3.4 Steel Posts. Steel posts and braces shall be in accordance with Section 1043.2.5. Corner, end, and pull posts shall be pipe of the sizes and weights shown on the plans. Line posts shall be of the lengths and shapes shown on the plans. Posts shall have a nominal weight of 1.33 pounds per linear foot and a minimum weight of 1.28 pounds per linear foot, exclusive of anchor plate. 1043.3.5 Post Tops and Miscellaneous Hardware. Post tops and miscellaneous fittings and hardware shall be in accordance AASHTO M 181. 1043.3.6 Brace Wire. Brace wire shall be no less than 0.143 inch diameter and shall be of material in accordance with Section 1043.3.1. 1043.3.7 Staples. Staples shall be of the screw shank type or equivalent, a minimum of 1¼ inches long, galvanized and of good commercial quality. 1043.3.8 Wire Ties. Wire used for ties shall be in accordance with Section 1043.2.7, except that the wire may have a minimum diameter of 0.115 inch.
1/31/2007
1043-3
Fence Material
1043.3.9 Gates. Gates for woven wire fence shall be in accordance with Section 1043.2.9, except that the filler shall be woven wire fabric meeting these specifications. 1043.4 Workmanship and Finish. Fabrication of chain-link or woven wire fencing material furnished under these specifications shall be in accordance with the sizes, shapes, and dimensions shown on the plans. Excessive roughness, blisters, sal-ammoniac spots, bruises, flaking, voids in coating, frozen knuckles, or other defects, if present to any considerable extent, will be cause for rejection. Polyvinyl chloride coating shall be without voids and without tears, cracks, or cuts that reveal the substrate. Welded seam pipe shall have smooth welds without skips or gaps. Non-uniform or damaged organic topcoats will be cause for rejection whether caused by fabrication, shipping or handling on the job. All burrs at the ends of posts and rails shall be removed. 1043.5 Sampling and Testing. 1043.5.1 Sampling. Materials Manual
Sampling of materials shall be in accordance with the MoDOT
1043.5.2 Testing. When fencing material is tested, tests shall be in accordance with the following methods. 1043.5.2.1 Weight. Weight of hot-dip zinc coatings shall be determined in accordance with AASHTO T 65 or, at the option of the Engineer, material may be accepted on the basis of magnetic gauge determinations made in accordance with ASTM E 376. Weight of aluminum coating shall be determined in accordance with AASHTO T 213 or, at the option of the Engineer, material may be accepted on the basis of magnetic gauge determinations made in accordance with ASTM E 376. 1043.5.2.2 Thickness. Thickness of zinc-rich organic coating shall be determined by magnetic gauge determinations made in accordance with ASTM E 376. Thickness of organic topcoat shall be determined by first determining the total thickness of the organic topcoat and exterior hot-dip zinc coating by magnetic gauge determinations made in accordance with ASTM E 376, then chemically stripping the organic topcoat and determining the thickness of only the exterior hot-dip zinc in accordance with AASHTO T 65 or ASTM E 376. The difference between the two measurements shall be the thickness of the organic topcoat. 1043.5.2.3 Tensile Strength. Tensile strength or breaking load shall be in accordance with AASHTO T 68. 1043.6 Inspection. The Engineer shall have access at all times to all parts of the manufacturer's or fabricator's works that concern the manufacture or fabrication of material furnished under this specification. Each product or article furnished under this specification shall be subject to inspection at the factory, fabricating plant, in laboratories of the Engineer's choosing, or at the point of delivery. The Engineer reserves the right to sample and test each product or article subsequent to acceptance at the place of manufacture or fabrication to determine conformance with the requirements of this specification or to verify a certification.
1/31/2007
1043-4
Fence Material
1043.7 Certification. Certifications shall be required as follows. 1043.7.1 Vinyl Coated Material. The Contractor shall submit to the Engineer certification that the vinyl material and vinyl coated fabric meet the requirements of these specifications. If vinyl coated items other than chain-link fabric are furnished, a certification shall also be required. 1043.7.2 Aluminum Alloy Material. The Contractor shall submit to the Engineer certification that the material is in accordance with the requirements specified. The certificate shall include or have attached a list or description of typical physical properties representative of the material. 1043.7.3 Organic Top Coated Material. The Contractor shall submit to the Engineer certification that the material is in accordance with the requirements specified and that the material is the same as prequalified by the Engineer. 1043.8 Packaging and Marking. Packaging and marking of the material shall provide ease of handling, storage, and identification. 1043.8.1 Each length of chain-link fabric, woven wire fabric, or barbed wire shall be tightly rolled and firmly tied. Each roll shall carry a tag showing, as applicable to the product, the length, kind of base metal, type of coating, specified wire size, mesh size, design (style), height or width of fabric, and the producer name, brand or trademark of the manufacturer. 1043.9.8.2 Each bundle or container of posts, hardware, and fittings shall be marked with the name, brand, or trademark of the manufacturer, type of material (steel, cast iron, aluminum alloy number, etc.), type of coating and any additional data required for proper identification or to determine apparent conformance to specified quality requirements.
1/31/2007
1043-5
Fence Material
(This Page Intentionally Left Blank)
1/31/2007
1043-6
Fence Material
Section 1044
Posts for Markers and Delineators
1044.1 Scope. This specification covers galvanized steel and flexible posts used for mounting mile and object markers, delineators, drain and right of way markers and other similar purposes. 1044.2 Steel Posts. Posts shall be rerolled rail steel in accordance with the mechanical requirements of ASTM A 499, Grade 60 and to the chemical requirements of ASTM A 1. 1044.2.1 section.
Shape and Dimensions.
Posts shall be of a channel or modified channel
1044.2.1.1 Mile Marker Posts. Posts for mile markers, object markers, and delineators shall be of the dimensions and weights shown on the plans. 1044.2.2 Drainage and Right of Way Markers. Posts for drainage and right of way markers shall weigh no less than 1.80 lb./ft. or more than 2.25 lb./ft., all tolerances included, and shall be of the lengths shown on the plans. Permissible variations in length shall be a maximum of 1 inch under and 2 inches over that shown on the plans. Posts shall have no less than 5 drilled or punched ⅜ inch holes along the centerline of the web. Holes shall be on 2 inch centers, beginning 1 inch from the top of posts. Anchors or pointed ends on posts will not be required. 1044.2.3 Galvanizing. AASHTO M 111.
Posts shall be galvanized after fabrication in accordance with
1044.2.3.1 Samples and Inspection. If requested, two posts shall be furnished for testing purposes from such lots as the Engineer may determine. 1044.3 Flexible Delineator Posts. Flexible delineator posts shall be manufactured from new or recycled polymer, copolymer, or elastomers, which will enable the delineators to meet the requirements of this specification. Clean rework material generated from the manufacturers own production will be permitted. Posts shall be pigmented and stabilized against fading or deterioration by ultraviolet or other light rays by the incorporation of adequate inhibitors. Posts shall be white or yellow in color, and shall meet the requirements for testing described in this specification. Each post shall be marked with the manufacturer's identification and the month and year produced. The marking shall be permanently affixed on the face of the post, away from oncoming traffic with ¼ inch minimum height letters, and shall be visible after installation. Flexible delineator posts shall be a minimum of 3 inches in width at the major axis. The delineator post shall provide an area suitable for the application of retroreflective sheeting specified here. If caps are furnished as a part of the delineator posts, the caps shall be firmly fastened to the top of the delineator posts by adhesive. The flexible delineator posts shall be capable of attaching to an anchor, which will hold the post in a vertical position by a locking mechanism. The mechanism shall be such that when a post is no longer serviceable, the post can be removed and a new post inserted to the anchor and locked into place.
1/31/2007
1044-1
Posts for Markers and Delineators
1044.3.1 Anchors. Anchoring systems for flexible delineator posts may be one of the following classes: 1) Class A. A drivable, reusable metal anchor shall be a minimum of 18 inches long, onto which a post can be attached and held in place by a locking mechanism. 2) Class B. A metal anchor designed for embedment in either Portland cement or bituminous concrete into which a post can be inserted and held in place by a locking mechanism. 3) Class C. A surface mount held in place with a bonding epoxy and a locking device to secure the post. 1044.3.2 Testing Criteria. The testing criteria for flexible delineator posts will be in accordance with the AASHTO NTPEP, "Flexible Delineator Impact Testing" report. 1044.3.3 Flexible Delineator Impact Acceptance. A flexible delineator post will be accepted to the qualified list if a minimum of 5 of the 8 tested has not failed. A flexible delineator post will be considered failed if: 1) The flexible delineator post has torn loose. 2) The flexible delineator post has been pulled out of the ground. 3) The flexible delineator post has lost more than 10% of the post's exposed length. 4) The flexible delineator post is at an angle of greater than 45 degrees from a vertical position. 5) The flexible delineator post has less than 50% of the reflectorized sheeting remaining. 1044.3.4 Prismatic Retroreflective Sheeting. Retroreflective sheeting shall be in accordance with Section 1042, Type 5. The retroreflective sheeting shall provide 12 inch2 of reflective surface with a minimum width of 3 inches. 1044.3.5 Manufacturer and Brand Name Approval. To obtain manufacturer and brand name approval of flexible delineator posts, the manufacturer shall submit to Construction Division Manager, three complete posts, including anchoring system if any, test results from the NTPEP "Flexible Delineator Impact Testing" report for the properties specified in Section 1044.3 of this specification, and certification for the retroreflective sheeting. 1044.3.5.1 Report. The NTPEP "Flexible Delineator Impact Testing" report information shall include the name of the manufacturer, brand name of the post, date of manufacture or lot number tested, and post dimensions.
1/31/2007
1044-2
Posts for Markers and Delineators
1044.3.5.2 Retroreflective Sheeting. The post manufacturer shall submit the sheeting manufacturer's test results for the specified properties of the retroreflective sheeting that will be used in the fabrication of the reflectorized flexible delineator posts. The report for the retroreflective sheeting shall include the name of the manufacturer, brand name of the sheeting, color, and lot, run number or date of manufacture of the material tested. 1044.3.5.3 Qualified List. Upon review and acceptance of the test reports for the flexible post and the retroreflective sheeting, the manufacturer's brand name will be placed on a qualified list. 1044.3.5.4 Acceptance. Prior to installation of the posts, the manufacturer of the posts shall submit certification to the Engineer that the posts and retroreflective sheeting furnished are of the same composition as originally qualified for manufacturer and brand name approval and in no way has been altered or changed. Final acceptance will be based on brand name, satisfactory manufacturer's certification and any sampling or testing deemed necessary by the Engineer.
1/31/2007
1044-3
Posts for Markers and Delineators
(This Page Intentionally Left Blank)
1/31/2007
1044-4
Posts for Markers and Delineators
Section 1045
Paint for Structural Steel
1045.1 Paint and Paint Material. 1045.1.1 General. All single component paints shall be ready-mixed at the factory to comply with the specification formula for the type of paint ordered; shall be well ground to a uniform consistency and smooth texture; shall be free from dirt, water and other foreign matter; shall be of such consistency to have good application, covering and leveling properties; and shall dry within the specified period to a good film without running, streaking or sagging. 1045.1.1.1 Any paint which that has livered or hardened or thickened to any extent in the container, or in which the pigment has settled such that the paint cannot be readily broken up with a paddle to a smooth uniform paint of good application consistency, will be rejected. 1045.1.1.2 All percentages and proportions shall be on a weight basis unless otherwise stated. 1045.1.1.3 All Volatile Organic Content (VOC) content requirements specified shall be a maximum when thinned for application. 1045.1.2 Sampling. Each batch or lot of paint shall be sampled and approved prior to use. Each batch or lot of each component of multiple-component paints shall be sampled and approved prior to use. 1045.1.3 Packaging. The lining of the containers shall not react with the paint. All components shall bear a label on which shall be clearly shown the name of the manufacturer, the kind of paint, the lot number, shelf life, date of manufacture and net weight of contents. The lot number and date of manufacture shall be stamped, stenciled, or painted directly onto the container using a weatherproof, durable material. 1045.1.4 Determination of Quantities. Quantities of paint shall be determined by volume. One gallon shall equal 231 inches3 at 77°F. 1045.2 High Solids Inorganic Zinc Silicate Coating. 1045.2.1 Description. High solids inorganic zinc coating shall be a solvent base multiple component material which, when mixed and applied in accordance with the requirements of Section 712, cures without the use of a separate curing solution. High solids inorganic zinc coating shall be in accordance with AASHTO M 300, Type IA. The volatile organic compounds (VOC) content shall not exceed 3.50 lb./gallon. If thinning is necessary for application, the maximum VOC content after thinning shall not exceed 3.50 lb./gallon.
1/31/2007
1045-1
Paint for Structural Steel
1045.2.2 Manufacturer and Brand Name Approval. Prior to approval and use of high solids inorganic zinc, the manufacturer shall submit to the Construction Division Manager a certified test report from an approved independent testing laboratory showing specific test results conforming to all quantitative and resistance test requirements of these specifications. The certified test report shall also contain the exact ratio by weight of each component of the coating used for the tests, the lot tested, the manufacturer's name, brand name of coating, and date of manufacture. Upon approval by the Engineer of this certified test report, further resistance tests will not be required, except as hereinafter noted, of that manufacturer for that brand name of coating. New certified test results shall be submitted any time the manufacturing process or the coating formulation is changed, and may be required by the Engineer when sampling and testing of material offered for use indicates nonconformance to any of the requirements herein specified. All resistance testing shall be performed on duplicate sets of test panels, and upon completion of the prescribed exposure testing, the manufacturer shall submit one set of the exposed panels to Construction Division Manager. 1045.2.3 Alternate Approval. If approved by Construction and Materials, compliance with all specified requirements for the system under the NTPEP or Northeast Protective Coating Committee (NEPCOAT), in addition to the physical property requirements of this specification, may be substituted for the manufacturer and brand name approval requirements of Section 1045.2.2. The manufacturer shall provide documentation identifying specific products evaluated, along with manufacturer's code numbers and/or report code numbers. 1045.3 High Solids Epoxy System G Intermediate Coating. 1045.3.1 Description. The coating shall be a multiple-component, modified epoxy primer with an amine/amide type curing system compatible as an intermediate coat over inorganic zinc primer and suitable for topcoating with polyurethane. 1045.3.2 Mixed Coating. The color shall be gray (Federal Standard 595b No. 26373) or brown (Federal Standard 595b No. 30045) unless otherwise specified. The color of the intermediate coat shall match the color of the finish coat, unless otherwise approved by the engineer. The physical properties of the mixed paint shall be as follows: High Solids Epoxy System G Intermediate Coating Item
Requirement
Viscosity, Krebs-Stormer, 77°F, KU
80-130
VOC Content, maximum, lb./gallon
3.50
Fineness of Grind, Hegeman Gage, minimum
4
Sag Resistance, Leneta Anti-Sag Meter, mils wet, minimum
8
Dry to Touch, hours, maximum
3
Dry to Handle, hours, maximum
6
1/31/2007
1045-2
Paint for Structural Steel
1045.3.3 Packaging and Labeling. Packaging and labeling shall be in accordance with Section 1045.1.3. 1045.3.4 Manufacturer and Brand Name Approval. Prior to approval and use of the specified coating system, the manufacturer shall submit to the Construction Division Manager, a one-gallon sample of the coating proposed. The manufacturer shall also submit a certified test report from an approved independent testing laboratory showing specific test results obtained on the specified coating system for Relative Humidity Resistance ASTM D 1735 or D 2247, 3000 hours, Salt Fog Resistance ASTM B 117, 3000 hours and Accelerated Weathering ASTM G 153 Cycle 1, Type EH (Carbon Arc), 4000 hours. ASTM G 155, Cycle 2, Xenon Arc, or G 154 Cycle 2 QUV (Fluorescent UV-Condensation Type using Type A lamps) may be used as an alternate to Carbon Arc. 1045.3.4.1 All coats of the system to be tested shall be applied to steel test panels which have been prepared according to AASHTO M 300. Each coat of the system shall be from the same manufacturer. Test panels for salt fog exposure shall be scribed as described in ASTM D 1654 and, when rated according to ASTM D 1654, each panel must receive a rating of 7 or greater. Test panels shall not exhibit more than slight rusting, undercutting, discoloration, fading, blistering, chalking, loss of gloss or change in color. Accelerated weathering resistance testing shall be performed on test panels that have received finish coats in the specified colors for which approval is being requested. After 4000 hours testing for accelerated weathering resistance, each color of the finish coat shall show a difference in color of no greater than 3 ∆E, when compared to the control panel. Color change measurements shall be made in accordance with Section 6.2 CIE 1976 L*a*b* of ASTM D 2244. All resistance testing shall be performed on duplicate sets of test panels, and upon completion of the prescribed exposure testing, the manufacturer shall submit one set of the exposed panels to the Construction Division Manager. 1045.3.4.2 The manufacturer shall also provide documentation that the specified coating system has performed satisfactorily for three years. The document shall include the name, address and telephone number of the proprietary agency and location of the structures. Upon approval of the coating by the Engineer, further submittals for preliminary approval will not be required of that manufacturer for that brand name of coating, except as hereinafter noted. A new sample shall be submitted any time the manufacturing process or the batching proportions are changed. The Engineer may withdraw manufacturer and brand name approval when sampling and testing of material offered for use indicates nonconformance to any of the requirements herein specified. All data submitted for preliminary approval will be considered confidential to County. 1045.3.5 Alternate Approval. If approved by Construction Division Manager, compliance with all specified requirements for the system under NTPEP or the NEPCOAT, in addition to the physical property requirements of this specification, may be substituted for the manufacturer and brand name approval requirements of Section 1045.3.4. If approval is requested under NEPCOAT or NTPEP, the accelerated weathering requirements stated in Section 1045.3.4 shall apply. The manufacturer shall provide documentation identifying specific products evaluated, along with manufacturer’s code numbers and/or report code numbers.
1/31/2007
1045-3
Paint for Structural Steel
1045.4 Polyurethane System G Finish Coating. 1045.4.1 Description. The coating shall be a multiple-component, aliphatic acrylic polyurethane suitable for use over Section 1045.3, High Solids Epoxy Intermediate Coating. The coating shall cure to a semi-gloss to high gloss, abrasion resistant surface and shall provide an easily cleanable finish. 1045.4.2 Mixed Coating. The mixed coating properties shall be as follows: Polyurethane System G Finish Coating Item
Requirement Gray 26373
Color, Federal Standard 595b
Brown 30045
Viscosity, Krebs-Stormer, 77°F, KU
65-96
VOC Content, lb./gallon, maximum
3.50
Fineness of Grind, Hegeman Gage, minimum
6
Sag Resistance, Leneta Anti-Sag Meter, mils wet, minimum
8
Dry to Touch, hours, maximum
4
Dry to Handle, hours, maximum
8
1045.4.3 Packaging and Labeling. Packaging and labeling shall be in accordance with Section 1045.1.3. 1045.4.4 Manufacturer and Brand Name Approval. Manufacturer and brand name approval shall be in accordance with Section 1045.3.4 or Section 1045.3.6. If approval is requested under Section 1046.6.6, the accelerated weathering requirements stated in Section 1045.3.4 shall apply. The manufacturer shall provide documentation identifying specific products evaluated, along with manufacturers code numbers and/or report code numbers. 1045.5 Waterborne Acrylic System H Intermediate and Finish Coating. 1045.5.1 Description. The intermediate coating shall be a single component waterborne acrylic compatible as a coating over high solids inorganic zinc primers. The finish coating shall be a single component waterborne acrylic suitable for use over a waterborne acrylic intermediate coating. The coating shall cure to a tough, abrasion resistant surface that performs well in weathering exposures. The gray finish coat shall cure to a semi-gloss finish, and the brown finish coat shall cure to a low-gloss finish.
1/31/2007
1045-4
Paint for Structural Steel
1045.5.2 Mixed Coating. The color of the intermediate coat shall be gray (Federal Standard 595b No. 26373) or brown (Federal Standard 595b No. 30045) unless otherwise specified. The color of the intermediate coat will normally be required to match the color of the finish coat. The mixed coating properties shall be as follows: Waterborne Acrylic System H Intermediate and Finish Coating Item
Requirement Gray 26373
Color, Finish Coat, Federal Standard 595b
Brown 30045
Viscosity, Krebs-Stormer, 77°F, KU
80-100
VOC Content, lb./gallon, maximum
3.50
Fineness of Grind, Hegeman Gage, minimum
7
Sag Resistance, Leneta Anti-Sag Meter, mils wet, minimum
8
Dry to Handle, hours, maximum
2
1045.5.3 Packaging and Labeling. Packaging and labeling shall be in accordance with Section 1045.1.3. 1045.5.4 Manufacturer and Brand Name Approval. Prior to approval and use of waterborne acrylic intermediate and finish coats, the manufacturer shall obtain manufacturer and brand name approval in accordance with Section 1045.3.4 or Section 1045.3.6 except that, after the 4,000 hour testing for accelerated weathering resistance, the Federal Standard 595b 30045 (brown) color of the finish coat shall show a difference in color of no greater than 4 ∆E when compared to the control panel. If approval is requested under Section 1046.6.6, the accelerated weathering requirements stated in Section 1045.3.4 shall apply. The manufacturer shall provide documentation identifying specific products evaluated, along with manufacturer's code numbers and/or report code numbers. 1045.6 Aluminum Epoxy-Mastic Primer. 1045.6.1 Description. The coating shall be a one-coat system aluminum epoxy-mastic primer designed for adhesion to rusty steel, aged galvanized steel and other uses. Aluminum epoxy-mastic primer will not be allowed for use in contact with fresh concrete. The epoxy-mastic shall be a two-component, modified epoxy-primer containing metallicaluminum flake. 1045.6.2 Pigment. The primary pigment shall be metallic-aluminum. 1045.6.3 Vehicle. The vehicle shall be an epoxy-type. The curing agent shall have suitable insensitivity to moisture to allow trouble-free application.
1/31/2007
1045-5
Paint for Structural Steel
1045.6.4 Mixed Coating. 1045.6.4.1 The coating shall be well-ground, not caked, skinned, or badly settled in the container. The mixed coating, when applied in one coat, shall be capable of achieving 5 mils dry film thickness without runs or sags. 1045.6.4.2 The mixed coating properties shall be as follows: Aluminum Epoxy-Mastic Primer Item
Requirement
Dry to touch, hours, maximum
24
Dry hard, days, maximum
5a
VOC Content, lb./gallon, maximum
3.50
a
When air-cured at a temperature of 75°F or above to a hard, tough film by evaporation of solvent and chemical reaction.
1045.6.5 Resistance Tests. Test panels of steel in accordance with ASTM D 609 and having dimensions of 2 inches x 5 inches x ⅛ inch shall be prepared by sandblasting all surfaces to a white metal condition in accordance with Structural Steel Painting Council SP5 (SSPC-SP5-82). The cleaned panels shall then be exposed to outdoor weather for thirty days or until uniform rusting occurs. The panel shall then be hand cleaned with a wire brush in accordance with SSPC-SP2-82. A 6 mil dry coating of the epoxy-mastic shall then be applied in one coat in accordance with the manufacturer's current printed instructions. The coating shall be cured as recommended by the manufacturer. Fresh Water, Salt Water, and Weathering and Salt Fog resistance tests as detailed herein shall be performed on one or more test panels. The material will not be approved if any individual test panel fails any of the resistance tests specified herein. 1045.6.5.1 Fresh Water Resistance. Panels shall be scribed down to base metal with an "X" of at least 2 inch legs, and shall be immersed in fresh tap water at 75°F ± 5°F. The panels shall show no rusting, blistering or softening beyond 1⁄16 inch from the scribe mark, when examined after thirty days. Discoloration of the coating will be allowed. 1045.6.5.2 Salt Water Resistance. Panels shall be scribed down to base metal with an "X" of at least 2 inch legs, and immersed in 5% sodium chloride at 75°F ± 5°F. The panels shall show no rusting, blistering or softening beyond 1⁄16 inch from the scribe mark upon examination after 7, 14, and 30 days. Discoloration of the coating will be allowed. The sodium chloride solution shall be replaced with fresh solution after each examination.
1/31/2007
1045-6
Paint for Structural Steel
1045.6.5.3 Weathering and Salt Fog Resistance. Panels shall be tested in the weatherometer in accordance with ASTM G 154 QUV (Fluorescent UV-Condensation Tape using Type A Lamps) for 300 hours using a test cycle consisting of 4 hours light followed by 4 hours condensation. After this period, the panels shall be removed and scribed with an "X" of at least 2 inch legs down to base metal. The test panels shall then be tested in accordance with ASTM B 117. After 1,000 hours of continuous exposure, the coating shall show no loss of bond, nor shall the coating show rusting or blistering beyond 1⁄16 inch from the center of the scribe mark. 1045.6.6 Packaging and Labeling. Packaging and labeling shall be labeled in accordance with Section 1045.1.3. 1045.6.7 Approval and Prequalification. 1045.6.7.1 Manufacturer and Brand Name Approval. Prior to approval and use of the epoxy-mastic primer, the manufacturer shall submit to Construction and Materials a one-gallon sample of the coating and a certified test report from an approved independent testing laboratory showing specific test results conforming to all quantitative and resistance test requirements of these specifications. The certified test report shall contain the exact ratio, by weight, of the pigment component to the vehicle component of the epoxy-mastic used for the tests, the lot tested, the manufacturer's name, brand name of the epoxy-mastic, and date of manufacture. In addition, the manufacturer shall submit a complete set of tested panels which have undergone each required resistance test. The set of panels submitted shall include one untested control panel that has been prepared according to Section 1045.6.5. Upon approval by Construction Division Manager of this certified test report, further resistance tests will not be required, except as noted, of that manufacturer for that brand name of epoxy-mastic primer. New certified test results shall be submitted any time the manufacturing process or the epoxymastic formulation is changed, and may be required by the Engineer when sampling and testing of material offered for use indicates nonconformance to any of the requirements specified herein. 1045.6.7.2 Final Acceptance. Final acceptance of the epoxy-mastic primer will be based on a manufacturer's certification submitted by the Contractor to the Engineer and upon results of tests made on samples of the material. Each lot of each component will be sampled and tested prior to approval or use of the material. 1045.7 Gray Epoxy-Mastic Primer. 1045.7.1 Description. This specification covers a one-coat gray epoxy-mastic primer system designed for adhesion to rusty steel, aged galvanized steel and other uses, including uses in contact with freshly poured Portland cement concrete. The epoxy-mastic shall be a multiple-component modified epoxy containing gray pigmentation and shall be in accordance with the requirements specified herein.
1/31/2007
1045-7
Paint for Structural Steel
1045.7.2 Pigment. The pigmentation shall be any pigment or combination of pigments formulated to offer the intended protective properties to the cured coating and shall be totally non-reactive to the constituents contained in both cured and uncured Portland cement concrete. 1045.7.3 Vehicle. The vehicle shall be an epoxy type. The curing agent shall have suitable insensitivity to moisture to allow trouble-free application. 1045.7.4 Mixed Coating. 1045.7.4.1 The provisions of Section 1045.6.4.1 shall apply. 1045.7.4.2 The mixed coating properties shall be as follows: Gray Epoxy-Mastic Primer Item
Requirement
Color, Federal Standard 595b
Gray 26373
Viscosity, (Krebs-Stormer, 25 C) KU
90 - 120
Volatile Organic Content, lb./gallon, maximum
3.50
Dry to touch, hours, maximum
24
Dry hard, days, maximum
7a
a
When air-cured at a temperature of 75°F or above to a hard, tough film by evaporation of solvent and chemical reaction.
1045.7.5 Resistance Tests. Test requirements and approval criteria shall be in accordance with Section 1045.6.5. 1045.7.6 Packaging and Labeling. Packaging and labeling shall be in accordance with Section 1045.61.3. 1045.7.7 Approval and Prequalification. 1045.7.7.1 Manufacturer and Brand Name Approval. Manufacturer and brand name approval shall be in accordance with Section 1045.6.7.1. 1045.7.7.2 Final Acceptance. Final acceptance will be in accordance with Section 1045.6.7.2.
1/31/2007
1045-8
Paint for Structural Steel
1045.8 Calcium Sulfonate System. 1045.8.1 Description. This specification covers calcium sulfonate sealer, calcium sulfonate primer and various colors of calcium sulfonate topcoat paints for steel. The color of topcoat will be specified in the contract and shall be in accordance with all requirements specified herein. 1045.8.1.1 The primary resin used to manufacture each coat of the calcium sulfonate system shall be a modified overbased crystalline calcium sulfonate that creates a highly polar complex capable of protecting the underlying steel from corrosion. In addition to the calcium sulfonate complex, the paint shall contain film forming oleoresinous compounds that act to reduce tack in the dry film. 1045.8.1.2 The coating material shall be uniform, stable in storage, and free from grit and coarse particles. 1045.8.2 Calcium Sulfonate Rust Penetrating Sealer. 1045.8.2.1 General. The sealer, after allowing a minimum drying time, may be recoated with an approved primer or topcoat. The sealer will be suitable for any steel structure which has developed pack rusting in overlapping steel plates, joints or at bolted areas. This coating shall be used on in-place structures as part of a long-term maintenance program, and as such shall be applied in accordance with SSPC-PA1 "Shop, Field, and Maintenance Painting". 1045.8.2.2 Properties. The mixed coating properties shall be as follows: Calcium Sulfonate Rust Penetrating Sealer Physical Property
Requirement
Color
red iron oxide
Modified Crystalline Overbased Calcium Sulfonate, percent by weight, minimum
15
Coarse Particles and Skins as retained on No. 325 mesh sieve, percent, maximum
1.0
Viscosity, #4 Ford Cup, Seconds
50 - 70
VOC Content, lbs./gallon, maximum
3.5
Drying Time, hours to recoat
2-6
Flash Point, °F, maximum
104
Salt Fog Resistance, 500 hours (Coating applied at 1-2 mils dry film over SSPC-SP5 cold rolled steel)
1/31/2007
1045-9
No more than 1% rust undercutting, blistering or peeling.
Paint for Structural Steel
1045.8.3 Calcium Sulfonate/Alkyd Primer. 1045.8.3.1 General. This primer will be used in non-abrasion exposures to provide a firm, corrosion resistant, highly adherent film. This primer may be used for in-place structures but shall not be used as a shop-applied primer. 1045.8.3.2 Properties. The mixed coating properties shall be as follows: Calcium Sulfonate/Alkyd Primer Physical Property
Requirement
Color
red iron oxide
Modified Crystalline Overbased Calcium Sulfonate, percent by weight, minimum Coarse Particles and Skins as retained on No. 325 mesh sieve, percent, maximum
15 1.0 90 – 120
Viscosity, 77°F, KU VOC Content, lbs./gallon, maximum
3.50
Fineness of Grind, Hegman Units, minimum
5
Drying Time, Hours (3 to 4 Mil Dry Film): Dust Dry
1–4
Tack Free
5 – 12
Dry Firm
24 – 48
Sag Resistance, Mils
12+
Salt Spray Resistance, 1500 hours (4 mil) dry film over SSP-SP-5 blasted cold rolled steel - 1 to 2 mil profile
1/31/2007
1045-10
No more than 1% under-cutting, blistering or peeling.
Paint for Structural Steel
1045.8.4 Calcium Sulfonate/Alkyd Topcoat. 1045.8.4.1 General. Calcium sulfonate/alkyd topcoat shall be a medium to light gray, brown, green, or tan low gloss coating as specified in the contract for use over calcium sulfonate/alkyd penetrating sealer or calcium sulfonate/alkyd primer. This paint will be used as a topcoat for a calcium sulfonate/alkyd corrosion inhibitive primer, and shall be applied in accordance with SSPC-PA 1 "Shop, Field, and Maintenance Painting". The topcoat may be used for in-place structures and shall not be used as a shop-applied finish. 1045.8.4.2 Properties. The mixed coating properties shall be as follows: Calcium Sulfonate/Alkyd Topcoat Item
Requirement
Color, Federal Standard 595b Modified Crystalline Overbased Calcium Sulfonate, per cent by weight, min. Coarse Particles and Skins as retained on No. 325 (45 µm) mesh sieve, percent, maximum
Brown
Gray
Tan
Green
30045
26373
23522
24260
15 1.0 90-130
Viscosity, 77°F, KU Fineness of Grind, Hegman Units, min.
5
Drying Time, 2-3 mils, hours: Dust Dry
1-4
Tack Free
5 - 12
Dry Firm
24 – 48
VOC Content, lbs./gallon, maximum
3.5
Sag Resistance, Mils
12+
QUV Weathering Resistance, 1000 hrs. (4 mil dry film over SSP-SP-5 blasted cold rolled steel - 1-2 mil profile Salt Spray Resistance, 1000 hrs. (4 mil) dry film over SSP-SP-5 blasted cold rolled steel – 1-2 mil profile
1/31/2007
1045-11
No excessive chalking, blistering, or change in color. No more than 1% rust under-cutting, blistering or peeling.
Paint for Structural Steel
1045.8.5 Test Methods. The test methods used to verify compliance with the properties specified in Sections 1045.8.2, 1045.8.3 and 1045.8.4 shall be as follows: American Standards for Testing and Materials (ASTM) G154
Practice for Operating Light- and Water-Exposure Apparatus
B117
Salt Spray (Fog) Testing
D562
Consistency of Paints Using the Stormer Viscometer
D1200
Viscosity of Paints, Varnishes and Lacquers by Ford Viscosity Cup
D1210
Fineness of Dispersion of Pigment-Vehicle Systems
D1475
Density of Paint, Varnish, Lacquer and Related Products
D3278
Flash Point of Liquids by Seta Flash Closed Tester
D3960
VOC Content of Paints
Federal Test Method Standard No. 141 Method 4061
Drying Time
Method 4494
Sag Test (multi-notch blade)
1045.8.6 Pigment Settlement. The paint shall have perfect suspension (10 rating) when tested as specified in ASTM D 869, when stored for six months. 1045.8.7 Working Properties. The paint shall be uniform and easily spray-applied when tested in accordance with Federal Standard No.141, Method 4331. The primer and topcoat shall show no streaking, running or sagging after drying. 1045.8.8 Storage. The paint shall show no thickening, curdling, gelling or hard caking when tested as specified in Federal Standard No.141, Method 3011 after storage for six months from date of delivery in tightly covered containers at a temperature of no less than 50°F or no more than 110°F. 1045.8.9 Packaging and Labeling. Packaging and labeling shall be in accordance with Section 1045.1.3.
1/31/2007
1045-12
Paint for Structural Steel
1045.8.10 Approval and Prequalification. 1045.8.10.1 Manufacturer and Brand Name Approval. Prior to approval and use of the calcium sulfonate coating system, the manufacturer shall submit to Construction and Materials a one-gallon sample of each coat of the coating system proposed. The manufacturer shall also submit a certified test report from an approved independent laboratory showing specific test results as follows: 1) Calcium Sulfonate Penetrating Sealer. Salt spray resistance of steel panels prepared and tested as specified in Section 1045.8.2.2. 2) Calcium Sulfonate Primer. Salt spray resistance of steel panels prepared and tested as specified in Section 1045.8.3.2. 3) Calcium Sulfonate Topcoat. Salt spray resistance and QUV weathering resistance as specified in Section 1045.8.4.2. 1045.8.10.2 Final Acceptance. Final acceptance of calcium sulfonate penetrating sealer, calcium sulfonate primer, and calcium sulfonate topcoat will be based on the manufacturer’s certification submitted by the Contractor to the Engineer, and upon results of tests conducted on samples of the material. Each lot will be sampled and tested prior to approval and use.
1/31/2007
1045-13
Paint for Structural Steel
(This Page Intentionally Left Blank)
1/31/2007
1045-14
Paint for Structural Steel
Section 1047
Corrugated Polyethylene Culvert Pipe
1047.1 Scope. This specification covers corrugated polyethylene culvert pipe used for the construction of culverts and other uses specified in the contract documents. 1047.2 Basis of Acceptance. Acceptance of polyethylene culvert pipe will be based upon the pipe being provided by a qualified manufacturer, certification, manufacturer quality control documentation, identification markings, and tests on samples of the material as required by the Engineer. 1047.3 Material. Corrugated polyethylene culvert pipe, couplings, and fittings shall be in accordance with AASHTO M 294, Type S pipe. In case of conflict with AASHTO M 294, these specifications shall govern. 1047.3.1 The pipe shall not be perforated unless specified otherwise. 1047.3.2 Field joints shall provide circumferential and longitudinal strength to maintain the pipe alignment, prevent separation of pipe, and prevent infiltration of fill material. Coupling bands, if used, shall be of the same base material as the pipe. Corrugations in the bands shall have the same configuration as the corrugations in the pipe ends being connected. Prior to use, the design of coupling bands and fastening devices shall be submitted to and approved by Construction Division Manager. Final acceptance of coupling bands and fastening devices will be based on field performance. 1047.3.3 The manufacturer shall provide to the Engineer an itemized statement of the sizes and lengths of pipe in each shipment. 1047.3.4 Each individual section of pipe shall be marked in accordance with AASHTO M 294 and shall have the Plastic Pipe Institute (PPI) seal affixed. 1047.4 Sampling, Testing and Acceptance Procedures. All manufacturers furnishing pipe to Saint Louis County projects shall be qualified as described herein. All pipe shall be subject to inspection by the Engineer at the source of manufacture, at an intermediate shipping terminal or at destination. The Engineer shall be allowed free access to all facilities and records as required to conduct inspection and sampling in accordance with Section 106. 1047.4.1 Application for Placement on Qualified List. To become qualified, a written request shall be sent by the manufacturer to Construction Division Manager, including the following: 1) A copy of the manufacturer's PPI certification. 2) A pipe manufacturer’s certified analysis certificate setting forth the name or brand of pipe to be furnished, the specified type, category, grade, and class of polyethylene compounds. The certificate shall be sworn for the manufacturer by a person having legal authority to bind the company. The certificate shall have attached a certified test report from an approved independent testing laboratory showing specific results of tests performed on each diameter pipe to be furnished, conforming to all requirements of these specifications. Pipes shall be randomly selected for test by
1/31/2007
1047-1
Corrugated Polyethylene Culvert Pipe
the independent testing laboratory and shall be representative of that manufacturer's pipe. 3) A guarantee that all pipe furnished shall be in accordance with the specification requirements, shall bear a suitable identification brand or mark, and shall be replaced without cost to the County when not in accordance with the specified requirements. The guarantee shall be worded as to remain in effect as long as the manufacturer continues to furnish material. The manufacturer shall conduct tests and measurements as necessary to ensure that the material produced complies with all specification requirements. These tests and measurements shall be identified by the identification symbols or code used on the pipe in a manner which will permit the manufacturer to produce specific reports showing test results representative of specific lots of polyethylene pipe. Copies of reports of these tests shall be kept on file and shall be submitted to the engineer upon request. The brand shall be removed or obliterated by the manufacturer on all material where control tests, as outlined herein, are not in accordance with this specification. 1047.4.2 Maintaining Qualification. To maintain qualification, the manufacturer shall perform and maintain a quality control program in accordance with the PPI Certification Program. The manufacturer's PPI certification shall be maintained. The bill of lading for each shipment of material used in the production of pipe shall be kept on file for one year. 1047.4.3 Disqualification of a Manufacturer. A manufacturer may be disqualified to provide pipe for use on St. Louis County projects based on the discretion of the Construction Division Manager, for reasons including, but not limited to, not maintaining PPI certification, failure of material to consistently meet specifications, falsification of any documentation, misbranding of pipe, unsatisfactory performance in the field or for other reasons indicating lack of consistent material quality. 1047.4.3.1 In a case where a manufacturer loses PPI certification and was not disqualified for any other reason, reinstatement will be considered when the manufacturer is recertified by PPI. 1047.4.3.2 A manufacturer will not be considered for reinstatement until after one year from the date of removal for falsification of documents. 1047.4.3.3 Three notices of failure to meet specification requirements will cause disqualification of the manufacturer for one year, effective from the date of the third notice. 1047.4.3.4 A manufacturer disqualified within one year of the end of a disqualification may be subject to permanent removal, with no application to be reinstated for a period of three years. 1047.4.4 Reinstatement of a Manufacturer. Consideration of reinstatement of a manufacturer once disqualified will be no sooner than specified in Section 1047.4.3, will require a written document from the manufacturer stating the reasons for disqualification and the action taken to correct those deficiencies, written concurrence from Construction Division Manager that the problem has been suitably addressed, followed by a new application in accordance with Section 1047.4.1.
1/31/2007
1047-2
Corrugated Polyethylene Culvert Pipe
1047.4.5 Sampling of Material. Random sampling of the pipe will be conducted by the Engineer to verify pipe and material is in accordance with Section 1047. Samples of polyethylene pipe will be obtained from fabricated culvert sections in accordance with AASHTO M 294 at a frequency determined by the Engineer. 1047.4.6 Inspection. Inspection will include an examination of the pipe for markings, deficiency in specified diameter, net length of fabricated pipe, and evidence of poor workmanship. The inspection may include taking samples. 1047.4.7 Testing. Specimen testing size and method of tests shall be in accordance with AASHTO M 294. The contractor or manufacturer shall provide the equipment and personnel to cut a sample from a section of pipe. The sample shall include the markings or a record of the markings for that section of pipe. 1047.4.8 Rejection. 1047.4.8.1 Any individual section of pipe failing to meet the marking, diameter, length, or workmanship requirements of these specifications will be rejected. If 10% of the pipe in any lot fails to meet these requirements, the entire shipment of that pipe diameter may be rejected. 1047.4.8.2 If a test specimen taken in accordance with Section 1047.4.7 fails to be in accordance with AASHTO M 294, the pipe sampled will be rejected and the lot will be resampled. A resample will be from the same diameter of pipe as the original sample. The resample shall be in accordance to these specifications or the entire shipment will be rejected.
1/31/2007
1047-3
Corrugated Polyethylene Culvert Pipe
(This Page Intentionally Left Blank)
1/31/2007
1047-4
Corrugated Polyethylene Culvert Pipe
Section 1048
Pavement Marking Material
1048.1 Scope. This specification covers Type 1 preformed pavement marking tape, extruded thermoplastic pavement marking, preformed removable pavement marking tape, preformed short term pavement marking tape, drop-on glass beads, temporary raised pavement markers, hot spray thermoplastic pavement marking, snowplowable raised pavement markers, epoxy pavement marking paint, acrylic copolymer fast dry pavement marking paint and acrylic waterborne pavement marking paint. 1048.1.1 Certification and Acceptance. All material contained in Section 1048 shall meet the following requirements. 1048.1.1.1 To obtain approval of the material, the manufacturer shall submit material and application specifications, samples of the material, and a history of satisfactory use to Construction Division Manager for testing and evaluation. The sample quantity submitted shall be at the discretion of Construction Division Manager. The approval process shall not be initiated prior to obtaining concurrence of Construction Division Manager. Following the testing and evaluation, satisfactory material will be placed on a qualified list. 1048.1.1.2 For acceptance on a project, the contractor shall furnish to the Engineer a manufacturer's certification stating the manufacturer and trade name, lot or batch number, and that all material furnished is similar to the material originally qualified. Acceptance of the material will be based on the manufacturer's certification, the results of such tests that may be performed by the Engineer and satisfactory performance in the field. 1048.1.1.3 The material may be inspected and sampled at the point of manufacture, at an intermediate shipping terminal or at destination. The Engineer shall be allowed access to all facilities and records as required to conduct inspection and sampling. The Contractor shall adequately mix the contents of all shipping containers prior to obtaining samples or transferring partial containers of material to tanks on the striping equipment. 1048.2 Preformed Pavement Marking Tape. 1048.2.1 Type 1 Preformed Pavement Marking Tape. 1048.2.1.1 Application. On bituminous surfaces, Type 1 preformed pavement marking tape shall be capable of being installed onto wearing surfaces during the final roller operation. Application on concrete surfaces shall be in accordance with the manufacturer’s application instructions. After application, the tape shall be immediately ready to receive traffic. 1048.2.1.2 Composition. The tape shall consist of a mixture of polymeric material, pigments and glass beads distributed throughout the cross-sectional area with a reflective layer of glass beads embedded in the top surface. The tape shall be sufficiently flexible so as to conform to the roadway without cracking or breaking.
11/1/2016
1048-1
Pavement Marking Material
1048.2.1.3 Dimensions. The tape, without adhesive, shall have a minimum thickness of 60 mils. A patterned surface will be allowable but shall have a minimum thickness of 60 mils over at least 50 percent of the tape’s surface. The edges of the tape shall not be tapered. 1048.2.1.4 Adhesive. The tape shall be supplied with a precoated factory-applied adhesive for immediate application to bituminous pavement without the use of heat, solvent or other adhesive operations. The tape and adhesive shall be of a type that water used on the compaction roller will not be detrimental to successful application. On concrete surfaces, application shall be in accordance with the manufacturer’s instructions. 1048.2.1.5 Reflectance. The tape shall have a minimum specific luminance as shown in the table below, expressed as millicandelas per footcandle per square foot. The tape shall be applied to an 8 inch x 36 inch panel in a longitudinal orientation and measured in accordance with MoDOT Test Method T 8 at 86 degrees entrance angle. Observation Angle
White
Yellow
0.2 degree
550
410
0.5 degree
380
250
1048.2.2 Type 2 Preformed Pavement Marking Tape. 1048.2.2.1 Application. receive traffic.
After application, the tape shall be immediately ready to
1048.2.2.2 Composition. Type 2 preformed pavement marking tape shall consist of a mixture of polymeric materials and pigments with beads distributed throughout the cross-sectional area and with a reflective layer of ceramic beads embedded in the embossed, patterned surface. The patterned surface shall have 50% plus or minus 15% of the surface area raised and presenting a near vertical face (angle of 0 degrees to 60 degrees from vertical) to traffic from any direction. The channels between the raised areas shall be substantially free of exposed beads or particles. The markings shall be capable of being adhered to bituminous or concrete surfaces by a flexible conforming backing. A primer may be required to precondition the pavement surface. 1048.2.2.3 Dimensions. The tape, without adhesive, shall have a patterned surface with a minimum thickness of 65 mils in the raised (thickest) area of the cross section and a minimum thickness of 20 mils in the depressed (thinnest) areas of the cross section. 1048.2.2.4 Adhesive. The tape shall be supplied with a precoated factory-applied pressure sensitive adhesive.
11/1/2016
1048-2
Pavement Marking Material
1048.2.2.5 Reflectance. The tape shall have a minimum specific luminance as shown in the table below, expressed as millicandelas per footcandle per square foot. The tape shall be applied to an 8 inch x 36 inch panel in a longitudinal orientation and measured in accordance with MoDOT Test Method TM-8.
Entrance Angle
Observation Angle
White
Yellow
86.0
0.2 degree
1100
800
86.5
1.0 degree
700
475
1048.2.2.6 Index of Refraction. The ceramic beads on the raised, patterned surface of the material shall have a minimum index of refraction of 1.70 when tested using the liquid oil immersion method. Ceramic beads with an index of refraction greater than 1.80 shall not be used. The beads mixed into the pliant polymer shall have a minimum index of refraction of 1.50 when tested by the oil immersion method. 1048.3 Extruded Thermoplastic Pavement Marking. 1048.3.1 Thermoplastic Compound. 1048.3.1.1 Thermoplastic material shall be in accordance with AASHTO M 249, shall be formulated with alkyd resin, and shall have a maximum specific gravity of 2.35. 1048.3.1.2 The thermoplastic material, when melted and ground to the fineness listed below, shall not have leachable lead or chromium levels greater than 4.0 ppm when tested by the Toxicity Characteristic Leaching Procedure (TCLP, USEPA Method 1311/6010). TCLP leachability testing shall be performed at each of the following levels of fineness: 1) Coarse Grind. - 100 % passing ⅜ inch and retained on ¼ inch sieve. 2) Medium Grind. - 100 % passing No. 8 and retained on No. 20 sieve. 3) Fine Grind. - 100 % passing No. 30 sieve. 1048.3.2 Primer. recommendations.
Primer, if required, shall be in accordance with the manufacturer's
1048.3.3 Testing. The thermoplastic material shall be tested in accordance with AASHTO M 249 and AASHTO T 250, as applicable. 1048.3.4 Packaging and Marking. Each package shall be labeled or marked with the color of the material, name of the manufacturer, date of manufacture, batch number, type of material (alkyd), net weight of contents, and the temperature to which the material shall be heated for application. Granular thermoplastic material may be packaged in thermally degradable bags which are designed to melt with the material, provided the label states the bag does not adversely affect the application or performance of the thermoplastic material. 11/1/2016
1048-3
Pavement Marking Material
1048.3.5 Drop-On Glass Beads. Drop-on glass beads shall be in accordance with Section 1048.6.4. 1048.4 Preformed Removable Pavement Marking Tape. Preformed removable tape shall be capable of being removed and shall leave no objectionable or misleading image or damage to the pavement after removal (ASTM D4592). 1048.4.1 Reflectance. Tape shall have a minimum specific luminance as shown in the table below, expressed as millicandelas per footcandle per square foot. The tape shall be applied to an 8 inch x 36 inch panel in a longitudinal orientation and measured in accordance with MoDOT Test Method T 8 at 86 degrees entrance angle.
Observation Angle
White
Yellow
0.2 degree
1750
1300
0.5 degree
1250
800
1048.4.2 Adhesive. Tape shall have a pre-coated pressure sensitive adhesive that requires no activation procedures. The adhesive shall be resistant to normal roadway chemicals or materials. 1048.4.3 Durability. The tape shall be weather-resistant and show no appreciable fading, lifting or shrinkage during the tape’s useful life. Samples of the tape applied to standard specimen plates and tested in accordance with Federal Test Method No. 141, Method 6192, for 1000 cycles, using a CS-17 wheel and 1000-gram load shall not expose the backing material over more than five percent of the abraded area. 1048.5 Preformed Short Term Pavement Marking Tape. 1048.5.1 Reflectance. The tape shall have a minimum specific luminance as shown in the table below, expressed as millicandelas per footcandle per square foot. The tape shall be applied to an 8 inch x 36 inch panel in a longitudinal orientation and measured in accordance with MoDOT Test Method T 8 at 86 degrees entrance angle. Observation Angle
White
Yellow
0.2 degree
1350
800
0.5 degree
750
500
1048.5.2 Adhesive. Tape shall have a pre-coated pressure-sensitive adhesive that requires no activation procedures. Adhesive shall be resistant to normal roadway chemicals or materials.
11/1/2016
1048-4
Pavement Marking Material
1048.5.3 Durability. The tape shall be weather resistant and show no appreciable fading, lifting, or shrinkage during the tape’s useful life. Samples of the tape applied to standard specimen plates and tested in accordance with Federal Test Method No. 141, Method 6192, for 1000 cycles, using a CS-17 wheel and 1000-gram load shall not expose the backing material over more than five percent of the abraded area. 1048.6 Drop-On Glass Beads. When tested in accordance with MoDOT Test Method T 70 for water resistance, the beads shall show no readily discernible dulling and the amount of 0.1 normal hydrochloric acid needed to titrate the filtrate shall not exceed 4.5 mL. When tested in accordance with MoDOT Test Method T 70 for calcium chloride and sodium sulfide resistance, the beads shall show no readily discernible darkening or dulling. 1048.6.1 Type 1 Drop-On Glass Beads. Type 1 beads shall be moisture-resistant and manufactured from glass of a composition that is highly resistant to traffic wear and to the effects of weathering. Glass beads shall be in accordance with AASHTO M 247, Type 1. 1048.6.2 Type L Drop-On Glass Beads. Type L (FP-96, Type 4) beads shall be embedment coated and manufactured from glass of a composition that is highly resistant to traffic wear and to the effects of weathering. The beads shall be in accordance with AASHTO M 247, Type 1, except as follows. 1048.6.2.1 Coating. The beads shall be coated to ensure satisfactory embedment and adhesion when applied to uncured traffic marking material. The coating shall be tested in accordance with MoDOT Test Method T 70. 1048.6.2.2 Roundness. Type L (FP-96, Type 4) beads shall have a minimum of 80 percent rounds per screen for the two highest sieve quantities and no more than 3 percent angular particles per screen, as determined by visual inspection. The remaining sieve fractions shall be determined visually per aspect ratio using microfiche reader to be no less than 75 percent rounds. The tests shall be in accordance with Federal Lands Highway - Test Method T520-93. 1048.6.2.3 Gradation. Type L (FP-96, Type 4)-beads shall meet the following gradation requirements when tested in accordance with ASTM D 1214:
11/1/2016
Sieve Size
Percent Passing
10
100
12
95 - 100
14
80 - 95
16
10 - 40
18
0-5
20
0-2
1048-5
Pavement Marking Material
1048.6.3 Intermix Beads. Intermix beads shall be uncoated and in accordance with AASHTO M 247, Type 1. Intermix beads shall be uniformly mixed throughout the thermoplastic material at the rate of no less than 30 to 35 percent by weight, retained on the No. 100 sieve, of the thermoplastic material. 1048.6.4 Type P Drop-On Glass Beads. Type P beads shall be manufactured from glass of a composition that is highly resistant to traffic wear and to the effects of weathering. If coating is required to meet the performance requirements for the specific marking material used, the beads shall be coated to ensure satisfactory embedment and adhesion. Glass beads shall have a minimum 95 mass percent passing a No. 18 sieve and a maximum 5 mass percent passing a No. 100 sieve. 1048.7 Temporary Lane Markers. 1048.7.1 Temporary lane markers shall consist of a flexible plastic body with prismatic retro reflective sheeting bonded to one or two vertical surfaces to reflect incident light from a single or opposite directions. An adhesive shall be laminated to the bottom surface of the marker body to provide for bonding the marker to the pavement. The marker shall be fitted with a flexible cover, which protects the marker during the application of the micro-surfacing or chip seal treatment. The cover shall be fastened to the body with two (2) staples. 1048.7.2 Color. The retro reflective material shall display either white or yellow as specified. The yellow markers shall have retro reflective material on both sides. The white markers shall have the retro reflective material on one (1) side. 1048.7.3 Reflectivity. The coefficient of luminous intensity and specific intensity shall not be less than the following table. The contractor shall supply certified test reports, in triplicate to the Engineer that represents the submitted lot and meets or exceeds the requirements specified.
Observation Angle (degrees)
0.2
Horizontal Entrance Angle (degrees) +4 or -4
Coefficient of Luminous Intensity (mcd)
Specific Intensity (cd/ft.)
White
Yellow
White
Yellow
320
230
3.5
2.5
1048.7.4 Adhesive. The adhesive shall be factory-applied to the base leg bottom, 0.125 inch thick, and shall have a minimum width by length of 0.75 inch by 4.0 inches on 1 inch wide release paper. The release paper shall remain on the marker until immediately before desired application. The adhesive shall be a solid compound with high initial bond strength and adhesion capable of retaining the marker in its installed position on the pavement.
11/1/2016
1048-6
Pavement Marking Material
1048.7.5 Dimensions. 1048.7.5.1 Body. The body shall be "L" shaped with a nominal wall thickness of 0.060 inch. The vertical wall shall be a minimum height by width of 2.0 inches by 4.0 inches. The base leg shall be a minimum width by length of 1.0 inch by 4.0 inches. The marker shall be formed of a high impact-resistant thermoplastic polyurethane or equivalent capable of presenting a strong white or yellow standard traffic daytime color. 1048.7.5.2 Sheeting. The sheeting shall be a prismatic retro reflective ultraviolet stabilized acrylic film with the micro prisms formed into the back surface of the film and is 0.10 inch thick. The sheeting shall be affixed along the top of the vertical section of the marker inside the I-beam on one or both sides. The back surface shall be metallized and coated with an adhesive, which will bond the sheeting securely to the marker body. 1048.7.5.3 Staples. The staples shall be 0.03 inch diameter galvanized high carbon steel wire with a 0.5 inch wide crown. The two (2) staples shall be attached to the cover in such a manner than the cover will remain in place and protect the reflective sheeting. Stapling or clipping devices used to retain the protective cover shall not protrude through the reflective material. 1048.7.5.4 Cover. The cover shall be in the shape of an inverted "U" with a minimum wall thickness of 0.03 inch. The cover shall be transparent and colorless flexible polyvinyl chloride that shall be removed immediately after paving. The reflective material shall be protected with an easily removable cover of heat resistant material capable of withstanding and protecting the reflective material from the application of 400°F liquid asphalt. 1048.7.6 Durability. 1048.7.6.1 The body and cover shall have a Shore A hardness of not less than 80, as tested in accordance with ASTM D 2240. 1048.7.6.2 The body shall have a minimum tensile strength of 4,600 psi. The cover shall have a minimum tensile strength of 1,900 psi. Tensile strengths shall be determined in accordance with ASTM D 412. 1048.7.6.3 The adhesive pad shall be installed in accordance with manufacturer's guidelines and the marker shall adhere to the road during its' intended use. 1048.7.6.4 Packaging. The brand name and manufacturer shall be stamped or indelibly printed on each container. The markers shall be packaged in a manner that ensures the vertical wall remains within 15 degrees of perpendicular to the base of the marker. 1048.7.6.5 Appearance. The markers, as applied, shall be in good condition, free of cracks or tears in the marker body or reflective material.
11/1/2016
1048-7
Pavement Marking Material
1048.7.7 Approval. 1048.7.7.1 Prior to approval and use of temporary lane markers, the manufacturer shall submit material specifications, application specifications and samples of the markers for evaluation and possible testing. The quantity, color and reflective type submitted shall be at the discretion of the Engineer. Following the testing and evaluation of the marker, satisfactory marker will be placed on a prequalified list. 1048.7.7.2 Temporary Lane Markers appearing on the prequalified list may be accepted on the basis of manufacturer, product trade name, and color as shown in the prequalified list, so long as satisfactory performance is obtained in the field. 1048.8 Hot Spray Thermoplastic Pavement Marking. 1048.8.1 Thermoplastic Compound. 1048.8.1.1 Except where otherwise specified, tests shall be performed in accordance with AASHTO T 250. 1048.8.1.2 The thermoplastic material shall be formulated with alkyd resin and intermix beads for application by the hot spray process at 45 mil thickness. Intermix beads shall be in accordance with Section 1048.6.3. Drop-on glass beads shall be in accordance with Section 1048.6.4. 1048.8.1.3 The thermoplastic material shall be in accordance with Section 1048.3.1.2. 1048.8.1.4 The binder shall consist of a mixture of synthetic alkyd resins. The total binder content of the thermoplastic compound shall be well distributed through the compound. The binder shall be free from all foreign material or ingredients that would cause bleeding, staining or discoloration. The binder shall be 25 percent minimum by weight of the thermoplastic compound as determined by ashing. 1048.8.2 Pigment. 1048.8.2.1 White. The pigment used for the white thermoplastic compound shall be a minimum of 93 percent pure titanium dioxide. 1048.8.2.2 Yellow. The pigments for the yellow thermoplastic compound shall be nontoxic, heat resistant, and color-fast yellows, golds and oranges, which shall produce a compound meeting the requirements of Federal 595 Color No. 33538. 1048.8.2.3 Filler. Any filler which is insoluble in 6 N hydrochloric acid shall be of such particle size as to pass a No. 100 sieve.
11/1/2016
1048-8
Pavement Marking Material
1048.8.3 Mixed Compound. 1048.8.3.1 Reflectance and Color. The mixed thermoplastic compound, after heating 2.2 pounds in an open, friction-top quart can with the rim removed for 4 hours ± 5 minutes at 375°F ± 3°F and cooling at 77°F, shall meet the requirements below for daylight reflectance and color, when tested using a color spectrophotomer with 45 degree circumferential / 0 degree geometry, illuminant C, and 2 degree observer angle. The color instrument shall measure the visible spectrum from 380 to 721 nm with a wavelength measurement interval and spectral bandpass of 10 nm.
a
Color
Daylight Reflectance (Y)
White
75 percent min
Yellowa
42 to 59 percent
Shall match Federal 595 Color No. 33538 and chromaticity limits as follows:
CIE Chromaticity Coordinate Limits 1
2
3
4
x
y
x
y
x
y
x
y
0.470
0.455
0.510
0.485
0.485
0.425
0.530
0.456
1048.8.3.2 Specific Gravity. The specific gravity of the thermoplastic material shall not exceed 2.15 as determined by the kerosene displacement method. 1048.8.3.3 Softening Point. After heating the thermoplastic as described in Section 1048.8.3.1 and testing in accordance with ASTM E 28, the material shall have a minimum softening point of 180°F, as measured by the ring and ball method. 1048.8.3.4 Tensile Bond Strength. After heating the thermoplastic as described in Section 1048.8.3.1, the tensile bond strength to unprimed, sandblasted Portland cement concrete block, 0.0625 inch thick film drawdown at 375°F, test at 75°F ± 2°F shall exceed 180 psi, when tested in accordance with ASTM D 4796. 1048.8.3.5 Impact Resistance. After heating the thermoplastic as described in Section 1048.8.3.1, the impact resistance shall be a minimum of 50 inch-pounds with no cracks or bond loss when 0.0625 inch thick film drawdown is made at 375°F on an unprimed, sandblasted Portland cement concrete block, male indentor ⅝ inch, no female die, tested at 75°F ± 2°F, when tested in accordance with ASTM D 2794.
11/1/2016
1048-9
Pavement Marking Material
1048.8.3.6 Yellowness Index. The unaged white thermoplastic material shall not exceed a yellowness index of 0.12, when tested in accordance with AASHTO T 250. 1048.8.4 Packaging. The thermoplastic material shall be packaged in suitable containers that will not adhere to the product during shipment and storage. Each container shall designate the color, type of binder, spray and user information. Each package shall be marked with the name of the manufacturer, type of material, month and year the material was packaged, lot number and the temperature to which the material shall be heated for application. 1048.9 Snowplowable Raised Pavement Markers. The snowplowable raised pavement marker (SRPM) shall consist of an iron casting to which is attached a replaceable retroreflector for reflecting light longitudinally along the pavement from one or two directions as specified. 1048.9.1 Material. 1048.9.1.1 Casting. The durable metal base casting shall be shaped to deflect a snowplow blade upward and prevent damage to the reflectors. The casting shall have leveling tabs to ensure proper embedment and shall be fastened to the road surface by an epoxy adhesive. The casting shall be designed for bi-directional plowing and shall be reusable. 1048.9.1.2 Reflector. The reflector shall have one or two retroreflective lenses as shown on the plans to reflect incident light from a single direction or from opposite directions. The lens shall be hermetically sealed and permanently bonded to the reflector base. The manufacturer's identification shall be molded in the face of the reflector lens or on the reflector body so as to be visible after installation. The reflector color shall be as shown on the plans. 1048.9.1.3 The reflector shall have nominal dimensions of 2.0" x 4.0" x 0.5". The reflector shall fit securely into a recessed area on the upper surface of the casting web and shall not protrude above the profile of the casting. The reflective surface of each lens face shall be a minimum of 1.55 square inches in area. 1048.9.1.4 Epoxy Adhesive. The epoxy adhesive used to bond the SRPM to the pavement shall be in accordance with the SRPM manufacturer's recommendations. 1048.9.2 In addition to the requirements of Section 1048.1.1, the SRPM shall have completed testing through NTPEP. A written request for qualification shall be sent by the manufacturer to Construction Division Manager with the following information: 1) Brand name of the product. 2) A copy of the actual test results from NTPEP. 3) Certification that the material meets this specification and is intended for use as described. 4) Specific installation instructions.
11/1/2016
1048-10
Pavement Marking Material
1048.9.2.1 To become qualified, the SRPM's shall receive at a minimum average ratings for each of the SRPM components for all NTPEP test decks. 1048.9.2.2 The casting shall receive at a minimum average rating of 4.0 for housing performance and 3.0 for lens and visibility after one year exposure on both concrete and asphalt test decks. 1048.9.2.3 The reflector shall receive at a minimum average rating of 3.0 for lens and visibility after one year exposure on both concrete and asphalt test decks. 1048.9.2.4 A retest on approved SRPM's and reflectors shall be conducted if the configuration changes. 1048.9.3 Rehabilitation. For rehabilitation projects, all requirements of Section 1048.9 will apply. 1048.10 Epoxy Pavement Marking Material. 1048.10.1 General. Epoxy pavement marking material shall not contain toxic heavy metals. The material shall be two-component, 100 percent solids, and formulated and tested to perform as a pavement marking material with glass beads applied to the surface. The two components shall be epoxy resin and an amine curing agent. 1048.10.2 Epoxy Types. Type A epoxy marking material shall be a slow cure material, and Type B epoxy marking material shall be a fast cure. 1048.10.3 Toxicity. Upon heating to application temperature, the material shall not release fumes that are toxic to persons or property. Upon curing, the material shall be completely inert, with all components fully reacted and environmentally benign. 1048.10.4 No Track Time. The material shall have a no-track time between 10 and 45 minutes for Type A and 10 minutes or less for Type B, when mixed in the proper proportions and applied at 25 mils wet film thickness at 75°F ± 2°F with the proper application of glass beads and when tested in accordance with ASTM D 711. The material shall fully cure under a constant surface temperature of 32°F or above. 1048.10.5 Adhesion to Concrete. The pavement marking material shall have a high degree of adhesion to the concrete surface such that there is a 100 percent concrete failure, when tested in accordance with ACI 503, Appendix A.1. The prepared specimens shall have a film thickness of 15 mils ± 1 mil and be applied to concrete with a minimum compressive strength of 4000 psi. The concrete surface shall be 90°F ± 2°F when the material is applied. The applied material shall be cured for 72 hours at 75°F ± 2°F before performing the test. 1048.10.6 Hardness. The material shall have a minimum Shore D Hardness of 75 when tested in accordance with ASTM D 2240. 1048.10.7 Tensile Strength. The material shall have a minimum tensile strength of 5000 psi after 72 hours cure at 75°F ± 2°F when tested in accordance with ASTM D 638.
11/1/2016
1048-11
Pavement Marking Material
1048.10.8 Compressive Strength. The material shall have a minimum compressive strength of 10,000 psi after 72 hours cure at 75°F ± 2°F when tested in accordance with ASTM D 695. 1048.10.9 Abrasion Resistance. The material shall have a maximum abrasion resistance of 150 mg at 15 mils ± 1 mil thickness after 72-hour curing time and with a CS-17 wheel under a load of 1000 grams for 1000 cycles, when tested in accordance with ASTM C 501. 1048.10.10 Yellowness Index. The material shall have a maximum yellowness index of 6 before the QUV test and a maximum of 23 after the 72-hour QUV test, when tested in accordance with ASTM D 1925. 1048.10.11 Color. The finished white color shall be free from tint, furnishing good opacity and visibility under both daylight and artificial light. The finished yellow color shall closely match Federal Test Standard 595 - Color Chip Number 13538. 1048.10.12 Drop-on Glass Beads (Double Drop System). For the first drop, furnish Type L (FP-96 Type 4) glass beads in accordance with Section 1048.6.2. For the second drop, furnish Type 1 drop-on glass beads in accordance with Section 1048.6.1. 1048.10.13 Qualification. In addition to the requirements of Section 1048.1.1, the material shall have been field tested at NTPEP test decks in a northern, wet climate region for a minimum of six months. The maintained retroflectivity and durability shall be in accordance with the following requirements after being installed on at least one NTPEP test deck for a minimum of six months, including December, January and February. 1048.10.13.1 Maintained Retroreflectivity. Photometric quantity to be measured will be the coefficient of retroreflective luminance (RL) in accordance with the requirements of ASTM E 1743 for 15-meter geometry or ASTM E 1710 for 30-meter geometry. The average RL for concrete and asphalt surfaces shall be expressed in millicandelas per square foot per footcandle and shall be at least 125 for 15-meter geometry or 100 for 30meter geometry, when measured in the wheel path area. 1048.10.13.2 Durability. Paint shall have a durability rating of at least 5 for both concrete and asphalt surfaces when tested in the wheel path area of the NTPEP test deck. 1048.10.14 Packaging. The manufacturer's name and address, product name, color, manufacturing date, date of expiration, and if the material is Part A or B shall be visible on the containers. In addition to the requirements of Section 1048.1.1, the certification supplied by the manufacturer shall include reference to the specific NTPEP test deck to which the paint formulation was applied, including NTPEP identification numbers and report numbers. 1048.11 Acrylic Copolymer Fast Dry Pavement Marking Paint. 1048.11.1 Description. Acrylic copolymer fast dry pavement marking paint shall be capable of receiving and holding glass beads for producing retroreflective traffic markings. 1048.11.2 Material. The paint shall not contain more than 3200 ppm lead or more than 800 ppm chromium based on dry weight and shall have limited VOC content as noted herein.
11/1/2016
1048-12
Pavement Marking Material
1048.11.2.1 General. The finished paint shall be formulated and manufactured from first-grade material and shall be a fast drying, solvent based, acrylic copolymer resin type paint capable of withstanding air and roadway temperatures without bleeding, staining, discoloring or deforming. The dried paint film shall be capable of maintaining original dimensions and placement without chipping, spalling or cracking. The dry paint film shall not deteriorate because of contact with normal roadway chemicals or materials. 1048.11.2.2 Durability Testing. Determination of conformance to this specification will include, but will not be limited to, the evaluation of test data from NTPEP or other MoDOT approved facilities. The maintained retroreflectivity and durability shall be in accordance with the following requirements after being installed on at least one NTPEP test deck in a northern, wet climate region for a minimum of six months, including December, January and February. 1048.11.2.2.1 Maintained Retroreflectivity. Photometric quantity to be measured will be the coefficient of retroreflective luminance (RL) in accordance with the requirements of ASTM E 1743 for 15-meter geometry or ASTM E 1710 for 30-meter geometry. The average RL for concrete and bituminous surfaces shall be expressed in millicandelas per square foot per foot-candle and shall be at least 100 for 15-meter geometry or 75 for 30-meter geometry, when measured in the wheel path area. 1048.11.2.2.2 Durability. Paint shall have a durability rating of at least 4 for both concrete and bituminous surfaces when tested in the wheel path area of the NTPEP test deck. 1048.11.2.3 Mixed Paint. 1048.11.2.3.1 The mixed paint shall be strained before filling, using a screen or a sieving device no coarser than 40 mesh. 1048.11.2.3.2 The VOC content of the finished paint shall be less than 1.25 pounds of volatile organic matter per gallon (150 g/L) of total non-volatile paint material when tested in accordance with ASTM D 3960. 1048.11.2.3.3 The paint shall have the following physical properties. Viscosity, KU
80 - 95
Laboratory Dry Time, ASTM D 711, minutes, max.
10
1048.11.2.3.3.1 Color. For white, the color shall closely match Color Chip 37925 of Federal Standard 595b. For yellow, the color shall closely match Color Chip 33538 of Federal Standard 595b. Color determination will be made for markings and the diffuse daytime color of the markings shall be in accordance with the below CIE Chromaticity coordinate limits. Color determination for liquid marking materials will be made over the black portion of a 2A or 5C Leneta Chart, or equal, at least 24 hours after application of a 15-mil wet film. Color 11/1/2016
1048-13
Pavement Marking Material
readings will be determined in accordance with the requirements of ASTM E 1349 using CIE 1931 2º standard observer and CIE standard illuminant D65. CIE Chromaticity Coordinate Limits (Initial) Color
1
2
3
4
x
y
x
y
x
y
x
y
White
0.334
0.357
0.334
0.317
0.297
0.357
0.297
0.317
Yellow
0.531
0.483
0.531
0.429
0.471
0.483
0.471
0.429
1048.11.2.3.3.3 Contrast Ratio. The contrast ratio shall be a minimum of 0.98 when drawn down as a 15 mil wet film on a 2A or 5C Leneta Chart, or equal and air-dried 24 hours. The contrast ratio shall be calculated as follows: Contrast ratio = Black/White. 1048.11.2.3.3.4 Reflectance. The daylight directional reflectance of a 15 mil wet film applied to a 2A or 5C Leneta Chart, or equal, and dried for a minimum of 24 hours shall be 84% minimum for the white paint and 50% minimum for the yellow paint. 1048.11.3. Acceptance. 1048.11.3.1 Except as noted, each batch or lot of paint shall be sampled and approved by the engineer prior to use. 1048.11.3.2 No paint shall be used that is more than 15 months old. 1048.11.3.3 In addition to the requirements of Section 1048.1.1, the certification supplied by the manufacturer shall include reference to the specific NTPEP test deck to which the paint formulation was applied, including NTPEP identification numbers and report numbers. 1048.12 Acrylic Waterborne Pavement Marking Paint. 1048.12.1 Description. Acrylic waterborne pavement marking paint shall be capable of receiving and holding glass beads for producing retroreflective pavement markings. 1048.12.2 Material. The paint shall contain no lead and / or chromium, based on dry weight, and shall have limited Volatile Organic Content (VOC), as noted herein. 1048.12.2.1 General. The finished paint shall be formulated and manufactured from quality material and shall be a fast-drying, water-based, acrylic resin type paint capable of withstanding air and roadway temperatures without bleeding, staining, discoloring or deforming. The dried paint film shall be capable of maintaining original dimensions and placement without chipping, spalling or cracking. The dry paint film shall not deteriorate because of contact with normal roadway chemicals or materials.
11/1/2016
1048-14
Pavement Marking Material
1048.12.2.2 Acrylic Emulsion Polymer. The acrylic emulsion polymer used in the manufacture of the paint shall be Rohm & Haas E-2706, Dow DT211, or equal. 1048.12.2.3 Durability Testing. Determination of conformance to this specification will include, but will not be limited to, the evaluation of test data from NTPEP or other MoDOT approved facilities. The maintained retroreflectivity and durability shall be in accordance with the following requirements after being installed on at least one NTPEP test deck in a northern, wet climate region for a minimum of six months including December, January and February. 1048.12.2.3.1 Maintained Retroreflectivity. Photometric quantity to be measured will be the coefficient of retroreflective luminance (RL) in accordance with the requirements of ASTM E 1743 for 15-meter geometry or ASTM E 1710 for 30-meter geometry. The average RL for concrete and bituminous surfaces shall be expressed in millicandelas per square foot per foot-candle and shall be at least 100 for 15-meter geometry or 75 for 30-meter geometry, when measured in the wheel path area. 1048.12.2.3.2 Durability. Paint shall have a durability rating of at least 4 for both concrete and bituminous surfaces when tested in the wheel path area of the NTPEP test deck. 1048.12.3 Mixed Paint. 1048.12.3.1 The paint shall be strained before filling, using a screen or a sieving device no coarser than 40 mesh or equivalent. 1048.12.3.2 The volatile content of the finished paint shall contain less than 150 grams of volatile organic matter per liter in accordance with ASTM D 3960. 1048.12.3.3 The paint shall have the following physical properties: Acrylic Waterborne Paint Physical Properties Viscosity, 77°F, KU
83-98
Grind (Hegman Gage), minimum
3
Laboratory Dry Time, ASTM D 711, minutes, max.
10
Dry Through Time, minutes, max.
150
1048.12.3.3.1 Color. For white, the color shall closely match Color Chip 37925 of Federal Standard 595b. For yellow, the color shall closely match Color Chip 33538 of Federal Standard 595b. Color determination will be made for markings, and the diffuse daytime color of the markings shall be in accordance with the below CIE Chromaticity coordinate limits. Color determination for liquid marking materials will be made over the black portion of a 2A or 5C Leneta Chart, or equal, at least 24 hours after application of a 15-mil wet film. Color readings will be determined in accordance with the requirements of ASTM E 1349 using CIE 1931 2º standard observer and CIE standard illuminant D65. 11/1/2016
1048-15
Pavement Marking Material
CIE Chromaticity Coordinate Limits (Initial) Color
1
2
3
4
x
y
x
Y
x
y
x
y
White
0.334
0.357
0.334
0.317
0.297
0.357
0.297
0.317
Yellow
0.531
0.483
0.531
0.429
0.471
0.483
0.471
0.429
1048.12.3.3.2 Flexibility. The paint shall show no cracking or flaking when tested in accordance with Federal Specification TT-P-1952B. 1048.12.3.3.3 Water Resistance. The paint shall conform to Federal Specification TT-P-1952B. There shall be no blistering or appreciable loss of adhesion, softening or other deterioration after examination. 1048.12.3.3.4 Freeze-Thaw Stability. The paint shall show no coagulation or change in consistency greater than 10 Kreb Units, when tested in accordance with Federal Specification TT-P-1952B. 1048.12.3.3.5 Heat Stability. The paint shall show no coagulation, discoloration or change in consistency greater than 10 Kreb Units, when tested in accordance with Federal Specification TT-P-1952B. 1048.12.3.3.6 Dilution Test. The paint shall be capable at any levels of dilution with water without curdling or precipitation such that the wet paint can be readily cleaned up with water only. 1048.12.3.3.7 Storage Stability. After 30 days of storage in a ¾ filled, closed container, the paint shall show no caking that cannot be readily remixed to a smooth, homogeneous state, no skinning, livering, curdling or hard settling. The viscosity shall change no more than 5 Kreb Units from the viscosity of the original sample. 1048.12.3.3.8 Contrast Ratio. The minimum contrast ratio (hiding power) shall be 0.96 when drawn down with a 0.005 bird film applicator on a 2A or 5C Leneta Chart, or equal, and air-dried for 24 hours. The contrast ratio shall be calculated as follows: Contrast Ratio = Black/White 1048.12.3.3.9 Reflectance. The daylight directional reflectance of a 15 mil wet film applied to a 2A or 5C Leneta Chart, or equal, and dried for a minimum of 24 hours shall be no less than 84 percent for the white paint and no less than 50 percent for the yellow paint. After drying 24 hours, measure the reflectance of the paint over the black portion of the chart using a HunterLab D25-9 Colorimeter, ASTM E 97.
11/1/2016
1048-16
Pavement Marking Material
1048.12.3.3.10 Bleeding. The paint shall have a minimum-bleeding ratio of 0.97, when tested in accordance with Federal Specification TT-P-1952B. The asphalt saturated felt shall be in accordance with ASTM D 226 for Type I. 1048.12.3.3.11 Dry Through Time. The paint shall be applied to a non-absorbent substrate at a wet film thickness of 15 mils ± 1 mil and placed in a humidity chamber controlled at 90% ± 5% R.H. and 72.5°F ± 2.5°F. The dry through time shall be determined in accordance with ASTM D 1640, except that the pressure exerted shall be the minimum needed to maintain contact with the thumb and film. 1048.12.4 Acceptance. 1048.12.4.1 Except as noted, each batch or lot of paint shall be sampled and approved by the engineer prior to use. The St. Louis County Department of Transportation reserves the right to make field tests of material prior to award to determine its suitability for application in its equipment and for purposes of determining compliance with drying time requirements of this specification. 1048.12.4.2 After storage for periods up to 9 months from the date of packaging: 1) The pigment shall not settle badly or cake in the container, nor shall the paint skin or thicken in storage sufficiently to cause an undesirable change in consistency, nor show spoilage. 2) The paint shall comply with all the provisions of these specifications and be capable of being redispersed with a paddle to a smooth uniform condition of useable consistency. 1048.12.4.3 In addition to the requirements of Section 1048.1.1, the certification supplied by the manufacturer shall include reference to the specific NTPEP test deck to which the paint formulation was applied, including NTPEP identification numbers and report numbers.
11/1/2016
1048-17
Pavement Marking Material
(This Page Intentionally Left Blank)
11/1/2016
1048-18
Pavement Marking Material
Section 1049
Precast Concrete Box Culvert
1049.1 Scope. These specifications cover precast concrete box culverts. 1049.2 Acceptance. Unless otherwise specified in the contract, acceptance of precast units will be on the basis of tests of material and inspection of the completed product. Acceptability of all types of sections covered by these specifications will be determined by the material tests required in Section 1049.3, by crushing tests on concrete cores or cured concrete cylinders; by absorption tests on selected samples of concrete from the wall of the sections; and by inspections of the finished sections, including quantity and placement of reinforcement, to determine conformance with these specifications and freedom from defect. 1049.3 Material. 1049.3.1 Cement. Cement shall be in accordance with Section 1019. Fly ash or GGBFS may be used to replace cement in accordance with Section 501. 1049.3.2 Fly Ash. Fly ash shall be in accordance with Section 1018. 1049.3.3 Ground Granulated Blast Furnace Slag. Ground granulated blast furnace slag shall be in accordance with the requirements of Section 1017. 1049.3.4 Aggregate. Fine and coarse aggregate for the concrete mixture shall be in accordance with Section 1005, except the requirements for gradation and percent passing the No. 200 sieve will not apply. 1049.3.5 1036.3.
Steel Reinforcement.
Reinforcement shall be in accordance with Section
1049.3.6 Concrete Mixture. The aggregate shall be sized, graded, proportioned and thoroughly mixed in such proportions of cement and water, as will produce a homogeneous concrete mixture of such quality that the units will conform to the test and design requirements. Admixtures or blends may be used with approval from the Engineer. The proportion of Portland cement in the mixture shall be no less than 470 pounds per cubic yard of concrete. Fly ash may be used to replace cement in accordance with of Section 501, except approved Class C or F fly ash may be substituted for a maximum of 25% of Type I or II cement on an equivalent weight basis. 1049.4 Design. 1049.4.1 Except as otherwise specified herein, the precast concrete box sections for the culvert shall be in accordance with AASHTO M 259 for culverts with 2 feet or more of cover, or AASHTO M 273 for culverts with less than 2 feet of cover with both subject to HS20 live loading, Table 1. 1049.4.2 Substituted precast concrete box culvert sections shall be designed for the earth cover shown on the plans for the cast-in-place box culvert and shall be equal in height and cross sectional area or as approved by the Engineer.
1/31/2007
1049-1
Precast Concrete Box Culvert
1049.4.3 The manufacturer may request approval of modified designs which differ from the designs in AASHTO M 259 or AASHTO M 273. The request for such modified or special designs shall fully describe any deviations from those standards, including a drawing showing wall thickness, concrete design strength, the type, size and placement of reinforcement, and inside or outside dimensions of both of the box sections. 1049.4.4 The minimum barrel length for box or end section shall be 2 feet. 1049.4.5 End sections may be precast or cast-in-place. If precast, the barrel, floor and wing walls shall be cast as an integral unit. In either case the end sections shall be constructed to the same dimensions, shapes, and with the same reinforcement as shown on the plans for cast-in-place culvert. 1049.4.6 Segmented end sections may be provided, but will be considered a modified design and will require approval as such. 1049.4.7 Toe walls shall be provided on both the upstream and downstream ends as shown on the plans and may be cast-in-place or precast. Precast toe walls shall be connected to the end section floor. 1049.5 Manufacture. 1049.5.1 Curing shall be in accordance with the applicable provisions of Section 1026 until the concrete has developed the specified compressive strength. 1049.5.2 Hot or cold weather concreting and concrete testing equipment shall be in accordance with Section 703.
1/31/2007
1049-2
Precast Concrete Box Culvert
Section 1050
Lumber, Timber, Piling, Posts and Poles
1050.1 Scope. These specifications cover wood products as defined in the American WoodPreservers Association (AWPA) Standards. 1050.2 Posts. 1050.2.1 Posts and Blocks for Guardrail. Posts and blocks for guardrail shall be rectangular, standard rough sawn and of the size and length as shown on the plans. Posts and blocks shall be Douglas Fir or Southern Pine and pressure treated as listed in Table I. Other preservatives and wood species shall be in accordance with applicable AWPA Standards. All framing and boring shall be completed before treatment. Douglas Fir shall be "Dense No. 1 Structural Grade" in accordance with Paragraph 131-bb of the current Standard Grading Rules for West Coast Lumber. Southern Pine shall be "No. 1 SR Grade" in accordance with Paragraph 406 of the current Standard Grading Rules for Southern Pine Lumber. 1050.2.2 Posts for Fence. Posts for fence shall be round and of the sizes and lengths shown on the plans. Posts shall be pressure-treated as list in Table I for the noted species, other preservatives and wood species shall be in accordance to applicable AWPA Standards. Allowable tolerances for size and length will be as follows:
Minimum diameter
4 inches or smaller
+½ inch, no minus tolerance
Larger than 4 inches
+1 inch, no minus tolerance
Length (all diameters)
No limit on over length, minus 1 inch
1050.2.2.1 Grade. Wood for posts shall be sound, free of decay, excessive knots and of end splits and seasoning checks that might affect serviceability. Posts shall be free of multiple crooks, except crooks in one plane only that are in accordance with Section 1050.2.2.2 will be permitted. 1050.2.2.2 Straightness. A straight line drawn from the center of one end of the post to the center of the opposite end shall not deviate from the longitudinal axis of the post at any point more than one percent of the length of the post. 1050.2.2.3 Manufacture. Posts shall be clean peeled to remove all bark, except that strips of inner bark no more than ½ inch wide or no more than 3 inches long will be permitted to remain on the peeled post. All protruding knots shall be trimmed flush, and all spurs and splinters shall be removed. The natural taper of round posts shall be followed in machine peeling operations. The ends of all posts shall be cut square, except posts to be driven shall be machine-pointed on the small end prior to treatment.
1/31/2007
1050-1
Lumber, Timber, Piling, Posts and Poles
1050.2.3 Posts for One-Strand Access Restraint Cable. Posts for one-strand access restraint cable may be round or rectangular as shown on the plans. Round posts shall be in accordance with Section 1050.2.2. Rectangular posts shall be standard rough sawn and of the grade specified in Section 1050.2.2.1. All posts shall be of the species and pressure treated as listed in Table I. 1050.2.4 Posts for Signs. Posts for signs shall be rectangular, rough sawn or surfaced four sides (S4S), with square cut ends, and shall be of the grade, size and length shown on the plans. Posts shall be pressure-treated as listed in Table I for the noted species, other preservatives and wood species shall be in accordance with applicable AWPA Standards. If framing and boring is completed after pressure treatment, field treatment shall be in accordance with Section 1050.7. 1050.3 Lumber and Timber. 1050.3.1 Species and Grade Requirements. Unless otherwise specified, lumber and timber to be used as a permanent part of a structure shall be of the species listed in Table I or other treatable species as specified in the AWPA Standards and of the grade specified on the plans. Lumber and timber for temporary structures shall be of the species and grades shown on the plans. 1050.3.2 Dressing Requirements. Lumber and timber shall be standard rough sawn or shall be surfaced as specified in the contract. Lumber and timber shall be cut to exact lengths or to permissible variations in lengths shown in the contract documents. 1050.3.3 Treatment. If treatment is specified, lumber and timber shall be pressure-treated as listed in Table I for the noted preservatives or in accordance with the applicable AWPA Standards for other types of preservatives. 1050.4 Electric Substation, Service and Span Wire Assembly Poles. 1050.4.1 Services Poles. Service poles shall be of the length and class specified in the contract documents, and shall be in accordance with ANSI 05.1. Poles shall be of the species and type of preservative listed in Table I. Poles may be gained and drilled in the field after treatment. Areas exposed shall be treated in accordance with Section 1050.7 before cross-arms or equipment is mounted. 1050.4.1.1 Electric Substation Poles. Electric substation poles shall be of the length and class specified in the contract documents, and shall be in accordance with ANSI 05.1 or local utility guide lines. Poles shall be of the species and type of preservative listed in Table I. 1050.4.2 Span Wire Assembly Poles. Span wire assembly poles shall be of the length specified in the contract and shall be in accordance with ANSI 05.1, Class IV unless otherwise specified. The poles shall be of the species and type of preservative listed in Table I. All poles shall have a minimum diameter of 6¾ inches, measured at the top of the pole.
1/31/2007
1050-2
Lumber, Timber, Piling, Posts and Poles
1050.4.3 Pole Crossarms. The species, grade and treatment of crossarms to be erected on substation and service poles will be shown on the plans. 1050.5 Round Timber Piles. 1050.5.1 Material. All round timber piles shall be in accordance with ASTM D 25, except for size, which shall be in accordance with Table II for the class specified in the contract. 1050.5.2 Chemical Treatment. Piles shall be pressure treated to meet the requirements listed in Table I. Framing and boring will not be required before treatment. Exposed untreated areas resulting from framing of treated piling shall be field treated in accordance with Section 1050.7. Untreated piles for use in unexposed locations or in temporary bridges shall be of the species listed in Table I or of other species approved by the Engineer. 1050.6 Timber Preservatives. 1050.6.1 Creosote. Creosote shall be in accordance with AWPA P1. 1050.6.2 Pentachlorophenol. Pentachlorophenol shall be in accordance with AWPA P8 in a hydrocarbon solvent meeting the requirements of AWPA P9, Type A. 1050.6.3 Ammoniacal Copper Zinc Arsenate (ACZA). Arsenate shall be in accordance with AWPA P5.
Ammoniacal Copper Zinc
1050.6.4 Material for Repair. Handling, storage and repair of lumber items shall be as specified in AWPA Standard M4. 1050.6.5 Responsibility for Quality. The contractor shall use preservatives which meet these specifications or the treated material will be subject to rejection or to approved retreatment with an approved preservative. 1050.6.6 Final Steaming. All guardrail, one-strand access restraint cable and sign posts; substation, service and span wire poles; and lumber and timber, except material treated with ACA or CCA, shall be cleaned by a final steam bath in accordance with AWPA C2, C4 or C5, as applicable. In lieu of steam cleaning, sign posts may be strip stacked and air-dried for a minimum of 60 days after treatment. 1050.7 Care After Treatment. Care shall be taken in handling pressure-treated material to avoid damage. Cant hooks, peavies, pickaroons and end cant hooks shall not be used on the side surfaces of treated material. All handling of treated round stock with pointed tools shall be confined to the ends. If damaged material is permitted for use by the Engineer, or framing at site is required, such injuries, cuts or holes shall be liberally field-treated with the preservative of the same type used for the original treatment or of copper naphthenate. A second coat shall not be applied until after the first coat has been absorbed. Creosote preservative shall be hot when applied. Holes shall be treated by plugging one end and filling with preservative.
1/31/2007
1050-3
Lumber, Timber, Piling, Posts and Poles
1050.8 Inspection. 1050.8.1 Inspection. All material shall be inspected for compliance with these specifications in accordance with AWPA Standard M2. 1050.8.1.1 Timber products treated within St. Louis County or within 100 air miles of the border may be inspected by St. Louis County Department of Transportation personnel. 1050.8.1.2 The inspection of lumber, timber, piling, posts and poles shall be performed by the supplier or an approved inspection agency, and the cost for inspection shall be at the Contractor's expense. 1050.8.2 Inspection Agency. An approved inspection agency shall be a laboratory, accredited by the American Lumber Standards Committee (ALSC), or an experienced testing laboratory approved by the Engineer. Inspection agencies not accredited by the ALSC shall submit for approval a resume to the Construction Division Manager. The resume of the agency shall include the agency's history of inspection of timber and treated products, and a listing of state highway agencies which have approved the inspection agency and of state agencies for which the inspection agency has performed inspection. 1050.9 Certification. The Contractor shall furnish to the Engineer a certification from the supplier or inspection agency that the material furnished is in accordance with these specifications. Certification shall include or have attached a listing of the material being supplied. Except as noted, the certification shall have attached a certified test report, as detailed in Section 7.2 of AWPA Standard M2, from the supplier or inspection agency attesting to complete compliance with AWPA and these specifications. Electric substation, service and span wire assembly poles will not require certified test reports. 1050.10 Acceptance. Acceptance of material will be based on satisfactory supplier's certification or inspection agency certifications, and upon results of any tests deemed necessary by the engineer at destination to ascertain compliance with these specifications.
1/31/2007
1050-4
Lumber, Timber, Piling, Posts and Poles
TABLE I Type of Preservation and Minimum Retention (Pounds per Cubic Foot of Wood)
Species Southern Pine
Douglas Fir
Treated in accordance with AWPA Specification
Pentachlorophenol
ACZA
0.50
0.50
C5
Creosote
Round Posts for Guard Cable
X
Rectangular Posts for Guard Cable
X
X
0.60
0.50
C2
Posts and Blocks for Guardrail
X
X
0.60
0.50
C2
Posts for Fence
X
0.40
0.40
Posts for Signs
X
X
0.40
0.40
Lumber and Timber
X
X
0.60
0.60
Poles
X
0.38
0.60
Round Timber Piles
X
8
C5 C2
12
C2 C4
12
C3
Note: Where more than one species or type of preservative is shown, the contractor may furnish either.
TABLE II Circumferences (Cir.) and Diameters (Dia.) of Timber Piles (inches) Class A 3 Feet from Butt
Length
Min.
Max.
Class B
Tip
3 Feet from Butt
Min.
Min.
Max.
Class C
Tip
Tip
3 Feet from Butt
Min.
Min.
Max.
Min.
Cir.
Dia.
Cir.
Dia. Cir. Dia.
Cir.
Dia.
Cir.
Dia. Cir.
Dia.
Cir.
Dia.
Cir.
Dia.
Cir.
Dia.
Up to 50 feet
47
15
57
18
28
9
38
12
63
20
25
8
38
12
63
20
25
8
Over 50 feet
47
15
57
18
25
8
41
13
63
20
22
7
38
12
63
20
22
7
1/31/2007
1050-5
Lumber, Timber, Piling, Posts and Poles
(This Page Intentionally Left Blank)
1/31/2007
1050-6
Lumber, Timber, Piling, Posts and Poles
Section 1051
Slotted Drain
1051.1 Scope. This specification covers slotted drain. 1051.2 Pipe. The pipe portion of the slotted drain shall be 16 gage. The material and fabrication of the pipe shall be in accordance with Section 1020. The diameter of the pipe shall be as shown on the plans. 1051.3 Slotted Drain Grate Assembly. The grate assembly of Type A, B or C slotted drain shall be fabricated as shown on the plans. The grate assembly shall be 6 inches in height unless otherwise specified on the plans. 1051.3.1 Type B and Type C slotted drain grate assemblies shall be fabricated from 3⁄16 inch thick ASTM A 36 structural steel. The entire grate assembly shall be hot dip galvanized, prior to attachment to the pipe, in accordance with AASHTO M 111. 1051.3.2 Type A slotted drain guide assemblies shall be fabricated from 14 gage galvanized steel meeting the same material requirements as the pipe. The drain guide slot shall be assembled with mechanical interlocks requiring no welding. 1051.4 All coupling devices and other necessary fittings shall be in accordance with the applicable provisions of Section 1020.
1/31/2007
1051-1
Slotted Drain
(This Page Intentionally Left Blank)
1/31/2007
1051-2
Slotted Drain
Section 1052
Mechanically Stabilized Earth Wall System Components
1052.1 Scope. This specification covers material requirements for metallic soil reinforcement, non-metallic soil reinforcement, concrete facing panels for large block wall systems and concrete blocks for small block wall systems that are supplied as part of mechanically stabilized earth wall systems. 1052.2 Metallic Soil Reinforcement. This specification covers metallic soil reinforcement and the accompanying attachments that are utilized in mechanically stabilized earth wall systems. 1052.2.1 Reinforcement Strips. Metallic soil reinforcement strips shall be in accordance with the specifications established by the manufacturer of the wall system and according to the plans. The minimum grade of steel for strips and connection devices shall be AASHTO M 270 Grade 36 (AASHTO M 270M Grade 250). 1052.2.2 Reinforcement Mesh. Metallic soil reinforcement mesh shall be in accordance with the specifications established by the manufacturer of the wall system and according to the plans. The mesh, connector bars and connection devices, as a minimum, shall be in accordance with AASHTO M 32. Welding shall be in accordance with AASHTO M 55. 1052.2.3 Fasteners. Fasteners shall consist of either ASTM A 325 hexagon head bolts or ASTM A 325 hexagonal cap screws with nuts and washers. 1052.2.4 Galvanizing. All soil reinforcement material, except for fasteners, shall be galvanized in accordance with AASHTO M 111. Fasteners, including bolts, nuts and washers, shall be galvanized in accordance with AASHTO M 232. 1052.2.5 Certification. The manufacturer of the wall system shall certify in writing that the soil reinforcement, connections and fasteners meet the minimum requirements established by the design and this specification. This certification and any other supporting documentation shall be provided by the contractor to the engineer prior to the material being delivered to the construction site. 1052.3 Non-Metallic Soil Reinforcement. This specification covers non-metallic or geosynthetic soil reinforcement that is utilized in mechanically stabilized earth wall systems. 1052.3.1 Geogrids. 1052.3.1.1 Non-Metallic or geosynthetic soil reinforcement shall be of a polymeric nature and shall consist of a geogrid determined by the wall manufacturer or supplier. 1052.3.1.2 The geogrid shall be dimensionally stable and able to maintain geometry during transport, handling and installation.
11/1/2016
1052-1
Mechanically Stabilized Earth Wall System Components
1052.3.1.3 The geogrid manufacturer shall be responsible for maintaining a quality control program to ensure that the manufactured material meets the requirements of the index tests shown in Table I. Sampling and conformance testing for the index tests shown in Table I shall be done in accordance with ASTM D 4354.
Table I Property
Test Procedure
Specific Gravity (HDPE only)
ASTM D 1505
Wide Width Tensile
ASTM D 4595, GRI GG1
Melt Flow (HDPE and PP only)
ASTM D 1238
Inherent Viscosity (PET only)
ASTM D 4603, GRI GG8
Hydrolysis Resistance (PET only)
GRI GG7
UV Oxidation Resistance
ASTM D 4355
Survivability
ASTM D 5261
1052.3.2 Certification. The manufacturer of geogrid shall certify in writing that the geogrid is in accordance with this specification. The certification shall include the roll numbers and identification, the sampling procedures, the results of the quality control tests along with the tests used, and the Minimum Average Roll Value (MARV) values for each roll. This certification and any other supporting documentation shall be provided to the Engineer prior to the material being delivered to the construction site. 1052.4 Large Block Wall Systems-Concrete Facing Panels. This specification covers the concrete facing panels that are used as part of large block mechanically stabilized earth wall systems. 1052.4.1 Material. 1052.4.1.1 Concrete. Concrete material, proportioning, air entraining, mixing, slump and transporting of concrete shall be in accordance with Section 501, except as noted in this section. 1052.4.1.2 Aggregate. Fine and coarse aggregate for the concrete mixture shall meet the requirements of Section 1005, except that the requirements for gradation and percent passing the No. 200 sieve will not apply. 1052.4.2 Design. The concrete shall be Class A-1, air entrained, with a minimum compressive strength of 4,000 psi at 28 days. No additional admixtures will be permitted unless approved by the Engineer.
11/1/2016
1052-2
Mechanically Stabilized Earth Wall System Components
1052.4.3 Casting. The panels shall be cast in such a manner that the acceptance criteria of this specification are met. Soil reinforcement connection devices shall not be in contact with or attached to the reinforcing steel in the concrete facing panels. 1052.4.4 Testing. 1052.4.4.1 Compression tests shall be made on a standard 6 inch x 12 inch test specimen prepared in accordance with AASHTO T 23. Compressive strength testing shall be conducted in accordance with AASHTO T 22. 1052.4.4.2 During the production of the panels, the manufacturer shall randomly sample the concrete in accordance with AASHTO T 141. A single compressive strength sample, consisting of a minimum of four cylinders, shall be randomly selected for every production lot. A production lot shall be defined as a group of panels that will be represented by a single compressive strength sample and shall consist of either 40 panels or a single day's production, whichever is less. 1052.4.4.3 For every compressive strength sample, a minimum of two cylinders shall be cured in the same manner as the panels and tested at seven days or less. The average compressive strength of these cylinders, when tested in accordance with AASHTO T 22, shall represent the initial strength of the concrete. In addition, a minimum of two cylinders shall be cured in accordance with AASHTO T 23 and tested at 28 days. The average compressive strength of these cylinders, when tested in accordance with AASHTO T 22, shall represent the compressive strength of the production lot. 1052.4.4.4 Air content testing shall be performed in accordance with AASHTO T 152 or AASHTO T 196. Air content samples shall be taken at the beginning of each day's production and at the same time as compressive samples are taken to ensure compliance with this specification. 1052.4.4.5 Slump testing shall be performed in accordance with AASHTO T 119. The slump shall be determined at the beginning of each day's production and at the same time as the compressive strength samples are taken. 1052.4.5 Marking. The date of manufacture, production lot number and piece mark shall be clearly scribed on an unexposed face of each panel. 1052.4.6 Curing. Panels shall be cured in accordance with Section 1029.6. 1052.4.7 Handling, Storage and Shipping. All panels shall be free of chipping, discoloration, cracks, fractures, and any other defects determined to be detrimental to the cosmetic value or to the performance characteristics of the panels. The panels shall not be subjected to excessive bending stresses, and the panel connection devices and exposed exterior finish shall be protected from damage.
11/1/2016
1052-3
Mechanically Stabilized Earth Wall System Components
1052.4.8 Tolerances. 1052.4.8.1 Panel Dimensions. Panel connection devices shall be within 1 inch of the specified dimension. The panel face and thickness dimensions shall be within ⅛ inch of the specified dimension. All other dimensions or items shall be within ¼ inch of the specified dimensions. 1052.4.8.2 Panel Squareness. Squareness, as determined by the difference between the two diagonals, shall not exceed ½ inch. 1052.4.8.3 Panel Surface Finish. Surface defects on smooth formed surfaces measured over a length of 5 feet shall not exceed ⅛ inch. Surface defects on the textured-finish surfaces, measured over a length of 5 feet, shall not exceed ⅜ inch. 1052.4.9 Acceptance. 1052.4.9.1 Compressive Strength. Acceptance of the compressive strength of the concrete facing panels will be based upon production lots. Acceptance of the compressive strength of a production lot will occur if the compressive strength test result is equal to or greater than 4,000 psi at 28 days. If the compressive strength is less than 4,000 psi, the concrete facing panels will be accepted if all of the following criteria are met: 1) 90% of the compressive strength test results for the overall production exceed 4,100 psi at 28 days; 2) The average of any six consecutive compressive strength test results exceeds 4,250 psi at 28 days; 3) No individual compressive strength test results are below 3,600 psi at 28 days. 1052.4.9.2 Other Criteria. Concrete facing panels will not be accepted if any of the following defects are found: 1) Defects that indicate imperfect molding; 2) Defects indicating honeycombing or open texture concrete; 3) Cracked or severely chipped panels; 4) Color variation on front face of panel due to excess form oil or other reasons. 1052.4.9.3 Documentation. The contractor shall require the manufacturer of the concrete face panels to certify that the concrete face panels are in accordance with this specification. This certification, copies of test results for all required tests, and any other supporting documentation shall be provided to the engineer prior to the material being shipped to the construction site.
11/1/2016
1052-4
Mechanically Stabilized Earth Wall System Components
1052.5 Small Block Wall Systems-Concrete Blocks. This specification covers the concrete blocks that are used as part of small block mechanically stabilized earth wall systems. 1052.5.1 Material. 1052.5.1.1 Concrete. 1052.5.1.1.1 Concrete material, proportioning, air entraining, mixing, slump and transporting of concrete shall be in accordance with Section 501, except as noted in this section. 1052.5.1.1.2 Air-entraining agents, coloring pigments, integral water repellents, finely ground silica and other constituents shall be previously established as suitable for use and shall be in accordance with applicable ASTM standards or evidence shall be provided to prove that the product is not detrimental to the durability of the concrete blocks or any material customarily used in masonry construction. 1052.5.1.2 Aggregates. Fine and coarse aggregates for the concrete mixture shall meet the requirements of Section 1005, except that the requirements for gradation and percent passing the No. 200 sieve will not apply. 1052.5.2 Design. The concrete mixture shall be air entrained and shall have a minimum compressive strength of 4,000 psi at 28 days. The design of the mixture shall be submitted to the Engineer and approved before use. No additional admixtures will be permitted unless approved by the Engineer. 1052.5.3 Finish Color. Color and finish shall be as shown on the plans and shall be erected with a running bond configuration. If no color or finish is specified on the plans, the contractor shall provide a color and finish to the Engineer for approval. 1052.5.4 Testing. 1052.5.4.1 The manufacturer shall perform compressive strength tests for the concrete blocks on a lot basis with the maximum number of blocks per lot being 2000. The lot shall be randomly sampled in accordance with ASTM C 140. Compressive strength test specimens shall be cored or shall be in accordance with the saw-cut coupon provisions of Section 5.2.4 of ASTM C 140. 1052.5.4.2 The concrete blocks shall be tested for freeze-thaw durability in accordance with ASTM C 1262. Freeze-thaw durability shall be based on tests from five specimens made with the same material, concrete mix design, manufacturing process and curing process. Tests shall be required for every project or for every 10,000 concrete blocks that are provided, whichever is greater. The specimens shall be in accordance with both of the following provisions: 1) The weight loss of four out of five specimens at the conclusion of 150 cycles shall not exceed 1% of the initial weight when tested in water. 2) The weight loss of each of four of the five test specimens at the conclusion of 50 cycles shall not exceed 1.5% of the initial weight when tested in a 3% saline solution. 11/1/2016
1052-5
Mechanically Stabilized Earth Wall System Components
1052.5.5 Curing. Concrete blocks shall be cured in accordance with Section 1029.6.11. 1052.5.6 Tolerances. tolerances:
Concrete blocks shall be manufactured within the following
1) The length and width of each concrete block shall be within ⅛ inch of the specified dimension. 2) The height of each concrete block shall be within 1⁄16 inch of the specified dimension. 3) When a broken face finished is used, the dimension of the front face shall be within 1 inch of the theoretical dimension of the concrete block. 1052.5.7 Acceptance. 1052.5.7.1 Compressive strength acceptance of the concrete blocks will be determined on a lot basis. Concrete blocks represented by test coupons that do not reach an average compressive strength of 4,000 psi will be rejected. 1052.5.7.2 At the time of delivery to the work site, the concrete blocks shall be in accordance with the following physical requirements: 1) Minimum compressive strength shall be 4,000 psi based on an average of three test coupons. 2) Minimum compressive strength of an individual test coupon shall be 3,500 psi. 3) Maximum water absorption shall be five percent. 1052.5.7.3 All concrete blocks shall be sound and free of cracks or other defects that would interfere with the proper placing of the blocks or significantly impair the strength or permanence of the construction. Minor cracks shall be defined as cracks that are not wider than 1⁄64 inch and not longer than 25% of the block height. Minor cracks incidental to the usual method of manufacture or minor chipping resulting from shipment and delivery will not be grounds for rejection. 1052.5.7.4 Any exposed face of a concrete block shall be free of chips, cracks or other imperfections when viewed from a distance of 30 feet under diffused lighting. Up to five percent of a shipment may contain slight cracks or may contain small chips no larger than 1 inch.
11/1/2016
1052-6
Mechanically Stabilized Earth Wall System Components
1052.5.7.5 Concrete blocks will be rejected for failure to meet any of the requirements specified above. In addition, any or all of the following defects will be sufficient cause for rejection: 1) Defects that indicate imperfect molding; 2) Defects indicating honeycomb or open texture concrete; 3) Cracked or severely chipped blocks; 4) Color variation on front face of blocks due to excess form oil or other reasons. 1052.5.7.6 The contractor shall require the manufacturer of the concrete blocks to certify that the concrete blocks are in accordance with this specification. This certification, copies of test results for all required tests and any other supporting documentation shall be provided to the engineer prior to the material being shipped to the construction site. 1052.6 Coping and Top Cap Units. 1052.6.1 Precast or cast-in-place coping for MSE walls shall be constructed with epoxy coated Grade 60 (Grade 420) reinforcement and in accordance with the contract documents. Concrete shall be in accordance with the applicable requirements of Section 501 of the St. Louis County Standard Specifications for Road and Bridge Construction. Concrete for coping shall be Class B2 or B1.
11/1/2016
1052-7
Mechanically Stabilized Earth Wall System Components
(This Page Intentionally Left Blank)
11/1/2016
1052-8
Mechanically Stabilized Earth Wall System Components
Section 1053
Penetrating Protective Sealer Material
1053.1 Scope. This specification covers the material requirements of a low VOC penetrating type protective sealer for use on Portland cement concrete. 1053.2 General. The material shall be a one component material consisting of a penetrating sealer which does not alter the color or texture of Portland cement concrete. The sealer shall not permanently stain, discolor or darken the concrete. Application of the sealer shall not alter the surface texture or form a coating on the concrete surfaces. 1053.3 Material Requirements. Penetrating sealers shall dry clear, be a breathable, highperformance, sealer for protecting new and existing concrete surfaces. The sealer shall penetrate deeply, sealing out water, chloride ions, and acids, preventing damage from freeze / thaw cycles. 1053.3.1 Chemical Composition. Penetrating sealers shall be a one-part liquid, composed of 100 percent alkyltrialoxysilane material and have the following chemical composition: Property
Requirement
Solvent, by weight
Less than 0.1 percent
Chloride Ion Content
Less than 40 PPM
1053.3.2 Physical Properties. The sealer shall meet the physical requirements in one application. The material properties at 75°F and 50 percent relative humidity are: Property
Requirement
Test Method
Color
Applied: Water white or clear Post-Application (dry): Clear
Water Vapor Transmission
> 90 percent
ASTM D 1653
Flash point
> 100°F
ASTM D 56
VOC content
≤ 400 g/L, less water and exempt solvents
ASTM D 5095
Weight / gal
> 7.0 lbs/gal
Reduction in Absorbed Chloride
> 90 percent
NCHRP 244, Series IV, ASTM G 53
Average depth of penetration
≥ 0.2 inch (on NCHRP #244 Concrete)
NCHRP 244, Series IV
Water Absorption of Hardened Concrete- 48 hour water soak
< 1.0 percent absorption by weight
ASTM C 642
2/4/2011
1053-1
Penetrating Protective Sealer Material
1053.3.2.1 Drying Time. The required drying time is based on the concrete service status at the time of application. When tested in accordance with ASTM D 1640, the drying time required for concrete when: 1) In-service is less than or equal to one hour after application. 2) Not in-service is less than or equal to four hours after application. 1053.3.2 Workability. The material will not alter the appearance or texture of the surface or effect the skid resistance of the concrete surface to which it is applied. The product shall be applied as a "Single Component" mixture with no pre-blending requirement. 1053.3.3 Environmental Compliance Criteria. Sealant shall comply with all E.P.A. and Missouri Department of Natural Resources regulations regarding health, safety and V.O.C. (Volatile Organic Content), as determined by ASTM D 5095, shall be ≤ 400 g/L, less water and exempt solvents. Waste must be disposed of in accordance with federal, state and local regulations. Incineration is the preferred method. Empty containers must be handled with care due to the combustibility of product residue. The heating or cutting of the empty container with electric or gas torch is prohibited. 1053.3.4 Testing Requirements. An independent laboratory report shall be submitted, certifying that the product offered satisfies the chemical, physical, and environmental requirements of the specifications. The application rate, in square feet per gallon of material, shall also be reported for the class of concrete to be sealed. 1053.3.5 Packaging. The sealer shall be packaged in strong, substantial unopened 5 or 55 gallon containers. Each container shall be marked with the manufacturer's label identifying the product and with the seal(s) intact and clearly marked with the manufacturer's name and address; product name; date of manufacture and expiration date or shelf life; quantity of material; application instructions; lot / batch identification number; and storage requirements. 1053.4 Application and Storage. Material shall not be stored near heat, sparks or open flame. When applying the material in an enclosed area, air respirator should be used. The sealing material shall be stored within the temperature range specified by the manufacturer. Material shall be able to be applied when the air or surface temperature is above 40°F and less than 100°F. Material shall not be applied in below-grade applications, during inclement weather or if rain is expected within 12 hours. Concrete shall be cured a minimum of 28 days prior to application. Surfaces to be sealed shall be dry a minimum of 48 hours following rain or exposure to other sources of moisture. Mask or protect adjacent surfaces including grass, plants, shrubs glass, asphalt and metal or automobile finishes from overspray or direct spray. Do not apply by spray when wind speed is above 10 mph or when material may be blown onto unintended surfaces. Material shall not be diluted. All surfaces are to be cleaned to remove all traces of dirt, dust, efflorescence, mold, salt, grease, oil, asphalt, laitance curing compounds, paint, coatings and other contaminants. Prior to application all joints and moving cracks shall be sealed and fully cured. Applicators shall wear appropriate personnel protective equipment, such as goggles and gloves, when applying sealer. Material can be applied by low-pressure (15-25 psi) spray pumping equipment with a wet fan spray nozzle, by roller with a 1 inch nap or by brush. Excess material can be removed by the use of broom or squeegee. Clean all spills in a timely manner. On vertical surfaces, application of the sealer shall be made in a flooding 2/4/2011
1053-2
Penetrating Protective Sealer Material
application from the bottom up, so the material runs down 6 to 8 inches below the spray pattern. Manufacturer's application and storage guidelines shall be followed. 1053.4.1 Rate. The surface area per gallon application rate on concrete surfaces shall be as specified by the manufacture to achieve the minimum stated physical properties. The maximum allowable surface area per gallon application rate on concrete surfaces shall be as determined by the manufacture or:
Application Rate, ft.2/gal
Surface Type Bridge Deck
250
All other concrete, block, stone or brick surfaces exposed to deicing salts
225
1053.5 Basis of Acceptance. Acceptance of penetrating type sealers will be based upon the compliance of the manufacturer’s certification with the requirements of this section. The shelf life of this material shall not exceed one year from the date of manufacture printed on the product label. A Material Safety Data Sheet shall be supplied with each shipment of material.
2/4/2011
1053-3
Penetrating Protective Sealer Material
(This Page Intentionally Left Blank)
2/4/2011
1053-4
Penetrating Protective Sealer Material
Section 1054
Concrete Admixtures
1054.1 Scope. This specification covers air-entraining admixtures, water-reducing admixtures, retarding admixtures, accelerating admixtures and latex emulsion admixtures for concrete. Guidance on the use of admixtures for concrete can be found in ACI 212. 1054.2 Acceptance. All material under this specification shall be obtained from a source identified on the MoDOT's PAL designated for this specification. All material under this specification will be inspected and accepted in accordance with Section 106.11. 1054.3 Air-Entraining Admixtures. 1054.3.1 Air-entraining admixtures shall be in accordance with AASHTO M 154, except as modified herein. 1054.3.2 Certification. The manufacturer shall submit a certification to the Construction Division Manager prior to approval. The certification shall provide the following: 1) The brand name and designation; 2) The composition or description of the admixture; 3) The manufacturing ranges for percent total solids and pH by ASTM E 70; 4) The infrared spectrum; 5) The manner in which the material will be identified on containers; 6) The material will be in accordance with these specifications. 1054.3.2.1 The certifications shall include or have attached specific test results as required in Section 1054.3.2.2 or Section 1054.3.2.3. 1054.3.2.3 For an air-entraining admixture other than that specified in Section 1054.3.2.4, the certification shall include results of tests conforming to the requirements of AASHTO M 154. Tests for bleeding, bond strength and volume change will not be required. 1054.3.2.4 For an air-entraining admixture which is an aqueous solution of Vinsol® resin, manufactured by neutralizing the resin with sodium hydroxide, the certification shall include results of tests showing the ratio of sodium hydroxide to Vinsol® resin. The certification or test report shall also state that no other additive or chemical agent is present in the solution.
12/9/2013
1054-1
Concrete Admixtures
1054.3.3 Packaging and Marking. The containers in which air-entraining admixtures are delivered shall be plainly marked with the manufacturer's name, the brand name and designation of the material, lot number and net quantity. Bulk shipments shall be accompanied by a delivery ticket showing this information. If the manufacturer supplies airentraining admixtures in more than one concentration, the concentration shall be designated on the container, or for bulk shipments in a prominent manner on the delivery ticket. 1054.4 Water-Reducing Admixtures. 1054.4.1 Water-reducing admixtures shall be in accordance with AASHTO M 194, Type F or G, except as modified herein. Water reducing admixtures used shall achieve a water reduction greater than 15 percent and shall be composed of polyether-polycarboxylate and be designated as a high-range water reducing admixture (HRWRA). The water contained in the water reducer shall be considered in the calculation of the water / cementitious ratio when the dosage exceeds 0.5 gallon per cubic yard. 1054.4.2 Certification. The manufacturer shall submit a certification to the Construction Division Manager prior to approval. 1054.4.2.1 The certification shall provide the following: 1) The brand name and designation; 2) The composition or description of the admixture; 3) The manufacturing ranges for specific gravity at 77°F and percent total solids; 4) The infrared spectrum; 5) The manner in which the material will be identified on containers; 6) The material will be in accordance with these specifications. 1054.4.2.2 The certification shall include or have attached specific test results complying with AASHTO M 194, Type F or G, as applicable, and the recommendation for use including amounts to be added. 1054.4.3 Packaging and Marking. The containers in which water-reducing admixtures are delivered shall be plainly marked with the manufacturer's name, the brand name and designation of the material, lot number and net quantity. Bulk shipments shall be accompanied by a delivery ticket showing this information.
12/9/2013
1054-2
Concrete Admixtures
1054.5 Retarding Admixtures. 1054.5.1 Retarding admixtures shall be in accordance with AASHTO M 194, Type B, D or G except as modified herein. 1054.5.2 Certification. The manufacturer shall submit a certification to the Construction Division Manager prior to approval. 1054.5.2.1 The certification shall provide the following: 1) The brand name and designation; 2) The composition or description of the admixture; 3) The manufacturing ranges for specific gravity at 77°F and percent total solids; 4) The infrared spectrum; 5) The manner in which the material will be identified on containers; 6) The material will be in accordance with these specifications. 1054.5.2.2 The certification shall include or have attached specific test results complying with AASHTO M 194, Type B, D or G, and the recommendation for use including amounts to be added. 1054.5.3 Packaging and Marking. The containers in which retarding admixtures are delivered shall be plainly marked with the manufacturer's name, the brand name and designation of the material, lot number and net quantity. Bulk shipments shall be accompanied by a delivery ticket showing this information. 1054.6 Accelerating Admixtures. 1054.6.1 Non-calcium chloride accelerating admixtures when used, shall be in accordance with AASHTO M 194, Type C or E, except as modified herein. 1054.6.1.1 Calcium Chloride. Calcium Chloride accelerating admixture, when used, shall be in accordance with AASHTO M 144. Typical calcium chloride-based accelerator solids content is 30 percent. The water contained in the calcium chloride admixture shall be considered to add 7 pounds of water per gallon of admixture when determining the total amount of free water and the water / cementitious ratio.
12/9/2013
1054-3
Concrete Admixtures
1054.6.2 Certification. The manufacturer shall submit a certification to the Construction Division Manager prior to approval. 1054.6.2.1 The certification shall provide the following: 1) The brand name and designation; 2) The composition or description of the admixture; 3) The manufacturing ranges for specific gravity at 77°F and percent total solids; 4) The infrared spectrum; 5) The manner in which the material will be identified on containers; 6) The material will be in accordance with these specifications. 1054.6.2.2 For non-calcium chloride calcium nitrite accelerating admixtures (NCA), the certification shall include or have attached specific test results complying with AASHTO M 194, Type C or E, and the recommendation for use including amounts to be added. For calcium chloride accelerating admixtures, the certification shall include or have attached specific test results complying with AASHTO M 144 and the recommendation for use including amounts to be added. Liquid accelerating admixtures used at dosages greater than 64 ounces per cubic yard shall be considered to add 7 pounds of water per gallon of admixture when determining the total amount of free water and the water / cementitious ratio. 1054.6.3 Packaging and Marking. The containers in which accelerating admixtures are delivered shall be plainly marked with the manufacturer's name, the brand name and designation of the material, lot number and net quantity. Bulk shipments shall be accompanied by a delivery ticket showing this information. 1054.7 Latex Emulsion Admixtures. 1054.7.1 Latex emulsion admixtures shall be non-toxic, film-forming, polymeric emulsion in water to which all stabilizers have been added at the point of manufacture. The admixture shall be a styrene-butadiene latex emulsion in which at least 90% of the non-volatiles are styrene-butadiene polymers.
12/9/2013
1054-4
Concrete Admixtures
1054.7.1.1 The admixture shall be homogeneous, uniform in composition and shall meet the following requirements when tested in accordance with the procedures shown in Report Number FHWA-RD-78-35, April 1978, Styrene-Butadiene Latex Modifiers for Bridge Deck Overlay Concrete:
Property
Specific Value
Color
White
Polymer Type
Styrene-Butadiene
Percent Solids
46 - 53
pH
5.0 - 12.0, the pH may not vary more than ±1 from the pH of material submitted for prequalification.
Particle Size
1400 to 2500 Angstroms, the mean particle size shall not vary more than ±300 Angstroms from the mean diameter of material submitted for the prequalification.
Viscosity
±20 centipoises of the viscosity of material submitted for prequalification.
Percent Coagulum
0.10% by weight, max.
Freeze-Thaw Stability
0.10% by weight max., coagulum after 2 freeze-thaw cycles.
Surface Tension
50.0 dynes/cm, max.
Percent Butadiene
30 to 40 by weight
1054.7.2 Certification. The manufacturer shall submit a certification to the Construction Division Manager prior to approval. 1054.7.2.1 The certification shall provide the following: 1) The brand name and designation; 2) The composition or description of the admixture; 3) The manufacturing ranges for specific gravity at 77°F by AASHTO T 157, percent total solids by ASTM D 1644 Method A and pH by ASTM E 70; 4) The infrared spectrum; 5) The manner in which the material will be identified on containers; 6) The material will be in accordance with these specifications.
12/9/2013
1054-5
Concrete Admixtures
1054.7.2.2 The certification shall include or have attached specific test results complying with this specification. 1054.7.3 Packaging and Marking. The containers in which latex emulsion admixtures are delivered shall be plainly marked with the manufacturer's name, the brand name and designation of the material, lot number and net quantity. Bulk shipments shall be accompanied by a delivery ticket showing this information.
12/9/2013
1054-6
Concrete Admixtures
Section 1055
Concrete Curing Material
1055.1 Scope. This specification covers material to be used for the purpose of curing Portland cement concrete. Curing is a procedure for insuring the hydration of the cementitious materials in newly-placed concrete. It generally implies control of moisture loss and sometimes of temperature. These curing materials are divided into intermediate and final curing. 1055.1.1 Acceptance. Material under this specification may be obtained from a source identified on the MoDOT PAL designated for this specification. If the manufacturer is different from the source supplying the material, the manufacturer shall also be listed. All material under this specification will be inspected and accepted in accordance with Section 106.11. 1055.2 Intermediate Curing Materials (Moisture Retention) Scope. Intermediate curing materials are liquid or atomized materials placed between when the surface has been finished and before the final set of the concrete begins. The purpose of initial curing of concrete is to reduce the loss of moisture from the concrete surface. 1) VOC Content. The applied VOC Content shall be less than 350 g/l as determined by ASTM D 5095. 1055.2.1 Evaporation Reducers Scope. This specification covers material to be used for the purpose of reducing the rapid evaporation (when the rate of evaporation exceeds 0.1 lb./ft.2/hour as determined by ACI 305 chart of evaporation rates) of concrete pavement and superstructure immediately after the surface texture is applied. 1055.2.1.1 Material Requirements. Evaporation reducers shall produce a continuous mono-molecular film on fresh concrete surfaces and shall be: 1) Water-based. 2) Colored / tinted to assist in the uniform application of the product and that dissipates once the concrete surface is dry. 3) Shall have no effect on the concrete hydration process. 4) Reduce surface moisture evaporation by: a) 35 percent in sunlight. b) 75 percent in wind. 5) Applied at a rate not less than 1 gallon per no more than 200 sq. ft.
12/9/2013
1055-1
Concrete Curing Material
1055.2.2 Water Fogging Scope. This specification covers water fogging to be used for the purpose of reducing the rapid evaporation (when the rate of evaporation exceeds 0.1 lb./ft.2/hour as determined by ACI 305 chart of evaporation rates) of concrete pavement and superstructure immediately after the surface texture is applied. This process is used during hot weather conditions to increase the relative humidity in the air above the concrete surface, reducing the rate of evaporation. 1055.2.2.1 Material Requirements. Water fogging uses specially designed multi-port nozzles that atomizes the potable water (see Section 1070) into a fog-like mist. The fog spray is directed above, not at, the concrete surface, which means continuous fogging is necessary. Water from fogging shall not be worked into the surface in subsequent finishing operations. The applied water fogging temperature shall not be less than 20°F of the concrete at the time of placement. Water from fogging shall be either removed or allowed to evaporate before finishing. The concrete surface shall be kept moist at all times by fogging with approved atomizing nozzles until the surface has been covered by the final cure. 1055.2.2.2 Fogging Equipment. To supply additional moisture above the concrete surface to increase the relative humidity of the air just above the plastic concrete surface without accumulating any water on the concrete, use fogging equipment with the following characteristics: 1) Water to be used is defined in accordance with Section 1070; 2) A heavy-duty pump capable of delivering a minimum fog application not less than 10.6 gallons of water per hour per square yard to at least two solid brass multiport fogging nozzles that produce atomized water with a maximum droplet diameter of 0.003 inch at an air pressure of 100 psi; 3) The ability to consume approximately 22 ft³/minute of compressed air; 4) The rate of fogging shall be such that evaporation of water from the concrete surface is prevented and that standing water does no accumulate on the concrete surface; 5) A minimum ⅜ inch inside diameter hose long enough to reach all areas of the paved surface; and 6) An adjustable spray gun and tip to provide various patterns of atomized spray or fog for changing finishing conditions. 1055.2.2.3 Basis of Acceptance. The water fogging equipment and application method of reducing evaporation shall be submitted to the Division Manager of Construction for review, modification and approval 14 calendar days before the date of use. The submittals shall include manufacturer guide installation instructions and any deviation(s) required. The method will be accepted on the basis of the Engineer's visual inspection during the fogging operation.
12/9/2013
1055-2
Concrete Curing Material
1055.3 Final Curing Materials (Moisture Application) Scope. Final curing materials are liquid or wet burlap materials placed immediately after the final set of the concrete has taken place. Burlap materials are used in conjunction with potable curing water. Curing water shall not be less than 20°F of the concrete at the time of placement. Absorbent material shall be nonstaining and free of sugars or fertilizers. 1055.3.1 Ponding or Immersion. 1055.3.1.1 Scope. This specification covers the use of water ponding or immersion used in curing superstructure, precast, retaining wall or slip form concrete. After the concrete has achieve its final set, a pond of potable water can be created by a ridge, dike or other dam at the edge of the slab, culvert floor or footing. 1055.3.1.2 Material Requirements. Water shall be used that is in accordance with Section 1070. The water shall not be more the 20°F cooler than the concrete at the time of placement and the dike around the pound shall be secured from leaking during the curing period. After curing the material shall dissipate naturally or be removed in manner approved by the Engineer that does not contaminate storm water structures or open water channels. 1055.3.2.3 Basis of Acceptance. The use of water ponding for curing, including method for disposal of water, shall be approved in advance by the Engineer. Ponding shall not be used during winter concreting conditions, but may be used at other times with the approval of the Engineer. 1055.3.2 Burlap and Mats of Jute or Cotton. 1055.3.2.1 Scope. This specification covers requirements for burlap used in curing superstructure, precast, retaining wall or slip form concrete. Blanket material shall be maintained in a wet condition during the curing period using soaker hoses or sprinklers. 1055.3.2.2 Material Requirements. For curing, burlap cloth made from Jute or Kenaf and Cotton Mats shall be in accordance with AASHTO M 182, Class 4. The Burlap shall be of one type and be manufactured to weigh 10 to 12 ounces per linear yard on a 40 inch basis. Jute mats shall consist of two plies of burlap stitched together to maintain the shape and stability of the unit. Cotton mats shall consist of filler or cotton batts covered with unsized cloth or burlap, and tufted or stitched to maintain the shape and stability of the unit. Burlap and mats shall, in the judgment of the Engineer, be of such construction and in such condition as required to adequately maintain free moisture on the surface of the concrete with the type of system being used to provide the water. Material shall be free from deleterious matter harmful to concrete. Burlap shall be free from cuts, tears, uneven weaving and contaminants. The length of the mats shall be 2 feet 6 inches greater than the width of pavement to be cured. 1055.3.2.3 Basis of Acceptance. Burlap shall be cleaned and free from cuts, tears, uneven weaving and contaminants. The burlap will be accepted on the basis of a visual inspection by the Engineer, weighing of a sample at the point of use and by a certification that specifies this product conforms to this specification.
12/9/2013
1055-3
Concrete Curing Material
1055.3.3 White Burlap-Polyethylene Sheeting. 1055.3.3.1 Scope. This specification covers requirements for white burlap-polyethylene sheeting used in curing concrete. Blanket material shall be maintained in a wet condition during the curing period using soaker hoses or sprinklers. 1055.3.3.2 Material Requirements. White burlap-polyethylene sheeting shall be in accordance with ASTM C 171. White burlap-polyethylene sheeting shall consist of burlap weighing not less than 9 oz./yd2, extrusion coated on one side with white opaque polyethylene at least 4 mil (0.004 inch) thick and the white side shall have a minimum daylight reflectance of 70 percent as determined by ASTM E 1347. The water vapor transmission rate (WVTR) of the sheet material shall be no more than 10 g/m2 in 24 hours when tested in accordance with ASTM E 96. Each roll of white burlappolyethylene sheeting shall be identified with the length, width, and name and address of the manufacturer. 1055.3.3.3 Basis of Acceptance. White burlap-polyethylene sheeting shall be clean and free from cuts, tears, uneven burlap weaving and contaminants. The white burlappolyethylene sheeting will be accepted on the basis of a visual inspection by the Engineer, weighing of a sample at the point of use and by a certification that specifies this product conforms to this specification. 1055.4 Final Curing Material (Moisture Retention) Scope. Final curing materials are liquid or wet burlap materials placed immediately after the final set of the concrete has taken place. The following final curing sheet or liquid membrane curing materials are based on moisture retention. 1055.4.1 Sheet Curing Materials. 1055.4.1.1 Scope. This specification covers requirements for sheet curing materials used on concrete pavement. 1055.4.1.2 Waterproof Curing Paper. 1055.4.1.2.1 Material Requirements. Waterproof curing paper, in accordance with ASTM C 171, shall consist of two sheets of kraft paper cemented together with a bituminous material in which are embedded cords or strands of fiber running in both directions and not more than 1¼ inches apart. The paper shall be light in color, free of visible defects and shall have a uniform appearance. White paper shall have a white surface on at least one side. The white side shall have a minimum daylight reflectance of 50 percent as determined by ASTM E 1347. The water vapor transmission rate (WVTR) of the sheet material shall be no more than 10g/m2 in 24 hours when tested in accordance with ASTM E 96. 1055.4.1.2.2 Basis of Acceptance. Each shipment shall be accompanied by the manufacturer's certificate attesting to the fact that the shipment meets the specified standards. Upon request, the manufacturer shall supply a record of the results of the prescribed tests as made on the samples to the Engineer.
12/9/2013
1055-4
Concrete Curing Material
1055.4.1.3 Polyethylene Sheeting. 1055.4.1.3.1 Material Requirements. Polyethylene sheeting shall be in accordance with Section 1058 for curing Portland cement concrete. The water vapor transmission rate (WVTR) of the sheet material shall be no more than 10g/m2 in 24 hours when tested in accordance with ASTM E 96. 1055.4.1.3.2 Basis of Acceptance. Each shipment shall be accompanied by the manufacturer's certificate attesting to the fact that the shipment meets the specified standards. Upon request, the manufacturer shall supply a record of the results of the prescribed tests as made on the samples. 1055.4.1.4 Closed-Cell Curing Blankets (Multi-Use). 1055.4.1.4.1 Scope. This specification covers closed-cell curing blankets (multiuse) that shall be manufactured for hot and cold weather concrete curing use. 1055.4.1.4.2 Material Requirements. Closed-cell curing blankets shall be strong, durable construction made of closed-cell polypropylene foam adhesive bonded between strong, abrasive-resistant, U.V. stabilized polyethylene coating vinylcovered fabric, each layer at least 6 mil (0.006 inch) in thickness. One side will have a reflective silver-color and the other will have a non-reflective black color. Closedcell curing blankets material will be judged on its ease and practicability of installation, durability and imperviousness to moisture penetration and absorption. The minimum thickness for any blanket insulation considered shall be 1 inch. The thermal conductivity (k) of any proposed insulating material shall not exceed 0.32 BTU per square foot per F per inch of thickness (R-value ≥ 3). If the material does not meet ASTM C 171 water vapor transmission rate requirements specified below, then polyethylene sheeting in accordance with Section 1055.4.1.3 is required to supplement the closed-cell curing blankets: 1) Performance requirements for water vapor transmission rate (WVTR) of the sheet material be no more than 10g/m2 in 24 hours when tested in accordance with ASTM E 96. 2) Physical requirements Polyethylene Sheeting.
in
accordance
with
Section
1055.4.1.3,
1055.4.1.4.3 Basis of Acceptance. Closed-cell curing blankets for all-weather concreting shall be accepted on the basis of the manufacturer's certificate attesting to the fact that the shipment meets the specified standards. Upon request, the manufacturer shall supply a record of the results of the prescribed tests as made on the samples.
12/9/2013
1055-5
Concrete Curing Material
1055.4.2 Liquid Membrane Curing Materials. 1055.4.2.1 Scope. This specification covers white-pigmented and clear membrane curing compound material and quality requirements for spray application on surfaces of newly placed Portland cement concrete. 1055.4.2.2 General. Water retention properties for all curing compounds shall be determined by ASTM C 156 Test Method for Water Retention by Concrete Curing Materials. The vehicle class of all curing compounds shall be Class A except as modified herein. Sampling from containers prior to application may be made upon request. A sample of curing compound shall consist of one quart of material in a screw top can. Approved material shall be delivered to the work site in clean containers. The curing compound shall be agitated mechanically to a uniform consistency throughout the container immediately before use or sampling. Material supplied shall be of a sprayable consistency and have a maximum permissible volatile organic compound (VOC) content of 350 g/L as determined by ASTM D 3960 Determining Volatile Organic Compound (VOC) Content of Paints and Related Coatings. Curing compounds shall be applied by power-driven pressure sprayers with a pressure range of 25 to 100 psi. For small irregular areas pressurized hand-operated spraying equipment may be used with approval of the Engineer. Spray nozzles shall be of the proper type for the material being sprayed. The curing membrane shall display properties described as follows: 1) Water Retention. At the specified minimum application rate and tested in accordance with ASTM C 156, the material shall restrict the loss of water to not more than 0.55 kg/m2 in 72 hours. 2) Drying Time. At the specified minimum application rate and tested in accordance with ASTM C 156, the material shall dry to the touch in not more than 4 hours. 3) Consistency Requirement. Produce a uniform coating by spraying at temperatures above 40°F. 1055.4.2.3 Material Requirements. 1055.4.2.3.1 Type 1-D Curing Compounds. For curing concrete driveway, paved approach, steps and medians. Type 1-D liquid membrane-forming curing compounds shall be in accordance with ASTM C 309 for Type 1-D, Class A translucent with red fugitive dye that will fade uniformly. Type 1-D curing compounds are applied to concrete median, median strip, sidewalk (exposed aggregate concrete shall use dissipating curing compounds), steps, and paved approaches. When applied immediately after the final set (disappearance of the surface water sheen) of the concrete has taken place, material shall be applied at a minimum rate of one gallon per no more than 150 square feet of surface. The curing membrane shall display properties described in Section 1055.4.2.2 and as follows: 1) Fugitive Dye. The membrane-forming compounds with red fugitive dye shall be readily distinguishable upon the concrete surface for at least 4 hours after application, but shall become inconspicuous within 7 days after application if exposed to direct sunlight.
12/9/2013
1055-6
Concrete Curing Material
1055.4.2.3.2 Type 2 Curing Compounds. For curing concrete pavement, the compound shall consist of finely ground white pigment and wax or resin-based vehicle, ready mixed for immediate use without alteration. Type 2, liquid membraneforming curing compounds shall be in accordance with ASTM C 309 for Type 2, Class A white pigmented. The product shall not be frozen during storage. Type 2 curing compounds are applied to Portland cement concrete pavements. When applied immediately after the final set of the concrete has taken place the material shall be applied at a minimum rate of one gallon per no more than 150 square feet of surface. The curing membrane shall display properties described in Section 1055.4.2.2 and as follows: 1) Reflectance Property. When tested in accordance with ASTM E 1347 shall exhibit a daylight reflectance of not less than 60 percent. 1055.4.2.3.3 Dissipating Curing Compounds. For concrete superstructures and pavements or bases to receive an asphaltic overlay after being open to traffic, curing compounds shall be liquid membrane-curing compounds in accordance with ASTM C 1315 Class B, which is a clear all resin (no wax) cure, for Type 1-D or Type 2 and shall be designated to be dissipating over time with exposure to direct sunlight (ultraviolet light). All superstructure curing compounds shall be manufactured such that the curing compounds may be removed prior to dissipation. When applied immediately after the final set of the concrete has taken place the material shall be applied at a minimum rate of not less than one gallon per no more than 150 square feet of surface. 1055.4.2.3.3.1 Additional Certification. Certification for bridge curing compounds shall include a statement that the product is manufactured to dissipate. The certification shall specify the method by which removal of the compound prior to dissipation or removal of residual material from the surface can be accomplished. 1055.4.2.3.4 High Performance Curing Compound. High performance curing compounds are for concrete pavement opened to traffic in three days or less. High performance white liquid membrane-forming compounds shall conform to the requirements of ASTM C 1315 for Type 2, Class A or B as follows: 1) Percent Solids. The curing compound shall have a minimum of 42 percent solids (total solids minus pigment) by total weight and the vehicle shall be 100 percent poly-alpha Methyl Styrene (PAMS). 2) Water Retention. As per ASTM C 156 the loss of water shall not be more than 0.15 kg/m2 at 24 hours and no more than 0.40 kg/m2 at 72 hours. 3) Reflectance. As per ASTM E 1347, the three-day reflectance readings shall be greater than 65.
12/9/2013
1055-7
Concrete Curing Material
4) Drying Time. As per ASTM C 1315 Part 8.3, shall set to touch in no longer than one hour after application and will be tack-free in no longer than four hours after application. 5) Application Rate. Not less than 1 gallon per no less than 200 sq. ft. of surface. 6) Flash Point. Shall have a flash point greater than 100°F. 1055.4.2.4 Basis of Acceptance. Material or systems under this specification may be obtained from a source identified on MoDOT's PAL designated for this specification and meeting the requirements specified herein. All material under this specification will be inspected and accepted in accordance with Section 106.11. 1055.4.2.5 General. Each shipment shall be accompanied by the manufacturer's certificate attesting to the fact that the shipment meets the specified standards. Upon request, the manufacturer shall supply a record of the results of the prescribed tests as made on the samples. 1055.4.2.6 Shipment Documentation. After approval, the manufacturer shall furnish, with each shipment, a certificate of analysis and performance test results for each batch number furnished, verifying that it meets ASTM C 309 for the type and class of liquid membrane-forming curing compound furnished, a Materials Safety Data Sheet and application instructions. Each container of liquid membrane curing compound shall be delivered in the manufacturer's original clean, sealed container plainly marked with the manufacturer's name and trademark, the batch number, the type and class of cure, and a date of manufacture. In addition, each container shall be legibly marked with the nominal percentage of nonvolatile material and place of manufacture. For material shipped in bulk tankers, a label shall be furnished with each load to be placed on the project storage tank for identification purposes. Compounds shall be used in the same year as manufactured. The manufacturer's certification and test results shall be made available upon request. 1055.4.2.7 Sampling. Each lot or batch of liquid membrane-forming compound shall be subject to sampling, testing and approval prior and during use. 1055.4.2.8 Packaging. Material shall be supplied in either 5 gallon pails or 55 gallon drums. 1055.4.3 Cold Weather Protection and Curing. 1055.4.3.1 Scope. This specification covers the material details, quality requirements, and method of application for approval of form insulating materials or equipment used for above-grade winter concreting operations.
12/9/2013
1055-8
Concrete Curing Material
1055.4.3.2 Heated Curing Blankets Scope. Electrically heated curing blankets shall be manufactured to maintain the pavement or structural concrete element's specified maintained temperature range, throughout the minimum specified curing period or until the minimum compressive strength specified is achieved. 1055.4.3.2.1 Material Requirements. Heated curing blankets shall be rated at a minimum power density of 15 watts per square foot and work on a thermostatically controlled, grounded 110 volt system. Heated curing blankets shall maintain the concrete’s minimum temperature within the operating tolerance specified for the curing period specified. Heated curing blankets shall be properly weighted and secured at laps and edges. Heated curing blankets shall be lapped at least 8 inches and be free from holes, cuts, tears and contaminants. If the material does not meet ASTM C 171 water vapor transmission rate requirements specified below, then polyethylene sheeting in accordance with Section 1055.4.1.3 is required to supplement the heated curing blankets: 1) Performance requirements for water vapor transmission rate (WVTR) of the sheet material be no more than 10g/m2 in 24 hours when tested in accordance with ASTM E 96. 2) Physical requirements in accordance with Section 1055.3.2.2 Polyethylene Sheeting. 1055.4.3.2.2 Testing. Maturity sensor(s) shall be embedded in the concrete by the Engineer to monitor temperature during the curing cycle. The Engineer shall inspect the system at any time for line breaks, excessive temperature or direct contact with the concrete element. 1055.4.3.2.3 Basis of Acceptance. Heated curing blankets for winter concreting shall be accepted on the basis of the manufacturer's certificate attesting to the fact that the shipment meets the specified standards. Upon request, the manufacturer shall supply the Engineer a record of the results of the prescribed tests as made on the samples. The heated curing blanket system shall be submitted to the Division Manager of Construction for review and approval at least 14 calendar days before the date of use. 1055.4.3.3 Hydronic Heat Transfer System Scope. A system shall be manufactured to maintain the pavement or structural concrete element's specified maintained temperature range, throughout the minimum specified curing period, or until the minimum compressive strength specified is achieved.
12/9/2013
1055-9
Concrete Curing Material
1055.4.3.3.1 Supplemental Material Requirements. If the material does not meet ASTM C 171 water vapor transmission rate requirements specified below, then polyethylene sheeting in accordance with Section 1055.4.1.3 is required to supplement the Hydronic heat transfer system. Materials used shall meet the following performance and physical requirements: 1) Performance requirements for water vapor transmission rate (WVTR) of the sheet material be no more than 10g/m2 in 24 hours when tested in accordance with ASTM E 96. 2) Physical requirements in accordance with Section 1055.3.2.2, Polyethylene Sheeting. 1055.4.3.3.2 Equipment Requirements. A Hydronic heat transfer system shall consist of a circulating glycol / water solution in a closed system of pipes or hoses, uniformly spaced no more than two feet apart, which can maintain a concrete slab or structural element's specified maintained temperature range for the specified curing time. 1055.4.3.3.3 Testing. Maturity sensor(s) shall be embedded in the concrete by the Engineer to monitor temperature during the curing cycle. The Engineer shall inspect the system at any time for leaks, line breaks, excessive temperature or direct contact with the concrete element. 1055.4.3.3.4 Basis of Acceptance. The hydronic system and method of curing shall be submitted to the Division Manager of Construction for review, modification and approval at least 14 calendar days before the date of use. The submittals shall include manufacturer guide installation instructions and any deviation(s) requested. Approved insulating blankets and vapor barrier shall be included in the system submittal for approval. 1055.4.3.4 Form Insulating Materials for Winter Concreting. 1055.4.3.4.1 Scope. This specification covers the material details, quality requirements, and method of application for approval of form insulating pavement or structural elements during winter concreting operations. Stay in-place insulating concrete forms or insulated composite forms may be used with the approval of the Engineer. Insulated forms for cold weather protection may be used at approved locations in lieu of enclosures, if the method will keep the temperature of the concrete within the specified as-maintained limits. The contractor shall secure prior approval by the Engineer of the type of insulation, method of insulation, and the locations at which it is proposed for use.
12/9/2013
1055-10
Concrete Curing Material
1055.4.3.4.2 Material Requirements. Each insulating material will be judged on its ease and practicability of installation, durability and imperviousness to moisture penetration and absorption. The minimum thickness for any foam board and blanket insulation considered shall be 1 inch. The thermal conductivity (k) of any proposed insulating material shall not exceed 0.32 BTU per square foot per F per inch of thickness (R-value ≥ 3). 1055.4.3.4.3 Sampling and Testing. Application of approval of an insulating material shall be made to the Materials Testing Lab. Certified laboratory test results for thermal conductivity (k) and thermal resistance (R), F per BTU per hour per square foot, measured at the nominal product thickness shall be required for evaluation. A 3 foot square (minimum) sample shall accompany each request for approval. The sample shall exhibit all major features of the insulating product such as covers, seams, fasteners, grommets, etc. All necessary and normal product information shall accompany the sample. If there is a specific process required to apply the insulating material, complete details of the process shall accompany the sample. 1055.4.3.4.4 Sprayed Foam Supplemental Sampling and Testing. If sprayed foam is the material in question, the Contractor shall also be required to send the applicator's name plus a list of jobs done by the applicator during the last 12 months. If investigation of these jobs demonstrates quality workmanship, the applicator shall be issued a temporary approval good for one contract. Based upon its subsequent performance, a decision will be made as to whether or not to approve the applicator on future work. 1055.4.3.4.5 Basis of Acceptance. The approval of the form insulating material shall be based upon the submitted information and tests performed by the Materials Testing Lab. Such products shall then be accepted on the basis of the brand name labeled plainly on the material. The insulating materials for winter concrete shall be submitted to the Division Manager of Construction for review, modification and approval at least 14 calendar days before the date of use. 1055.4.3.5 Heated Enclosures. 1055.4.3.5.1 Scope. This specification covers the material requirements for heated enclosures, which are used to cure cast-in-place structural concrete during winter concreting operations. 1055.4.3.5.2 General. Concrete placed in cold weather shall be protected from freezing during the curing period by the use of a heated weatherproof enclosure when the ambient temperature is below 40°F for superstructure, substructure units, and box culverts of an opening size 15 square feet or greater.
12/9/2013
1055-11
Concrete Curing Material
1055.4.3.5.3 Material and Equipment Requirements. Enclosures shall be designed to keep the concrete between the specified ranges of maintained concrete temperatures. When dry heat is used, at least 40 percent relative humidity shall be maintained at the concrete surface. The exposed surfaces of the concrete shall be kept moist either by the application of steam or wet burlap mats. When heaters are required they shall be vented to carry combustion gasses to the outside. The concentration of carbon dioxide in the enclosure air shall not be greater than 1.5 percent by volume when workers are present. The contractor shall provide adequate fire protection at all times and shall maintain proper temperature and humidity conditions within the housing during the specified curing period. Operations of the heater(s) are to be supervised continuously by the contractor. The contractor shall secure prior approval by the Engineer of the type of insulation, method of insulation, and the locations at which it is proposed for use. 1055.4.3.5.4 Testing. Maturity sensor(s) shall be embedded in the concrete by the Engineer to monitor temperature during the curing cycle. The Engineer shall inspect the system at any time for leaks, line breaks, excessive temperature or direct contact with the concrete element. 1055.4.3.5.5 Basis of Acceptance. The heated enclosure method of curing shall be submitted to the Division Manager of Construction for review, modification and approval at least 14 calendar days before the date of use. The submittals shall include manufacturer guide installation instructions and any deviation(s) requested. Approved liquid curing materials, insulating blankets and vapor barrier shall be included in the system submittal for approval. 1055.4.4 Curing System for Precast Concrete. This specification covers the material and equipment requirements for curing of precast concrete box culverts and reinforced concrete pipe. 1055.4.4.1 Water Curing. Concrete products are water cured by covering with watersaturated material, or by a system of perforated pipes, mechanical sprinklers, porous hose, or by any other Engineer approved method that will keep the products moist during the curing period. 1055.4.4.2 Sealing Membrane. A sealing membrane in accordance with ASTM C 309 is applied and shall be left intact until the required strength requirements are met. The concrete at the time of application of the membrane shall be within 10°F of the atmospheric temperature. All concrete surfaces shall be kept moist prior to the application of the membrane and shall be damp when the membrane is applied. 1055.4.4.3 Accelerated Curing with Low Pressure Steam or Radiant Heat. The manufacturer may use accelerated curing with low pressure stream or radiant heating in accordance with Section 1055.4.5 when approved by the Engineer. 1055.4.4.4 The manufacturer is not prohibited from combining the above methods provided the required concrete compressive strength is attained.
12/9/2013
1055-12
Concrete Curing Material
1055.4.4.5 Basis of Acceptance. The curing system for precast concrete shall be submitted to the Division Manager of Construction for review, modification and approval at least 14 calendar days before the date of use. 1055.4.5 Accelerated Curing with Low Pressure Steam or Radiant Heat Scope. This specification covers the material and equipment requirements for curing of precast prestressed concrete members with low pressure steam or radiant heat. All water applied for curing shall be in accordance with Section 1070. Burlap materials shall be in accordance with Section 1055.3.2.2. 1055.4.5.1 Radiant Heating. Radiant heat may be applied by means of pipes circulating steam, hot oil or hot water, or by electric heating elements. Perform radiant heat curing under a suitable waterproof enclosure to contain both heat and moisture. Minimize moisture loss by covering all exposed concrete surfaces with 2 layers of wet burlap. Temperature maintained in the enclosure and the concrete shall meet the requirements in accordance with Section 1055.4.5.2. 1055.4.5.2 Steam Curing. Concrete products are placed in a low pressure curing chamber, free of outside drafts, and cured in a moist atmosphere maintained by the injection of steam for such time and temperature as needed to enable the products to meet the specified strength requirements. When steam curing is applied, the jets shall not impinge directly on the concrete or on the forms; free circulation around the units shall be maintained; the steam shall be thoroughly saturated at all times; the temperature around the concrete shall not be raised more than 40°F per hour and shall not exceed 160°F at any time, while the maximum internal concrete temperature shall be limited to 180°F. Hold the maximum temperature until the concrete has reached the desired strength. After the expiration of the steam curing period, the temperature inside the chamber shall be reduced at a rate of not more than 40°F per hour until a temperature has been reached about 20°F above the temperature of the air to which the concrete will be exposed. Do not allow the temperature of the concrete to drop below 50°F at any time. 1055.4.5.3 Application of Heat or Steam Time Limitations. Allow the initial set of the concrete to take place by delaying the initial application of steam or heat from 2 to 4 hours after the final placement of concrete. If retarders are used, increase the waiting period before application of the steam or radiant heat to 4 to 6 hours. If the time of initial set is determined by the standard method of test for "Time of Setting of Concrete Mixtures by Penetration Resistance", ASTM C 403, the time limits described above may be waived. 1055.4.5.3.1 Instrumentation. When accelerated curing is used, install instruments during the curing period for measuring and recording temperature and humidity inside curing enclosures and for measuring and recording temperature in the concrete for each 200 feet of casting bed. Provide a minimum of 2 calibrated instrument installations of each type for each enclosure. The location of each instrument must be approved by the Engineer. Humidity level indicators may be waived by the Engineer.
12/9/2013
1055-13
Concrete Curing Material
1055.4.5.3.2 Recording Thermometers. Provide calibrated recording thermometers showing the time-temperature relationship throughout the curing period from placing concrete to transfer of prestress. All temperature records will be retained by the Engineer as part of the curing records. Missing or incomplete timetemperature records shall be cause for rejection of the corresponding prestressed units. Temperature limits and use of recording thermometers are the same when curing with steam or radiant heat. Due to the slow rise of ambient temperatures with radiant heat, application of heat cycles may be accelerated to meet climatic conditions, however, do not increase the ambient air temperature within the curing enclosure by more than 40°F per hour. 1055.4.4 Basis of Acceptance. The Accelerated Curing with Low Pressure Steam or Radiant Heat system, shall be submitted to the Division Manager of Construction for review, modification and approval at least 14 calendar days before the date of use. 1055.5 Documentation. The distributor shall maintain certification that the material and equipment supplied is in accordance with these specifications. The certification shall be made available upon request.
12/9/2013
1055-14
Concrete Curing Material
Section 1056
Concrete Tinting Material
1056.1 Scope. This specification covers material for colored and white pigments in powder form to be used as admixtures in concrete for the purpose of producing integrally colored concrete as specified in the contract documents. 1056.1.1 The maximum prescribed dosage rate of a pigment shall be specified by the manufacturer and be equal to or less than 10 percent of the mass of cement. 1056.2 Acceptance. The contractor shall supply the engineer with a manufacturer's certification indicating that the material supplied is in accordance with this specification. This certification shall include a report made in accordance with ASTM C 979 Standard Specification for Pigments for Integrally Colored Concrete Section 8 Report, representing the lot supplied. 1056.3 Rejection. 1056.3.1 Individual packages or containers varying more than 5 percent from the stated mass may be rejected. 1056.3.2 Individual packages or containers not clearly labeled in accordance with Section 1056.4 may be rejected. 1056.4 Delivery, Storage and Handling. 1056.4.1 Deliver materials in original packaging with labels intact. Packages or containers shall be clearly marked as to color designation and the net mass. 1056.4.2 The package or container, when so designated by the manufacturer, shall be added to the concrete batch, provided that it is composed of disintegrating paper or soluble material, which, when tested as a unit (pigment and packaging or container), conforms to the requirements of ASTM C 979. 1056.4.3 Store in clean, dry and protected location, according to manufacturer's requirements. 1056.5 Material. This material shall consist of a homogeneous mixture mineral oxide pigment of an approved tint with such other additives as deemed necessary by the manufacturer. The tinting material shall conform to specification outlined on ASTM C979. The material shall be free from oil, grease, dirt and nonferrous particles. The tinting material shall not contain any material that might promote oxidation of the iron particles if exposed to air and moisture, or that might have any detrimental effect on concrete.
2/4/2011
1056-1
Concrete Tinting Material
(This Page Intentionally Left Blank)
2/4/2011
1056-2
Concrete Tinting Material
Section 1057
Material for Joints
1057.1 Scope. This specification covers joint material to be used as specified or as shown on the plans. 1057.2 Acceptance. Material under this specification shall be obtained from a source identified on the MoDOT PAL designated for this specification. The Engineer on a project-byproject basis will review material sources not listed in a MoDOT PAL. 1057.3 Corrosion-Resistant Coated Dowel Bars. Dowels for transverse joints shall be in accordance with the requirements AASHTO M 254, Type B (ASTM A 615) Grade 40 or 60. The dowels shall be epoxy coated in accordance with Section 1036, except the non-abraded coating thickness shall be 7 ± 2 mils, the flexibility of coating requirement will not apply and the cut ends will not be required to be coated. The dowels shall be saw cut and free of cutting burrs and other projections. Dowel supporting units shall be in accordance with one of the types shown Standard Drawing C502.11. Welding to achieve a fixed-end condition shall be sufficiently strong to maintain dowel alignment under the forces imposed by concrete placement and construction practices. A minimum of 4 bar samples shall be submitted for testing from each size and each heat. Dowel bar diameters and length for various pavement thicknesses are summarized in the following table:
Dowel Bars - Epoxy Coated Bar Size
Pavement Thickness (T), inches
Minimum Diameter, inches
Length, inches
T<7
None
None
7≤T<9
1
18
9 ≤ T < 11
1¼
18
T ≥ 11
1½
18
1057.3.1 The free end of the dowel bar shall be coated with an approved graphite grease for a length of 11 inches. Graphite grease shall contain a minimum of 25 percent graphite, and the graphite content shall be certified by the manufacturer or shown on the container label. The graphite grease shall be applied with a thin, uniform coating that will result in a thorough covering of the free end of the bar.
10/1/2017
1057-1
Material for Joints
1057.3.2 In lieu of the graphite grease application, the dowel bar basket supplier may supply completed basket units pre-dipped in an approved bond breaker solution. The bond breaker solution shall not be applied in a spray or field application. The resulting dry dowel bar coating shall be visually evident. The coating shall be uniformly applied without excessive drips or thickness. Dirty or excessively scraped dowel bar units will be rejected. Rejected units may be used if the units are fully cleaned of all dirt and bond breaker coating and graphite grease is applied according to specifications. The dowel basket supplier shall provide a certification for the coating with each shipment, certifying the bond breaker product name, manufacturer and date of coating application. 1057.3.3 Recycled Content. Reinforcing steel manufactured with post-consumer or preconsumer material shall meet the AASHTO or ASTM requirements specified herein. When recycled materials are submitted for use, the recycled content shall be indicated in the certification documents and shall meet one of the following minimum requirements. 1057.3.3.1 Materials with recycled content such that the sum of post-consumer recycled content plus one-half of the pre-consumer content constitutes at least 10 percent (based on cost) of the total value of the material. 1057.3.3.2 Materials with recycled content such that the sum of post-consumer recycled content plus one-half of the pre-consumer content constitutes at least 20 percent of the total value of the material. 1057.4 Tie Bars. Tie bars for longitudinal joints and construction joints shall be round, deformed and shall be in accordance with AASHTO M 31 (ASTM A 615) Grade 60 except that tie bars which are to be bent and straightened shall be in accordance with AASHTO M 31, Grade 40. Tie bar diameters shall be No. 5 (No. 6 for pavement thickness ≥ 11 inches) for longitudinal construction joints, No. 4 for vertical curb dowels, or as specified in the contract documents. Tie bar lengths shall be 30 inches (40 inches for pavement thickness ≥ 11 inches) longitudinal construction joints, equal to the thickness of the pavement plus the height of the curb less 3 inches for vertical curb dowels, or as specified in the contract documents. Tie bars shall not be bent and straightened more than one time. Tie bars shall be epoxy coated in accordance with Section 1036, except the coating thickness shall be 7 ± 2 mils, the flexibility of coating requirement will not apply and the cut ends will not be required to be coated. Test reports shall be supplied for each heat. Bars shall be tagged with manufacturer's heat number or test identification number. Bar sample quantities shall be specified in the contract documents. If not specified in the contract documents then a straight tie bar sample shall be cut to size from the supplied bars and submitted for testing of each size and from each heat. 1057.4.1 Recycled Content. When recycled materials are submitted for use, the recycled content shall be in accordance with Section 1057.3.3. 1057.5 Joint and Crack Sealer, Hot-Poured Elastic Type. The sealer material shall be in accordance with ASTM D 6690 and as modified herein. The joint sealer material shall be packed and shipped in suitable commercial containers clearly marked with the name of the material, the name of the manufacturer, brand name, weight, batch number, pouring temperature recommended by the manufacturer, and maximum safe heating temperature.
10/1/2017
1057-2
Material for Joints
1057.5.1 Materials for sealing cracks in asphaltic concrete pavements, joints in concrete pavements and in previously sealed joints shall be a polymer based hot poured elastic type meeting specification requirements of ASTM D 6690, Type I "Joint and Crack Sealants, Hot Applied for Concrete and Asphalt Pavements" and shall conform to the following physical property requirements:
Test
Method
Specification Minimum
Maximum
Cone penetration (nonimmersed), 77°F, 0.1 mm
ASTM D 5329
50.0
90.0
Resilience, 77°F, percent
ASTM D 5329
40
-
Flow, 140°F, mm
ASTM D 5329
-
5
Softening point (USP Glycerin), °F
ASTM D 36
176
-
Bond (non-immersed), 0°F, 50 percent extension
ASTM D 5329
Pass 5 cycles
Asphalt compatibility
ASTM D 5329
Compatible
Minimum application temperature
ASTM D 5167
No more than 20°F below the Maximum Heating Temperature
Maximum (safe) heating temperature
ASTM D 6690
As per Manufacturer Product Data Sheet
Unit weight, 60°F, pounds per gallon Minimum recycled rubber content, by overall weight, percent 1
St. Louis County QA-49
Box weight, pounds2 Notes:
9.3
-
13
-
-
50
1
For each lot a certification shall be provided by the manufacturer that includes the physical properties specified above and include the rubber content, by mass of asphalt components. The minimum rubber content as determined by asphalt components shall be at least 18 percent. 2 May be increased to 60 pounds if material is split into two parts.
10/1/2017
1057-3
Material for Joints
1057.5.1.1 The sealant shall be supplied in solid form. When melted in accordance with procedures recommended by the supplier and properly applied, the sealant shall form a resilient and adhesive compound that will effectively seal cracks and joints in both asphalt and Portland cement concrete pavements in moderate climates. The sealant shall have a minimum application life when heated from 12 to 15 hours and may be extended by adding fresh product as quantity in the melter decreases. Product shall have a re-heat capability of at least one time after initial heat-up. The sealant, when melted to application temperature, shall be free of any dispersed or settling component and be of a uniform consistency suitable for filling joints and cracks without inclusion of large air holes or discontinuities. When the flow exceeds 5 mm, the material will be considered reject and the material in the melter will not be considered for further use. 1057.5.1.2 Packaging. Each box shall be packaged and shipped in suitable commercial boxes, legibly marked with the manufacturer name, trade name of the sealant, mass, part number, lot number, specification number and type, minimum application and maximum (safe) heating temperatures and safety instructions. The maximum safe heating temperature must be at least 20°F higher than the minimum application temperature. Product Information submittals required for each contract prior to application: •
Product Data Sheets
•
Material Safety Data Sheet
•
Certification
1057.5.2 Preformed Fiber Expansion Joint Filler. This material shall be in accordance with AASHTO M 213 (ASTM D 1751) and shall have a uniformly distributed asphalt content of no less than 35 percent by mass of the finished product. The joint filler material shall have resilience, that when compressed to half of original thickness, recovers to a minimum of 70 percent of original thickness before the load test. The joint filler material thickness shall be 2 inches across for concrete pavement Type A2 expansion joints, 1 inch across the intersection of concrete sidewalk and concrete entrances and at Type A or AA expansion joints, ¾ inch across street inlet sumps, ½ inch across concrete sidewalk or of the joint thickness specified. The joint filler material shall be of a width equal to the full depth of the pavement less the depth of the joint sealer and of a length no less than across the width of the face of the inlet, sidewalk or no less than the pavement section width.
10/1/2017
1057-4
Material for Joints
1057.5.3 Backer Material for Use with Cold- and Hot-Applied Joint Sealants in PortlandCement Concrete and Asphalt Joints. This material shall be in accordance with ASTM D 5249, Type I. Backer material must be ordered by diameter or size in relation to the joint opening and be 25 to 35 percent larger than the joint width.
Physical Properties
Test Method
Requirements Minimum
Maximum
Density, lb./ft3
ASTM D 1622
-
6
Tensile strength, psi
ASTM D 1623
20
-
Water absorption, by volume, percent
ASTM C 1016, Procedure B
-
0.5
-
15
90
-
-
10
25 percent compression deflection force, psi Compression recovery, percent Heat resistance, at 392°F ± 5°F, maximum shrinkage, percent
ASTM D 5249, 9.4
ASTM D 5249, 9.5
1057.6 Polyurethane Elastomeric Joint Sealant. This material shall be used for sealing dynamic exterior joints in horizontal pedestrian or vehicular trafficked surfaces, between materials of dissimilar porosity, coefficients of expansion and surface texture. This material is to also be used for sealing joints containing preformed grey sponge rubber expansion material. The joint sealant material shall be: 1057.6.1 A one component, primer-less, pourable grade polyurethane sealant that has sufficient flow to form a smooth, level surface when applied in a horizontal joint at 40°F. 1057.6.2 Self-leveling (when applied at an atmospheric temperature no less than 40°F) meeting the specification requirements of ASTM C 920, Type S, Grade P, Class 25, Use T1. 1057.6.3 Supplied ready-to-use in 28-30 ounce (approx.) cartridges with no premixing requirement. 1057.6.4 Stored in the original unopened container at temperatures of not more than 80°F shall be capable of meeting the requirements of this specification for at least 6 months after date of delivery.
10/1/2017
1057-5
Material for Joints
1057.6.5 Tested, after being conditioned for at least 24 hours in a laboratory controlled at 73.4°F ± 3.6°F and 50% ± 5% relative humidity. 1057.6.6 The color which has been agreed upon between the purchaser and the supplier. The material shall be capable of adhering to a prepared joint without the use of primers and provide serviceable joint sealant at temperatures between -40°F and 180°F. The material shall be supplied in either limestone or gray color for normal concrete sidewalk or pavement. The material shall be supplied in a brown color for exposed aggregate concrete. 1057.6.7 In accordance with the following physical property requirements: Physical Property
Test Method
Requirements Minimum
Maximum
Rheological Property, self-level @ 40°F
ASTM C 639
Extrusion Rate, mL/minute
ASTM C 1183, Procedure A
10
Application Life, hours
ASTM C 1183, Procedure A
3
Hardness, Shore A (25-50)
ASTM C 661
25
50
Weight Loss, Effects of Heat Aging, 1 percent of original weight
ASTM C 1246
-
7
Tack Free Time, hours
ASTM C 679
-
72
Stain and Color Change
ASTM C 510
Adhesion and Cohesion Under Cyclic 2 Movement, mortar, total loss in bond, in.
ASTM C 719
-
1.5
ASTM C 794
5
-
Adhesion in Peel, concrete, lb./f (PLI) Effects of Accelerated Weathering
2
1 2
-
Passes: No Color Change
ASTM C 793
Application Temperature, °F Notes:
Passes
Passes 40
122
Or shall be no cracking or chalking when tested. Sealant shall show no more than 25 percent adhesive bond loss for each test.
1057.6.8 Backer material shall be in accordance with Section 1057.12.
10/1/2017
1057-6
Material for Joints
1057.7 Joints for Concrete Structures. 1057.7.1 Polyvinylchloride Waterstop. The waterstop shall be of the shape and dimensions shown on the drawings accompanying the project specifications. The plastic waterstop shall be produced by an extrusion process that will result in a material that will be dense, homogeneous and free from holes and other imperfections. No recycled material shall be incorporated in the waterstop. The cross section of the waterstop shall be uniform along its length and shall be symmetrical transversely so that the thickness at any given distance from either edge of the waterstop will be uniform. The waterstop shall extruded from a basic resin of polyvinyl chloride (PVC) with additional resins, plasticizers and stabilizers as necessary to produce a durable material that meet the following performance requirements. Property
Test Method
Requirements Minimum
Maximum
Water absorption, percent
ASTM D 570
-
0.20
Tear Resistance , lb./in.
ASTM D 624
250
-
Ultimate Elongation, percent
ASTM D 638
200
-
Tensile Strength, psi
ASTM D 638
1,800
-
Low Temperature Brittleness
ASTM D 746
No Failure @ -35 F
Stiffness in Flexure, psi
ASTM D 747
600
-
Specific Gravity
ASTM D 792
-
1.38
Tensile Strength after accelerated extraction, psi
CRD-C 572-74
1,500
-
Elongation after accelerated extraction, percent
CRD-C 572-74
280
-
Effect of Alkali's after 7 days: Weight Change, percent Hardness Change, points
CRD-C 572-74
-0.10 -5
+0.25 +5
o
Splices shall be made by heat sealing the adjacent waterstop edges together using a thermoplastic splicing iron utilizing a non-stick surface specifically designed for waterstop welding. The correct temperature shall be used to sufficiently melt without charring the plastic. The spliced area, when cooled, shall show no signs of separation, holes, or other imperfections when bent by hand in as sharp an angle as possible. Samples taken across splices shall meet the following requirement. Property Splice Tensile Strength, psi
10/1/2017
Test Method CRD-C 573
1057-7
Requirements Minimum
Maximum
1,000
-
Material for Joints
1057.7.2 Rubber Waterstop. The waterstop shall be of the shape and dimensions shown on the drawings accompanying the project specifications. The rubber waterstop shall be produced by a process that will result in material that will be dense, homogeneous and free from holes and other imperfections. Minor surface defects, such as surface peel covering less than one square inch, and surface cavities or bumps less than ¼ inch in the longest lateral dimension and less than 1⁄16 inch deep, will be acceptable. 1057.7.2.1 Rubber waterstop shall consist of a durable, elastic, cured rubber compound (SBR for water containment structures; neoprene for structural exposure to sewage, water treatment or chemical environments) capable of effectively sealing joints in concrete against the infiltration of moisture and that will produce a durable material that meet the following performance requirements. Property
Test Method
Water absorption, percent (by weight after immersion in water for two days at 158°F) (SBR & Neoprene)
Requirements Minimum
Maximum
ASTM D 471
-
5
Hardness, Shore Type A (SBR & Neoprene)
ASTM D 2240
60
70
Ultimate Elongation, percent (SBR & Neoprene)
ASTM D 412
450
-
Tensile Strength, psi SBR Neoprene
ASTM D 412
2,500 2,000
-
Compression Set, percent1 SBR Neoprene
ASTM D 395 (Method B)
-
30 40
Tensile Strength after Aging, percent2 (SBR & Neoprene)
ASTM D 573
80
-
Elongation after accelerated extraction, percent (SBR & Neoprene)
ASTM D 573
80
-
Ozone Resistance, 7 days at 0.50 PPM @ 100°F, 20 percent elongation (SBR & Neoprene)
ASTM D 1149
Notes:
10/1/2017
1 2
No cracks
After 22 hours at 158°F. The tensile strength of the test specimen, after accelerated oxygen aging test of 94 hours at 158°F, shall be no less than 80 percent of the tensile strength prior to the aging test.
1057-8
Material for Joints
1057.7.2.2 Samples taken across splices shall meet the following requirement: Property Splice Tensile Strength, psi SBR Neoprene
Requirements Minimum Maximum
Test Method CRD-C 573-74
1,250 1,000
-
1057.7.3 Copper Sheeting for Flashing. Copper sheeting shall be of soft grade containing no less than 99.7 percent copper, and shall be capable of being bent cold through an angle of 180 degrees flat upon itself without evidence of cracking. Test specimens shall have an elongation in 2 inches of no less than 20 percent. The weight per square foot of the sheeting to be used will be shown on the plans. Tolerances in thickness shall be in accordance with ASTM B 248. 1057.7.4 Preformed Sponge Rubber Expansion and Partition Joint Filler. This material shall be in accordance with AASHTO M 153 (ASTM D 1752), Type I, Sponge Rubber and contain no reclaimed rubber or factice. Unless otherwise specified, the sponge rubber shall have a cement gray color to blend with the concrete in appearance. Joint filler shall be of the joint thickness specified, be of a width equal to the full depth of the pavement less the depth of the joint sealer and of a length no less than the pavement section width.
Requirements
Physical Property
Minimum
Maximum
Compression, psi
50
1,500
Density, lb./ft3
30
-
Recovery, percent
90
-
1057.8 Sewer and Stormwater Pipe Joint. 1057.8.1 Joint Materials for County / MoDOT acceptance (non-MSD). Plastic Joint Compound for Vitrified Clay and Concrete Pipe shall be a homogeneous blend of bituminous or butyl rubber material, inert filler and suitable solvents or plasticizing compounds thoroughly mixed at the factory to a uniform consistency suitable for sealing joints of vitrified clay and concrete pipe. The physical requirements of the compound shall be in accordance with ASTM C 990. Primer, as recommended by the manufacturer, shall be used with extruded rope or flat tape types, if required to maintain the material in position while pipe sections are being joined.
10/1/2017
1057-9
Material for Joints
1057.8.2 Joint Materials for County / MSD Acceptance. The type of jointing material to be used shall be compatible with the specified pipe as follows: Sanitary and Combined Sewers
Type of Joint
Vitrified Clay Pipe (VCP)
C
Reinforced Concrete Pipe (RCP) - Larger than 27 inches
B
Polyvinyl Chloride (PVC)
D
Composite Sewer Pipe (ABS and PVC) Fiberglass Pipe (RPM)
D and E F
Stormwater Sewers Vitrified Clay Pipe (VCP)
Type of Joint C
Concrete Pipe - 12 inches and larger
A or B
Reinforced Concrete Pipe (RCP) - 12 inches and larger
A or B
a) Type A Joints - The physical requirements shall be in accordance with ASTM C443. Band-type gaskets depending on cement for adhesion and resistance shall not be used. b) Type B Joints - The physical requirements shall be in accordance with ASTM C361 with a 25-foot head. Band-type gaskets depending on cement for adhesion and resistance shall not be used. c) Type C Joints - The physical requirements shall be in accordance with ASTM C425. d) Type D Joints - The physical requirements shall be in accordance with ASTM D3212. e) Type E Joints - The physical requirements shall be in accordance with ASTM D2680. f) Type F Joints - The physical requirements shall be in accordance with ASTM D4161. g) Other Type Joints - The County may consider other types of joints for approval. A written request by the Contractor to the Director to use other types, materials, methods or kinds of joints shall be made.
10/1/2017
1057-10
Material for Joints
h) Lubricants for Prefabricated Pipe Gaskets - The material shall be compatible with the gasket material and as recommended by the manufacturer. i)
Primers and Adhesives - Adhesive materials shall be compatible with the gasket material and as recommended by the manufacturer. Primers and solvents used with ABS composite sewer pipe shall be in accordance with ASTM D2335.
j)
Adapters and Couplings - For sanitary sewer pipe 4-15 inches in diameter and of dissimilar material or of different sizes or for the repair of sanitary sewer pipes of similar material may be made by means of an MSD approved connector or adaptor of the compression or mechanical seal type. The connector or adapter material shall conform to applicable ASTM standards: C 425, C 443, C 564, and D 3212. Couplings of the mechanical type shall have tightening clamps or devices made of 300 series stainless steel with stainless steel shear ring and stainless steel hardware, as specified by ASTM A167. If a stainless steel shear band is not used, a concrete collar as shown in MSD standard details is required.
1057.9 Tubular Joint Seal. Tubular joint seal shall be manufactured from extruded closedcellular rubber, the base polymer being a blend of nitrile and vinyl meeting the physical requirements of ASTM D 1056, Type 2, Class C, Grade 1, and meeting the chemical resistance requirements of AASHTO M 198. The seal shall be a single continuous part conforming to the joint shape. The outer surface shall be completely covered with a natural skin. The crosssectional diameter and installation shall be in accordance with the manufacturer's recommendations for the size of pipe being placed. 1057.10 Silicone Expansion Joint Sealant. The sealant for expansion joints shall be in accordance with Section 717.30. The silicone joint sealant shall be rapid cure, self-leveling, cold applied, two-component silicone sealant. The sealant, upon curing, shall demonstrate resilience, flexibility and resistance to moisture and puncture. The sealant shall demonstrate excellent adhesion, to Portland cement concrete, polymer concrete and steel over a range of temperatures from -30°F to 130°F, while maintaining a watertight seal. The sealant shall not contain any solvents or diluents that cause shrinkage or expansion during curing. Acid cure sealants shall not be used. The date of manufacture or "use-by date" shall be provided with each lot of sealant or primer. Material 12 months old or older from the date of manufacture or past the "use-by date" shall not be used. The Engineer reserves the right to test representative samples from material proposed for use. The manufacturer shall certify that the sealant meets or exceeds the following test requirements before installation begins:
10/1/2017
1057-11
Material for Joints
Physical Properties
Test Method
Requirement Minimum
Maximum
Each Component as Supplied: Specific Gravity
ASTM D 1475
1.2
1.4
Extrusion Rate, g/minute
ASTM C 1183
200
550
Durometer Hardness, Shore
ASTM D 2240
30
60
"00" (32°F and 77° ± 3°F) Ozone and U.V. Resistance
ASTM C 793
No chalking, cracking or bond loss after 5,000 hours
After Mixing: Flow
Self-Leveling
Tack-Free Time, minutes
ASTM C 679
-
60
Upon Complete Cure: Joint Elongation (Adhesion to concrete / steel / polymer concrete), percent
ASTM D 5329
a
600
-
Joint Modulus (at 100 percent elongation)
ASTM D 5329
a
3
12
a
Modified; sample cured two days at 77°F ± 2°F and 50% ± 5% relative humidity.
1057.11 Silicone Joint Sealant for Saw Cut and Formed Joints. The silicone joint sealant shall be a cold applied, single component, chemically curing gray (brown for exposed aggregate sidewalk) sealant with 100 percent elongation and 50 percent compressive joint movement capability. The sealant shall be type NS (Non-Sag) and the physical properties shall be in accordance with the following:
Physical Properties
Test Method
Requirement Minimum
Maximum
Gray (brown for exposed aggregate sidewalk)
Color
ASTM D 5893
Tack free time, minutes
ASTM D 5893
-
75
Cure time, days (75°F - 90°F and 45 - 55 percent Relative Humidity)
ASTM D 5893
-
7
Elongation, percent
ASTM D 5893
1,200
-
10/1/2017
1057-12
Material for Joints
1057.12 Backer Rod. The backer rod shall be closed cell and shall be in accordance with ASTM D 5249, Type 3. Backer material must be ordered by diameter or size in relation to the joint opening and be 25 to 35 percent larger than the joint width.
Physical Properties
Test Method
Requirements Minimum
Maximum
Density, lb./ft3
ASTM D 1622
-
6
Tensile Strength, psi
ASTM D 1623
20
-
Water absorption, by volume, percent
ASTM C 1016, Procedure B
-
0.5
-
15
90
-
25 percent Compression deflection force, psi Compression recovery, percent
ASTM D 5249, 9.4
1057.13 Certification. The Contractor shall furnish a manufacturer's certification for all material specified in this section prior to installation. The certification shall show representative test results of the material and certifying that the material supplied is in accordance with the requirements specified.
10/1/2017
1057-13
Material for Joints
(This Page Intentionally Left Blank)
10/1/2017
1057-14
Material for Joints
Section 1058
Polyethylene Sheeting
1058.1 Scope. construction.
This specification covers polyethylene sheeting for uses in highway
1058.2 Polyethylene Sheeting for Curing. Polyethylene sheeting for curing Portland cement concrete shall have a minimum nominal thickness of 4.0 mils and be white opaque, clear or black depending on weather conditions. Polyethylene sheeting physical requirements shall be in accordance with ASTM C 171. 1058.3 Polyethylene Sheeting as a Bond Breaker. Polyethylene sheeting for use as a bond breaker between a bridge approach slab and a granular base shall be in accordance with ASTM E 1745 Performance Class A. 1058.4 White-Burlap Polyethylene Sheeting for Curing. White-Burlap Polyethylene Sheeting for Curing shall consist of burlap weighing not less than 9 ounce/yard2 extrusion coated on one side with white opaque polyethylene of a minimum nominal thickness of 4.0 mils and meeting the requirements of ASTM C 171. 1058.5 Certification and Acceptance. The Contractor shall furnish a manufacturer's certification that the material supplied is in accordance with the requirements specified.
10/1/2012
1058-1
Polyethylene Sheeting
(This Page Intentionally Left Blank)
10/1/2012
1058-2
Polyethylene Sheeting
Section 1059
Protective Coating Material
1059.10 Protective Coating - Concrete Bents and Piers (Urethane). 1059.10.1 Scope. This specification covers modified urethane or polyurethane elastomeric coating to be used as shown on the plans. This material will typically be applied under expansion devices for protection from deleterious agents in areas where aesthetics is not a high priority. 1059.10.2 General Requirements. The material shall be suitable for outdoor exposure and shall be resistant to deterioration by ultraviolet light. Additives for ultraviolet stabilization shall not be added after the original manufacturing process. The material shall be suitable for application to concrete surfaces. The surface preparation shall be in accordance with the manufacturer's recommendations. The material shall be suitable for application to obtain a thickness of 40 mils dry film without runs or sags when applied to a vertical concrete surface. The material shall have a minimum shelf life, in unopened containers, of at least six months from the date of delivery. 1059.10.3 Cured Material. The cured material shall be in accordance with the following requirements: Protective Coating - Concrete Bents and Piers (Urethane) Item
Requirement
Shore A Hardness, ASTM D 2240, (material shall be cured in 40 mil thick film for 7 days at 75°F ± 2°F at 50% relative humidity. Test specimen shall be composed of plied pieces, to a minimum ¼ inch thickness.
15
Tensile Strength, psi, ASTM D 412 (method and time of cure may be modified as recommended by the manufacturer), min.
45 psi
Elongation, percent, ASTM D 412 (method and time of cure may be modified as recommended by the manufacturer), min.
200%
Water Vapor Permeability, perms, ASTM D 1653 or ASTM E 96, Method BW 40 mil film thickness, max.
0.8 perms
1059.10.4 Packaging. All two-component material shall be prepackaged to exact mixing quantities. 1059.10.5 Manufacturer and Brand Name Qualification. Prior to approval and use, the manufacturer shall submit a representative one-gallon sample to Construction and Materials. Upon approval of the material, the brand name and manufacturer will be placed on a list of qualified Urethane Protective Coating Agents for Concrete Bents and Piers. The sample shall be identified by brand name, manufacturer's name and address, and shall be accompanied by the following:
2/1/2017
1059-1
Protective Coating Material
1) Manufacturers complete material data showing typical test results for the properties specified, generic name of the major components of the material, mixing instructions, surface preparation and application instructions, and intended use. 2) Test results after 1000 hours exposure in a weatherometer, in accordance with ASTM D 822, Procedure B. The film thickness of test specimens shall be 40 mils and shall show no cracking, flaking or blistering after exposure. Slight discoloration will be permitted. 3) In lieu of the weatherometer test results required in Section 1059.10.5 - Item 2, the manufacturer may submit a use history showing satisfactory performance for three years in at least two exposed applications. Name, address and telephone number of the users shall be included in the use history. 1059.10.6 Acceptance. The contractor shall furnish a manufacturer's certification stating that the material supplied is in accordance with all requirements specified and certifying the material furnished is of the same composition as originally qualified. The engineer reserves the right to sample the material at destination if deemed necessary. 1059.20 Protective Coating - Concrete Bents and Piers (Epoxy). 1059.20.1 Scope. This specification covers two-component modified polyamide converted epoxy to be used as shown on the plans. This material will typically be applied under expansion devices where aesthetics is a high priority. 1059.20.2 Material. The material shall be suitable for application to obtain a minimum coating thickness of 6 mils, dry film without runs or sags when applied to a vertical concrete surface. Pot life and method and time of cure shall be in accordance with the manufacturer's recommendation. The material shall be suitable for outdoor exposure and shall be resistant to deterioration by ultraviolet light. Additives for ultraviolet stabilization shall not be added after the original manufacturing process. The material shall have a minimum shelf life, in unopened containers, of at least six months from the date of delivery. 1059.20.2.1 Color. The color shall be clear or concrete gray. 1059.20.2.2 Finish. The finish shall be high gloss. 1059.20.3 Packaging. Two-component material shall be prepackaged to exact mixing quantities. 1059.20.4 Manufacturer and Brand Name Qualification. Prior to approval and use, the manufacturer shall submit a representative one-gallon sample to Construction and Materials. Upon approval of the material, the brand name and manufacturer will be placed on a list of qualified Epoxy Protective Coating Agents for Concrete Bents and Piers. The sample shall be identified by brand name, manufacturer's name and address, and accompanied by the following information:
2/1/2017
1059-2
Protective Coating Material
1) Manufacturers complete material data showing typical test results for the properties specified, generic name of the major components of the material, mixing instructions, surface preparation and application instructions, and intended use. 2) Test results after 1000 hours exposure in an accelerated weathering device shall be provided. The tests shall be conducted in accordance with ASTM D 822 or ASTM G 154 using test cycle No. 2 defined in ASTM D 822, except that during the six hour period of darkness, the relative humidity of the air shall be 95% ± 4%. If ASTM G 154 QUV exposure testing is used, Type A lamps shall be used. 1059.20.4.1 For either test, specific operating conditions shall be summarized and provided with the test results. The film thickness on test specimens shall be 6 mils and shall show no cracking, flaking or blistering after exposure. Only slight discoloration will be permitted. 1059.20.4.2 In lieu of the weatherometer test results required in Section 1059.20.4 Item 2, the manufacturer may submit a use history showing satisfactory performance for three years in at least two exposed applications. Name, address and telephone number of the users shall be included in the use history. 1059.20.5 Acceptance. The contractor shall furnish a manufacturer's certification stating that the material supplied is in accordance with all requirements specified and certifying the material furnished is of the same composition as originally qualified. The engineer reserves the right to sample the material at destination if deemed necessary. 1059.30 Concrete and Masonry Protection System. 1059.30.1 Scope. This specification covers clear penetrating siloxane or silane based sealer for use as shown on the plans. 1059.30.2 Physical Properties. The sealer shall be breathable and non-yellowing and shall be in accordance with the following requirements: Concrete and Masonry Protection System Specification Itema
Sealer Type Vertical Application
Horizontal Application
Solids Content, percent by weight, min
6.7%
20%
Reduction in Water Absorption, percent, min
80%
85%
Reduction in Chloride Intrusion, percent, min
82%
85%
Water Vapor Transmission, percent, min a
2/1/2017
110%
Tested in accordance with NCHRP 244 Series tests.
1059-3
Protective Coating Material
1059.30.3 Manufacturer and Brand Name Qualification. Prior to approval and use, the manufacturer shall submit a representative one-quart sample to Construction and Materials. The sample shall be identified as to brand name, designation as to horizontal or vertical application, manufacturer's name and address, and accompanied by the manufacturer’s data and application sheets and test results in accordance with Section 1059.30.2. The manufacturer shall submit certification that the material complies with all requirements of this specification. Upon approval of the material, the brand name and manufacturer will be placed on a list of qualified Concrete and Masonry Protection Systems. 1059.30.4 Field Approval. Prior to application of the sealer, including bulk purchase and delivery of products, the contractor shall prepare a minimum 12 inch x 12 inch application sample on each of the specified concrete or masonry products for the purpose of demonstrating the final effect, visual and physical / chemical, of the planned installation. The contractor shall proceed with work only after the engineer's acceptance of the test application for color and compatibility with the substrate. 1059.30.5 Acceptance. The contractor shall furnish a manufacturer's certification stating that the material supplied is in accordance with all requirements specified and certifying the material furnished is of the same composition as originally approved. The engineer reserves the right to sample the material at destination if deemed necessary. 1059.40 Sacrificial Graffiti Protection System. 1059.40.1 Scope. This specification covers a sacrificial graffiti protection system for application to all surfaces as shown on the plans. 1059.40.2 Physical Properties. The sacrificial graffiti protection system shall be in accordance with the following physical properties and shall be chemically compatible with any other coatings to be used. The material shall be suitable for application to obtain a wetfilm thickness of 4 to 6 mils without runs or sags when applied to a vertical surface. Sacrificial Graffiti Protection System Item
Requirement
Melting Point, °F,ASTM F 766
165°F ± 5°F
Solids Content, min., percent by weight, ASTM D 2834 Volatile Organic Content (VOC), lb./gal, max, ASTM D 3960
26% 0.58 lb./gal
1059.40.3 Manufacturer and Brand Name Qualification. Prior to approval and use, the manufacturer shall submit a representative one-gallon sample to Construction and Materials. The manufacturer shall submit documentation to Construction and Materials stating brand name, manufacturer's name and address, and accompanied by the manufacturer's data and application sheets. The manufacturer shall submit certification, including specific test results that the material complies with all requirements of this specification. Upon approval of the material, the brand name and manufacturer will be placed on a list of qualified Sacrificial Graffiti Protection Systems.
2/1/2017
1059-4
Protective Coating Material
1059.40.4 Field Approval. Prior to application of the sacrificial graffiti protection system, including bulk purchase and delivery of products, the contractor shall prepare a minimum 12 inch x 12 inch application sample on each of the specified concrete or masonry products for the purpose of demonstrating the compatibility of the planned installation. If the sacrificial graffiti protection system is to be applied over previous coatings, the test specimen shall have already received these previous coatings. The contractor shall proceed with work only after the engineer's acceptance of the test application for appearance and compatibility. 1059.40.5 Acceptance. The contractor shall furnish a manufacturer's certification stating that the material supplied is in accordance with all requirements specified and certifying the material furnished is of the same composition as originally approved. The engineer reserves the right to sample the material at destination if deemed necessary. 1059.50 Temporary Coating - Concrete Bents and Piers (Weathering Steel). 1059.50.1 Scope. This specification covers a system for protection against absorptive staining from unpainted, corrosion resistant steel during initial weathering as shown on plans. 1059.50.2 Physical Properties. The temporary coating shall be in accordance with the following physical properties and shall be compatible with any other coatings to be used. The material shall be suitable for application to obtain a wet-film thickness of 4 to 6 mils without runs or sags when applied to a vertical surface. Temporary Coating – Concrete Bents and Piers (Weathering Steel) Item
Requirement
Melting Point, °F,ASTM F 766
165°F ± 5°F
Solids Content, min., percent by weight, ASTM D 2834 Volatile Organic Content (VOC), lb./gal, max, ASTM D 3960
26% 0.58 lb./gal
1059.50.3 Manufacturer and Brand Name Qualification. Prior to approval and use, the manufacturer shall submit a representative one-gallon sample to Construction and Materials. The manufacturer shall submit documentation to Construction and Materials stating brand name, manufacturer's name and address, and accompanied by the manufacturer's data and application sheets. The manufacturer shall submit certification, including specific test results that the material complies with all requirements of this specification. Upon approval of the material, the brand name and manufacturer will be placed on a list of qualified Rust Staining Protection Systems. 1059.50.4 Acceptance. The contractor shall furnish a manufacturer's certification stating that the material supplied is in accordance with all requirements specified and certifying the material furnished is of the same composition as originally approved. The engineer reserves the right to sample the material at destination if deemed necessary.
2/1/2017
1059-5
Protective Coating Material
(This Page Intentionally Left Blank)
2/1/2017
1059-6
Protective Coating Material
Section 1060
Electrical Conduit
1060.1 Scope. This specification covers electrical conduit to be used as specified or as shown on the plans. 1060.2 Acceptance. All material in this section will be accepted based on certification indicating the material is in accordance with this specification and any testing as required by the Engineer. 1060.3 Material. 1060.3.1 Rigid Metallic Conduit and Tubing. Except for rigid aluminum conduit, the conduit shall be galvanized on both the inside and the outside surfaces. The weight of zinc coating shall be no less than 0.5 oz./ft2 of coated surface, as determined in accordance with AASHTO T 65. The interior or exterior surface, or both, may be given a coating of suitable material to facilitate installation of wires and cables and to permit the conduit to be readily distinguished from pipe used for purposes other than electrical. 1060.3.1.1 Rigid Steel Conduit, Zinc Coated. Rigid steel conduit, zinc coated, (GRC) shall be in accordance with ANSI C80.1, except as noted herein. 1060.3.1.2 Intermediate Metal Conduit. Intermediate metal conduit (IMC) shall be in accordance with ANSI C80.6, except as noted herein. 1060.3.1.3 Rigid Aluminum Conduit. accordance with ANSI C80.5.
Rigid aluminum conduit (RAC) shall be in
1060.3.1.4 Electrical Metallic Tubing, Zinc Coated. Electrical metallic tubing (EMT), zinc coated shall be in accordance with ANSI C80.3 except as noted herein. 1060.3.1.5 Fittings for Rigid Metal Conduit and Electrical Metallic Tubing. Fittings shall be in accordance with ANSI C80.4. 1060.3.1.6 Fittings for Intermediate Metal Conduit. Fittings shall be in accordance with UL 1242, except the coating shall meet the same requirements as the conduit with which the fittings are used. 1060.3.1.7 Inspection. Conduit, tubing and fittings will be inspected for compliance with specifications. Any desired samples will be taken at either the project location or warehouse, as directed by the Engineer. Test specimens for determination of weight of coating will be at least 2 inches long, cut no less than 6 inches from the end of the length of conduit or tubing selected for testing. If the prescribed two additional samples for retests are taken, and either does not comply, the lot represented will be rejected.
1/31/2007
1060-1
Electrical Conduit
1060.3.2 Rigid Nonmetallic Conduit. Rigid nonmetallic conduit shall be either polyvinyl chloride (PVC) or high density polyethylene (HDPE). 1060.3.2.1 Polyvinyl Chloride Conduit. PVC conduit, bends, couplings and fittings shall be in accordance with UL 651. 1060.3.2.2 High Density Polyethylene Conduit. HDPE conduit shall be in accordance with ASTM D 3035 SDR11. 1060.3.2.3 Fittings for Polyvinyl Conduit. Fittings for PVC conduit shall be in accordance with UL 514. Cement used for the fittings shall be in accordance with the manufacturer's recommendations. 1060.3.2.4 Fittings for High Density Polyethylene Conduit. Fittings for HDPE conduit shall be in accordance with ASTM D 2683. Epoxy used for the fittings shall be in accordance with the manufacturer’s recommendations. 1060.3.2.5 Inspection and Testing. Material will be inspected for compliance with the specifications, and samples for testing will be taken at either the project location or warehouse, as determined by the Engineer. 1060.4 Certification. The Contractor shall furnish a manufacturer's certification that the material supplied is in accordance with all requirements. If requested by the Engineer, the Contractor shall also furnish typical test results representative of the material.
1/31/2007
1060-2
Electrical Conduit
Section 1063
Temporary Traffic Control Devices
1063.1 Scope. These specifications cover material to be used for temporary traffic control devices. 1063.2 General Requirements. All temporary traffic control devices shall be manufactured as shown on the plans and as specified, in accordance with current MUTCD requirements and be NCHRP 350 compliant. Nominal dimensions will be allowed for dimensional lumber where applicable. All temporary traffic control devices shall exhibit good workmanship and shall be free of objectionable marks or defects that affect appearance or serviceability. The brand name or model number shall be permanently identified on each traffic control device. 1063.2.1 Retroreflective Sheeting. Retroreflective sheeting shall be in accordance with ASTM D 4956, except as noted herein. Retroreflective sheeting shall have sufficient strength and flexibility such that the sheeting can be handled, processed, and applied according to the manufacturer's recommendations without appreciable stretching, tearing, cracking, or other damage. The sheeting surface shall be readily screen processed and compatible with recommended transparent and opaque screen process colors. The retroreflective sheeting manufacturer shall furnish information as to the type of solvent or solvents that may be used to clean the surface of the sheeting without detrimental loss of brightness and durability. Sheeting having a datum mark on the surface shall be oriented vertically. The sheeting shall be properly oriented on the sign face to meet retroreflection requirements as specified herein. 1063.2.1.1 Type 3. Type 3 retroreflective sheeting shall be in accordance with ASTM D 4956, Type III, high intensity encapsulated lens, Class 1 or 2. 1063.2.1.2 ASTM D 4956, Type IV. Retroreflective sheeting shall be high intensity prismatic classification. 1063.2.1.3 Fluorescent Retroreflective Sheeting. Fluorescent orange retroreflective sheeting shall be in accordance with ASTM D 4956, Type IX or greater. 1063.2.1.3.1 Coefficient of Retroreflection. Retroreflective sheeting shall meet or exceed the minimum coefficient of retroreflection requirements shown below, expressed as candelas per foot-candle per square foot (candelas/lux/m2). The RA values will be the mean of test rests obtained from readings taken with orientation angles of 0 degrees and 90 degrees. Retroreflective Sheeting - Minimum Coefficient of Retroreflection, RA Observation Angle, Degrees
Entrance Angle, Degrees
Orange
Yellow Green
Yellow
Fluorescent Orange
0.2 0.2 0.5 0.5
-4 +30 -4 +30
145 82 90 50
300 170 190 110
230 130 145 81
115 65 72 41
7/1/2016
1063-1
Temporary Traffic Control Devices
1063.2.1.3.2 Color Specification Limits and Luminance Factor. Fluorescent retroreflective sheeting shall meet the color specification limits (daytime) and luminance factor (daytime) requirements shown below. Fluorescent Retroreflective Sheeting Color Specification Limits (Daytime) - Luminance Factor, Y% 1
2
3
Luminance Factor (Y%)
4
x
y
x
y
x
y
x
y
Min.
Max.
Orange
0.583
0.416
0.523
0.397
0.560
0.360
0.631
0.369
20
---
Weathered Orange
0.583
0.416
0.523
0.397
0.560
0.360
0.631
0.369
20
45
Yellow Green
0.387
0.610
0.460
0.540
0.421
0.486
0.368
0.539
60
---
Weathered Yellow Green
0.387
0.610
0.460
0.540
0.421
0.486
0.368
0.539
50
---
Yellow
0.498
0.412
0.557
0.442
0.479
0.520
0.438
0.472
40
---
Note: The four pairs of chromaticity coordinates will determine the acceptable color in terms of the CIE 1931 Standard Colorimetric System measured with CIE Standard Illuminant D65.
1063.2.1.3.3 Specular Gloss. Fluorescent retroreflective sheeting shall have a specular gloss of no less than 50. 1063.2.1.3.4 Daytime Luminance Factor (Y%). The daytime luminance factor shall be in accordance with minimum and maximum range for the color specified as per Table 2 of ASTM D 4956. 1063.2.1.4.5 Outdoor Weathering for Construction Work Zone Applications. The outdoor weathering shall be 12 months as determined in accordance with Section 6.4 of ASTM D 4956, meeting a minimum of at least 80 percent coefficient of retroreflection (RA) of observation and entrance angles measurements specified in Section 1063.2.1.3.2. 1063.3 Channelizing Drums, Cones, Tubular Markers, and Moveable Barricades. All channelizers shall be manufactured from a non-metallic material, pigmented and molded of a Highway Orange color throughout and stabilized against fading by ultraviolet or other light rays by the incorporation of adequate inhibitors. Drum-like channelizers shall be closed-top with a pre-manufactured handle. Retroreflective marking, as shown on the plans, shall be in accordance with Section 1063.2.1.1, Type 3, and ASTM D 4956, Supplemental Requirements, Section S2. Retroreflective marking on cones will not be required. 1063.4 Type III Movable Barricades. Type III movable barricades shall be entirely free standing and portable. Type IV retroreflective sheeting, Section 1063.2.1.2, shall be applied to both sides of the barricade.
7/1/2016
1063-2
Temporary Traffic Control Devices
1063.5 Signs. 1063.5.1 Rigid Signs. 1063.5.1.1 Sign Substrate. All signs shall be fabricated of substrate designed to provide satisfactory structural rigidity. 1063.5.1.2 Sign Sheeting. All signs shall have a retroreflectorized background. Retroreflective sheeting shall be in accordance with Section 1063.2.1.3, Fluorescent Retroreflective Sheeting (fluorescent orange), as shown on the plans. Sheeting shall be applied to aluminum flat sheet sign substrate, which is designed to provide satisfactory structural rigidity in accordance with the manufacturer's recommendations. The surface shall be free of air bubbles, wrinkles or other blemishes as determined by the Engineer. All signs shall be sized in accordance with the current MUTCD. 1063.5.2 Roll-up Signs. 1063.5.2.1 Sign Substrate. Sign and overlay blanks shall consist of fluorescent orange microprismatic retroreflective sheeting sealed to a heavy-duty coated fabric or vinyl material. The sheeting shall have a minimum coefficient of retroreflection, expressed as candelas per foot-candle per square foot, as shown below, when measured in accordance with ASTM E 810. The color specifications shall be in accordance with ASTM D 4956. Material shall be submitted by the manufacturer to NTPEP for a minimum exposure time of one year. Results shall be published by NTPEP and available for County review. For all NTPEP test decks, weathered material shall be within the color specification limits. Minimum Coefficient of Retroreflection for Fluorescent Orange Sheeting Observation Angle (Degrees)
Entrance Angle (Degrees)
Candelas (per FootCandle, per Square Foot)
0.2
-4
200
0.2
+ 30
100
0.5
-4
80
0.5
+ 30
30
1063.5.2.2 Overlays. Overlays, when used, shall be mechanically fastened to the face of the sign in a manner that will ensure the overlay remains securely attached. Fasteners shall not detract from the appearance of the sign when the overlay is not in use. Velcro fasteners will not be permitted. 1063.5.2.3 Bracing. Each sign shall have a horizontal and vertical cross brace and at least one anti-kiting device located near the center of the sign. Cross braces of sufficient cross-section shall be fastened to each other at the midpoints and the ends securely held to the back of the sign by mechanical means. The design shall ensure that the sign remains taut and retains the sign's intended shape when exposed to normal field conditions.
7/1/2016
1063-3
Temporary Traffic Control Devices
1063.5.3 Legend and Borders. Legend and borders of all signs shall be vinyl or silkscreened. Vinyl shall be cut by die or a computer driven cutter. Stencil ink used shall be in accordance with the sheeting manufacturer's recommendations. Free-hand legend and borders will not be permitted. 1063.5.4 Sign Layout and Design. Sign layout and design shall be as shown on the plans or as directed by the Engineer. 1063.6 Strobe Lights. Strobe lights shall be 12/24 VDC battery or solar powered with amber fresnel, high-profile lenses. Strobe lights shall have a flash rate of 60 to 80 flashes per minute. Each strobe light shall provide no less than 500,000 candlepower of illumination. Each light shall be fully visible through an arc of approximately 120 degrees when viewed facing the sign. 1063.7 Flashing Arrow Panels. All lamps shall have a nominal 5 inch, 360 degree tunnel visor. A lamp on the back side of the flashing arrow panel shall be continuously energized during operation of the flashing arrow panel. Lamps shall be visible at an angle of 15 degrees to the left and right of center and 4 degrees above and below center during "on" time. The flashing arrow panel shall contain a device to align the arrow panel to oncoming traffic. Arrow panels shall be capable of displaying the flashing arrow, flashing double arrow, and four corner flashing caution modes. Solar powered flashing arrow panels shall be capable of operating in the flashing arrow mode for 20 consecutive days and shall be provided with a device to indicate the remaining charge in batteries. 1063.7.1 Trailer-Mounted Flashing Arrow Panels. Trailer mounted flashing arrow panels shall be MUTCD, Type C. Trailer mounted flashing arrow panels shall be 4 feet high and 8 feet wide and shall have a minimum of 15 lamps. Trailer mounted flashing arrow panels shall be solar powered. 1063.7.2 Truck-Mounted Flashing Arrow Panels. Truck-mounted flashing arrow panels shall be MUTCD, Type B. Truck-mounted flashing arrow panels shall be 30 inches high and 60 inches wide and shall have a minimum of 13 lamps. 1063.8 Changeable Message Sign. Each changeable message sign (CMS) shall consist of a message board, solar power supply, computer interface and mounting and transporting equipment. 1063.8.1 Message Board. Each sign shall consist of three lines containing eight individually changeable characters per line. Each character shall be yellow in display on a black background. The CMS shall be legible up to a distance of 650 feet for both day and night operation. 1063.8.2 Computer Interface. The CMS shall have a modem and cellular phone capable of receiving a message over standard phone lines from a remote location and forwarding the message to the CMS controller to change the displayed message. Modems shall have a minimum baud rate of 14,400 bytes per second. In addition to the modem, the CMS shall have the necessary hardware to allow the message to be changed from the CMS location without a phone line connection. A minimum 5 foot connecting cable shall be provided to connect the CMS controller to a notebook computer. The supplier shall provide the Department the required software and licenses necessary to change the message from a remote location. This software shall be compatible with Windows XP, Vista and 7 operating
7/1/2016
1063-4
Temporary Traffic Control Devices
systems and shall be able to issue Hayes or Hayes compatible modem commands. The supplier shall provide technical assistance with the installation and operation of software. 1063.8.3 Solar Power Supply. The power supply shall use a battery bank with sufficient capacity to operate a full display of characters for 20 consecutive days with no sun. All terminals and connections shall be clearly labeled. 1063.8.4 Support. A factory trained service representative shall be available at the delivery location to provide technical assistance, including the installation and operation of software. No additional payment will be made for travel expenses. 1063.9 Portable Traffic Signals. Each portable traffic signal (PTS) system shall consist of two or more trailer-mounted PTS units. One PTS trailer mounted unit shall have a full controller assembly and act as a master to the remaining PTS trailer mounted units via a communication link. Each PTS unit shall consist of signal heads and indications, a solar power supply, vehicle detection system and mounting and transporting equipment. All components shall be capable of operating in a temperature range of -20°F to 120°F. 1063.9.1 Controller Assembly. The controller assembly shall be a minimum four phase, solid state traffic signal controller with conflict monitor capable of operating the signals in accordance with current MUTCD requirements and NEMA Standard TS1. The controller shall operate as a fully actuated unit. 1063.9.2 Communication Link. A continuous communications link between the PTS units shall be provided. If a break in communications between the PTS units occurs, the system shall change to a preset condition programmed into the controller and CMU. 1063.9.3 Signal Heads and Indications. Each unit shall consist of two polycarbonate signal heads, including backplates and visors. One signal head shall be mounted on the mast arm assembly and the other on the vertical upright. The signal head mounted on the mast arm shall provide a minimum lateral clearance of 9½ feet from the center of the outer signal head to the edge of the trailer and a minimum vertical clearance of 16 feet from the bottom of the backplate to the roadway surface. The signal head mounted on the vertical upright shall provide a minimum clearance of 8 feet from the bottom of the backplate to the roadway surface. All signal indications shall be 12 inches in diameter. Traffic signal heads and indications shall be in accordance with the vehicle traffic control signal head requirements of Institute of Transportation Engineers (ITE) and NEMA Standard TS1 and TS2. The signal head mounted on the mast arm shall have a louvered backplate to reduce wind resistance. 1063.9.4 Solar Power Supply. The power supply shall use a battery bank with sufficient capacity to operate the PTS for 20 consecutive days with no sun. All terminals and connections shall be clearly labeled. 1063.9.5 Vehicle Detection. Detection shall be provided by one of the non-intrusive vehicular detection methods specified in Section 904 or as approved by the Engineer. 1063.9.6 Support. A factory trained service representative shall be available at the delivery location to provide technical assistance and training, including the installation and operation of software. No additional payment will be made for travel expenses.
7/1/2016
1063-5
Temporary Traffic Control Devices
1063.10 Radar Speed Advisory System. Each radar speed advisory system shall consist of a radar unit, speed display, speed limit display, solar power supply and mounting and transporting equipment. 1063.10.1 Radar Unit. The radar unit shall include necessary cables for connection to the digital display and power supply, shall be capable of instantaneously displaying and locking readings, and shall meet the following minimum requirements: Radar Unit Speed range
15 to 99 mph
Accuracy
+1 mph
Internal test
32 mph check
1063.10.2 Speed Display. The speed display shall be a minimum of 12 inches high and shall be capable of displaying the radar unit output from 0 to 99 mph. 1063.10.3 Speed Limit Display. The speed limit display shall indicate the work zone speed limit by means of a 36 inch x 48 inch speed limit sign. The speed limit sign may be comprised of a rigid or roll up sign or a rigid sign with a variable speed display. The variable speed display shall be a minimum of 12 inches high and shall be capable of displaying two digits. 1063.10.4 Solar Power Supply. The power supply shall be capable of operating the radar unit, speed display, and speed limit display, if applicable, for a minimum of eight hours per day. 1063.11 Truck Mounted Attenuators. Each Truck Mounted Attenuator (TMA) shall be in accordance with Test Level 3 criteria as set forth in NCHRP 350. Each TMA shall have a standard trailer lighting system, including brake lights, taillights, turn signal lights, and Federal Motor Carrier Safety Administration identification bar lights. In the operating position, the rear facing of the TMA shall be marked with alternating 8 inch yellow and 8 inch black retroreflective sheeting. The marking shall form an inverted "V" at the center and slope downward at an angle of 45 degrees toward each side of the unit. The TMA shall be marked with this same pattern and have the same standard trailer lighting system noted above when the unit is in the transport position. 1063.12 Certification. The Contractor shall furnish a manufacturer's certification for all material governed by this specification. The certification shall indicate full compliance with each applicable specification.
7/1/2016
1063-6
Temporary Traffic Control Devices
Section 1064
Temporary Concrete Traffic Barrier
1064.1 Scope. This specification covers temporary concrete traffic barrier for use in roadway construction. 1064.2 Material. 1064.2.1 All material shall be in accordance with the following specifications: Item
Specification
Reinforcing Steel for Concrete
AASHTO M 31, Grade 60
Anchor Bolts
ASTM A 307
Connection Rod Assembly
AASHTO M 183
Retainer Bolt and Nut
SAE Grade 8
1064.2.2 All reinforcing steel shall be deformed bar. Loop steel shall be 0.75 inch smooth steel bars with a minimum yield of 60 ksi, a tensile strength of no less than 1.25 times the yield strength but a minimum of 80 ksi, a minimum 14% elongation in 8 inches, and passing a 180 degree bend test using a 3.5 times diameter pin bend diameter. The loops shall be installed within 0.125 inch of the plan dimensions. 1064.3 Manufacture. 1064.3.1 Welding of loop steel shall be limited to the minimum surface welding necessary to maintain the position required for placement. Any welding beyond the surface of the bar will be cause for rejection. 1064.3.2 Visual cracks in the loop steel will be cause for rejection. 1064.3.3 Concrete shall be air-entrained concrete with 28-day compressive strength of 5000 psi. Concrete barrier units shall not be removed from the forms until a minimum of 1750 psi is attained and shall be continuously cured until 5000 psi is attained. Temporary concrete traffic barrier shall be manufactured in accordance with industry standard practices for pre-cast construction. 1064.3.4 All temporary concrete traffic barrier units shall be permanently marked with the name and location of the manufacturer, and the month and year of manufacture in a location visible after installation. Paint or other liquid marking will not be permitted.
1/31/2007
1064-1
Temporary Concrete Traffic Barrier
1064.3.5 Surface of temporary concrete traffic barrier shall be smooth and non-deformed and substantially free of honeycomb, surface spalls and surface defects. Barrier units shall be straight and square on the ends and shall meet the following tolerances: Dimension
Tolerance
Length
+ ¾ inch
Width
+ ¼ inch
Height
+ ¼ inch
1064.4 Certification. The manufacturer shall provide certification to the contractor that the barrier is in accordance with the contract documents.
1/31/2007
1064-2
Temporary Concrete Traffic Barrier
Section 1065
Concrete Traffic Barrier Delineators
1065.1 Scope. This specification covers concrete traffic barrier delineators for use in roadway construction. 1065.2 Body. The delineator body shall be manufactured from high impact, weather-resistant thermoplastic. The final body thickness shall be a minimum of 0.08 inch. The face on which the retroreflective sheeting is to be placed shall have a nominal dimension of 3½ inches x 4½ inches. 1065.3 Retroreflective Sheeting. The retroreflective sheeting shall be an approved MoDOT Type 5 sheeting in accordance with Section 1042. Retroreflective sheeting shall be permanently affixed to the body of the delineator, having a minimum reflective surface of 12 inches square. Manufacturer certification shall be provided for delineator sheeting to be used on Type A, B, C and D concrete traffic barriers. For temporary concrete traffic barrier delineators, an alternate retroreflective material may be used with the approval of the Engineer. The alternate retroreflective material shall meet the dimensions required in this specification.
1/31/2007
1065-1
Concrete Traffic Barrier Delineators
(This Page Intentionally Left Blank)
1/31/2007
1065-2
Concrete Traffic Barrier Delineators
Section 1066
Mortars and Grout
1066.1 Scope. This specification covers mortars and grout for use in pipe joints, and rubble and brick masonry. 1066.2 Mortars and Grout. Mortars and grout shall be mixed in small quantities as needed and shall not be retempered or used after setting has begun. Type I Portland cement shall be accordance with Section 1019. Sand shall be clean and shall be in accordance with Section 1005, except the minus No. 200 sieve requirement will not apply. Water shall be in accordance with Section 1070. 1066.2.1 Mortar for Pipe Joints. Mortar shall consist of one part Type I Portland cement and two parts sand, by volume, mixed with sufficient water to form a plastic mortar. 1066.2.2 Mortar for Grout. Mortar used for grout shall consist of one part Type I Portland cement and three parts sand, by volume, mixed with sufficient water to form a grout of proper consistency. 1066.2.3 Mortar for Rubble and Brick Masonry. The mortar shall be composed of one part Portland cement plus 10%, by volume, of hydrated lime and of two parts sand by volume. Hydrated lime shall be in accordance with ASTM C 207, Type N. After the dry material has been thoroughly mixed, water shall be added, and the mixture shall be turned and chopped by hand or mechanical methods until a stiff mortar results. Mortar shall be mixed no more than 30 minutes in advance of use. Mortar for pointing shall be mixed in the proportions of one part Portland cement to one part sand by volume. 1066.2.3.1 Mortar for MSD Brick Masonry Construction. Mortar materials used in brick masonry construction shall consist of Portland cement conforming to the requirements of ASTM C 150, Type I cement and natural sand, consisting of clean, hard, durable, uncoated grains. Mortar for sewer construction shall consist of a uniform mixture of Portland cement and masonry sand with the minimum amount of water necessary to produce the required consistency for the particular required use. No admixtures shall be used without the permission of the Director. Mortar for brick masonry and plastering shall consist of one volume of cement and three volumes of sand. Mortar shall be prepared in suitable mixing equipment or for small amounts, on a hard imperious surface. It shall be kept free at all times from earth, debris, contamination or other deleterious substances. Retempered or partially set mortar shall not be used. Mortar required for patching or jointing areas in the vicinity of sanitary sewage shall be of an approved rapid setting variety. A prepared foundation shall be placed for all brick structures after the foundation excavation is completed. This shall be of the materials and dimensions shown in the Standard Details of Sewer Construction or on the project plans and specifications.
1/31/2007
1066-1
Mortars and Grout
All bricks shall be thoroughly clean. The bed which is to receive the bricks shall be thoroughly cleaned and damp, but should be free of water before placing mortar thereon. All bricks shall be laid in courses in freshly-made mortar, using the shoved-joint method so as to thoroughly bond them into the mortar, and always with the joints completely filled with mortar. The bricks shall be laid in a workmanlike manner, and true to the lines and grades indicated on the plans. The arrangement of headers and stretchers shall be such as will thoroughly bond the masonry. Unless otherwise indicated, brick masonry shall be of alternate headers and stretchers with consecutive courses breaking joints. In manholes, all bricks in each course shall be headers. The course shall be laid continuously with joints broken or alternating evenly with the joints in the preceding courses. Horizontal joints shall average ⅜ inch, but shall be not less than ¼ inch nor more than ½ inch in thickness. Face joints shall be flush and neatly struck, and all joints on unexposed faces shall be solidly filled. No spalls or bats shall be used except in shaping around irregular openings or connections or when unavoidable to finish out a course. In this case, a full brick shall be used at the corner with the bat in the interior of the course. If any brick is moved or a joint broken during laying, the brick shall be removed, the mortar thoroughly cleaned from the brick, bed, and joints, and the brick re-laid in fresh mortar. Where required by the Standard Details of Sewer Construction or by the project plans and specifications, the inside and outside surfaces of brick masonry shall be neatly plastered with mortar to a thickness not less than ½ inch, and be finished to a true, uniform, continuous, smooth surface. On completion of each brick structure, all waste mortar and debris shall be immediately removed from the structure, and any necessary repairs or required pointing shall be completed. Brick masonry, plastering, and mortar shall be protected against damage from freezing or lack of moisture. Brick masonry shall not be constructed when the temperature is 40°F or lower without permission of the Director, nor without adequate approved means for protection against freezing. Brick masonry shall have sufficient moisture for proper curing and be protected from drying. Requirements for protection of brick masonry and masonry materials are the same as required for concrete structures. 1066.2.4 Expansive Mortar. 1066.2.4.1 Aluminum Powder Expansive Mortar. The mortar shall consist of one part Type I Portland cement and three parts sand, by volume, mixed with sufficient water to form a stiff plastic mortar. Unpolished aluminum powder at the rate of 4 grams per sack of cement shall be thoroughly dry mixed with the cement before incorporation with other ingredients. 1066.2.4.2 Other Expansive Mortars. Upon approval by the Engineer, other expansive mortars may be used. The expansive mortars shall not contain more than 0.02% chlorides by weight and, when subjected to a pull out test, shall equal or exceed the results of tests made using the material specified in Section 1066.2.4.1.
1/31/2007
1066-2
Mortars and Grout
Section 1068
Calcium Chloride
1068.1 Scope. These specifications cover solid and liquid calcium chloride to be used for concrete admixtures, dust laying, stabilization, ice/snow removal, and other road conditioning purposes. Type L will be used when specified as an accelerating admixture for non-reinforced concrete. Two types of calcium chloride are covered as follows: 1) Type S (Solid). Regular flake, pellets, or granular calcium chloride (CaCl2). a) Grade 1. Minimum concentration of 77%. i)
Class A. Flake
ii) Class B. Granular b) Grade 2. Minimum concentration of 90%. i)
Class A. Flake
ii) Class B. Pellet iii) Class C. Granular iv) Class D. Powder c) Grade 3. Minimum concentration of 94%. i)
Class A. Flake
ii) Class B. Pellet iii) Class C. Granular iv) Class D. Powder 2) Type L (Liquid). Water solutions of calcium chloride (CaCl2). a) Minimum concentration of 30% CaCl2 by weight. When sampled after a delivery, a tolerance of 1 percent below the minimum calcium chloride shall apply. 1068.2 Chemical Composition and Gradation. The chemical composition, maximum impurities content, and gradation shall conform to the requirements of ASTM D 98, for the type specified. 1068.2.1 County Snow and Ice Removal Special Requirements. The delivered product shall be Type S Grade 2 or 3, Class B or Type L and: 1) Be harmless to grass, shrubs, animals and rubber; 2) Must not discolor concrete walks, pavement or pit asphalt pavement or walks; 3) Shall not leave a residue that could be tracked indoors.
2/1/2015
1068-1
Calcium Chloride
1068.3 Packaging and Marking. The calcium chloride in solid form may be delivered in moisture proof bags containing not more than 100 pounds nominal capacity each, or in airtight drums having a weight of not more than 450 pounds nominal capacity each, or it may be delivered in bulk in tank cars, covered hopper cars, or covered trucks; and the calcium chloride in liquid form shall be delivered in bulk in 55 gallon drums, 275 gallon totes, or tank trucks. When requested for bulk storage units, the delivery equipment shall be capable of transferring the liquid solution from the transport vehicle into the bulk storage tanks. The name of the manufacturer, name of the product, net weight, and percentage of calcium chloride guaranteed by the manufacturer, shall be legibly marked on each container for package shipments. Calcium chloride brine shall include similar identification for the product prior to it being mixed into brine. Bulk shipments shall be accompanied by delivery tickets or invoices showing the above information. 1068.3.1 County Snow and Ice Removal Special Requirements. Pellets shall be packaged in 50 pound bags of 5-ply multi-wall construction with a plastic liner that can be stored safely for 2 years from the date of purchase. 1068.3.2 County Snow and Ice Removal Special Shipping Requirements. Ordering procedures shall be established by each County Department. 1) Calcium chloride pellets shall be delivered by the vendor, within 24 hours after receipt of telephone order, F.O.B. to the various County Department locations in St. Louis County, Missouri. The vendor shall also maintain a local (St. Louis) stock. The vendor shall fill a minimum order of not less than one pallet as received. No accumulations of orders for a one-time delivery will be permitted. 2) Liquid Calcium Chloride shall be delivered by the vendor, within 5 hours after receipt of telephone order and on any day. The vendor shall also maintain a local (St. Louis) storage facility with a minimum capacity of 40,000 gal. Delivery shall be made to all 5 District substations or as directed by each County Department in sufficient quantities to maintain a "nonstop" operation. 1068.4 Sampling and Testing. The calcium chloride will be sampled and tested in accordance with the requirements of AASHTO T 143, except that routine samples may be submitted in friction-top metal containers. If the material is sampled after delivery, a 1% variation in content of CaCl2 from that marked on each container, as required in Section 1068.3, will be permissible. Sampling chloride brine shall consist of three samples selected from each storage tank, drum, tote, or truck to form a composite sample. The composite sample of calcium chloride brine shall be tested in accordance with ASTM D 1429, Method D. At the time of delivery the calcium chloride brine shall meet the following physical requirements: Property
Minimum
Maximum
Calcium Chloride (CaCI2) concentration, % by weight:
30
-
Specific Gravity (ASTM D 1429, Method D) Allowable Impurity Content: Total magnesium as MgCI2, % Maximum Total Alkali Chlorides as NaCl, % Maximum Calcium hydroxide, % Maximum
1.295
-
-
6.0 0.5 0.2
2/1/2015
1068-2
Calcium Chloride
1068.5 Rejection. The calcium chloride may be rejected if it fails to conform to any of the requirements of these specifications or if it has become caked or sticky in shipment. Calcium chloride brine containing undissolved clumps of solid calcium chloride or other solid contamination may be rejected. 1068.6 Certification. A supplier's certification shall be furnished stating that representative samples have been inspected and tested in accordance with this specification and have been found to meet the requirements of the material ordered. A report of the test results shall be furnished for each batch produced. A Material Safety Data Sheet shall also be provided.
2/1/2015
1068-3
Calcium Chloride
(This Page Intentionally Left Blank)
2/1/2015
1068-4
Calcium Chloride
Section 1070
Water
1070.1 Scope. This specification covers the water used for mixing and curing concrete, water applied to seed or sodded areas, plants or planted areas, curing concrete and in mortar and grout. 1070.1.1 Definition. Water for use in mixing and curing concrete, applied to seed or sodded areas, plants or planted areas, curing concrete and in mortar and grout, shall be reasonably clean and shall be free from oil and injurious quantities of deleterious substances such as acidity and alkalinity, chlorides or organic matter. Mixing water shall consist of batch water, ice, water added by truck operator, free moisture on the aggregates and water introduced in the form of admixtures when this water increases the watercementitious ratio by more than 0.01. 1070.1.2 Sampling, Testing and Acceptance. Mixing and curing water shall meet the requirements of ASTM C 1602, Mixing Water Used in the Production of Hydraulic Cement Concrete or as modified by these specifications. Mixing and curing water shall be sampled in 2-quart clean glass or plastic containers. Test in accordance with ASTM C 1602. Potable water may be accepted for use as mixing water in concrete without being tested. Requirements for testing water for mixing or curing, applied to seed or sodded areas, plants or planted areas, or curing concrete purposes may be waived if in the judgment of the Engineer, the water is considered satisfactory for the purpose. 1070.1.2.1 Water applied to seeded or sodded areas, plants or planted areas shall be free from oil, be free from impurities injurious to vegetation, and have the following acidity and alkalinity limits. Property
Test Method
Minimum
Maximum
Acidity or Alkalinity, pH
ASTM C 114
6.0
8.0
1070.1.2.2 Water for curing concrete shall not contain impurities in sufficient amount to cause discoloration or surface deterioration. 1070.2 Non-Potable Water. For sources of non-potable mixing or curing water, initial Engineer testing and approval shall be required before use. 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. Upon approval, minimum sampling and testing of water quality shall be performed at a frequency of not less than annually. Water for use in mixing and curing concrete, and in mortar and grout, shall be reasonably clean, free from oil and shall be free from injurious quantities of acidity and alkalinity, chlorides, organic matter, vegetable matter or other deleterious substances and meet the following standards:
2/1/2017
1070-1
Water
Property
Test Method
Minimum
Maximum
Sulfate (SO4) Ion Concentration, ppm
AASHTO T 290
-
3000
Chloride (Cl) Ion Concentration, ppm
ASTM D 512
-
600
Total Organic Solids, ppm
ASTM C 1603
-
400
Total Inorganic Solids, ppm
ASTM C 1603
-
1500
Acidity or Alkalinity, pH
ASTM D 1067
5.0
8.5
Alkalies, as (Na2O + 0.658 K2O), ppm
AASHTO T 105
-
600
Continued material supplier independent laboratory testing, in accordance with Section 1070.2.1, will be required by the Engineer if the above properties are not met and when: 1) The water source is not fit for human consumption, 2) The water is recovered from the process of hydraulic concrete production that includes: a) Wash water from mixers or that was part of a concrete mixture, b) Water collected in a basin as a result of storm water runoff at a concrete production facility or c) Water that contains quantities of concrete ingredients. 3) The water density exceeds 1.01. 1070.2.1 Combined Mixing Water from Concrete Production Testing and Documentation Requirements. The concrete, grout or mortar material supplier shall maintain documentation on the characteristics of water as follows: 1070.2.1.1 The water shall be tested for compliance before use and thereafter every 3 months or more often when there is reason to believe that a change has occurred in the characteristics of the source. The following concrete performance requirements shall also be met. Autoclaved bars, made with the water and cement which shows satisfactory soundness when mixed with distilled water, shall show an expansion not to exceed 0.5 percent. The compressive strength at seven days of a mortar consisting of one part Type I cement and 2.75 parts of natural silica sand and the water being tested shall show a reduction of not more than 10 percent of the compressive strength developed by 1:2.75 mortar containing the same cement and sand and mixed with distilled water. Concrete testing to verify compliance with these requirements shall be conducted on concrete samples obtained from production batches or in laboratory batches in accordance with ASTM C 192.
2/1/2017
1070-2
Water
1070.2.1.2 When water density is less than 1.01 the water density shall be tested at a frequency of once per day in accordance with ASTM C 1603. 1070.2.1.3 When the water density is between 1.01 and 1.03 water shall be tested for compliance before use and thereafter monthly. 1070.2.1.4 When the water density exceeds 1.03, water shall be tested for compliance before use weekly or more often when there is reason to believe that a change has occurred in the characteristics of the source. 1070.2.1.5 The water Optional Chemical Limits for Combining Mixing Water as specified in ASTM C 1602, Table 2, other than the total solids requirement, shall be tested for compliance to ASTM C 1602, Table 1, before use and thereafter once every 6 months.
2/1/2017
1070-3
Water
(This Page Intentionally Left Blank)
2/1/2017
1070-4
Water
Section 1071
Asphalt Release Agents and Liquid Anti-strip Additives
1071.1 Scope. This specification covers asphalt release agents for use in coating truck beds and bituminous mixture additives. 1071.2 Acceptance. 1071.2.1 All material under this specification shall be obtained from a source identified on the MoDOT Pre-Acceptance List designated for this specification. 1071.2.2 All material under this specification will be inspected and accepted in accordance with and in full compliance with Section 106. All other applicable contract documents, and shall be certified as such by the source of the material. 1071.3 Asphalt Release Agent. The asphalt release agent shall not be detrimental to bituminous mixtures and shall not dissolve asphalt binder when applied to the truck bed. 1071.3.1 Physical Properties. The following physical properties shall be determined. 1071.3.1.1 Unit Weight. The weight per gallon shall be determined in accordance with AASHTO T 59, "Weight per Gallon of Emulsified Asphalt". 1071.3.1.2 Solids. The percent solids shall be determined in accordance with the requirements of ASTM D 1644, Method A. 1071.3.1.3 Acidity or Alkalinity Level (pH). The pH of the undiluted agent shall be determined by appropriate methods. 1071.3.1.4 Asphalt Miscibility. When tested in accordance with MoDOT Test Method T63, the asphalt release agent shall show no evidence of dissolving the asphalt binder. 1071.3.2 Dilution. Dilution by diesel or other petroleum products will not be allowed. 1071.3.3 Documentation. The manufacturer shall submit a certification and guarantee to Construction and Materials prior to initial approval showing the brand name and designation, the composition or description of the release agent, and the manner in which the material will be identified on the containers. The manufacturer shall certify that the material is in accordance with this specification and shall list typical values of current tests for the properties listed in Section 1071.3.1. The certified test report shall show the manufacturer's name, brand name of material, lot and date tested. The manufacturer shall also submit a one-quart sample accompanied by a Material Safety Data Sheet (MSDS) for the material. In addition, the manufacturer shall furnish information for any dilution requirements including the minimum dilution rate and special application requirements.
11/1/2016
1071-1
Asphalt Release Agents and Liquid Anti-Strip Agents
1071.3.4 Packaging and Marking. The containers in which release agents are delivered shall be plainly marked with the manufacturer's name, the brand name and designation of the material, lot number and net quantity. Special applicators and dilution rates shall be designated on the container. Bulk shipments shall be accompanied by a delivery ticket showing this information. 1071.5 Liquid Anti-Strip Additives. Liquid anti-strip additives shall not be detrimental to the bituminous mixture. 1071.5.1 Physical Properties. Amine-type liquid anti-strip additives, which are physically mixed with the asphalt binder, will be classified as Type I. Latex type liquid anti-strip additives, which are applied to the aggregate, will be classified as Type II. The following physical properties shall be determined for each type. 1071.5.1.1 Type I. Test
Test Method
Specific Gravity @ 77°F
AASHTO T 228
Brookfield Viscosity (77°F) using an RVT viscometer. The report shall include the corresponding test temperature, speed, spindle and model of instrument.
ASTM D2196
Pensky-Martens Closed Cup Flash Point or Cleveland Open Cup Flash Point
ASTM D93 AASHTO T 48
Infrared Spectrum (neat material)
Appropriate Method
1071.5.1.2 Type II. Test
Test Method
Weight Per Gallon @ 77°F
ASTM D1475
Brookfield Viscosity (77°F) using an RVT viscometer. The report shall include the corresponding test temperature, speed, spindle and model of instrument.
ASTM D2196
pH
Appropriate Method
Percent Solids
ASTM D1644 Method A
Infrared Spectrum (latex portion)
11/1/2016
Appropriate Method
1071-2
Asphalt Release Agents and Liquid Anti-Strip Agents
1071.5.2 Heat Stability. The additive shall be stable and not separate under all manufacturer listed storage and use temperatures. When Type I or Type II additives are blended with the proposed bituminous material to be used at the anticipated application rate, the blended material shall still meet all bituminous material specifications and shall be heat stable. Heat stability shall be established by comparing AASHTO T 283 specimens made by preparing three conditioned specimens using aged, blended material that has been held at 325°F for 96 hours and three conditioned specimens using fresh blended materials. The average tensile strength of conditioned specimens using aged material shall be compared with conditioned specimens made with fresh blended material. If the average conditioned strength of the mixture with aged material is less than 90% of the mixture with fresh blended material, the anti-strip additive will not be allowed for use. This requirement shall also be met if tested on any specific mix design using the approved anti-strip additive. 1071.5.3 Unconditioned Strength. The anti-strip additive shall not significantly lower the unconditioned strength of AASHTO T283 specimens. This shall be determined by preparing an additional six unconditioned specimens, three with and three without the liquid anti-strip additive. The average tensile strengths of unconditioned specimens shall be compared with and without the liquid anti-strip additive. If the average unconditioned strength of the mixture with additive is less than 90% of the mixture without additive, the anti-strip additive will not be allowed for use in that asphaltic or bituminous mixture. 1071.5.4 Documentation. The manufacturer shall submit a certification and guarantee to Construction and Materials prior to initial approval showing the brand name and designation, the composition or description of the anti-strip liquid, and the manner in which the material will be identified on the containers. The manufacturer shall certify that the material is in accordance with this specification and shall list typical values of current tests for the properties listed in Section 1071.5.1. A copy of the bituminous mix design used to test for heat stability and unconditioned strength shall be included with the test results. The certified test report shall show the manufacturer's name, brand name of material, lot and date tested. The manufacturer shall submit at least a one-gallon sample accompanied by a Material Safety Data Sheet (MSDS) for the material. 1071.5.5 Packaging and Marking. The containers in which anti-strip liquids are delivered shall be plainly marked with the manufacturer's name, the brand name and designation of the material, lot number and net quantity. Bulk shipments shall be accompanied by a delivery ticket showing this information.
11/1/2016
1071-3
Asphalt Release Agents and Liquid Anti-Strip Agents
(This Page Intentionally Left Blank)
11/1/2016
1071-4
Asphalt Release Agents and Liquid Anti-Strip Agents
Section 1073
Joint Material for Structures
1073.1 Scope. This specification covers material for performed compression seals and strip seals with lubricant-adhesive for sealing joints and expanded or extruded polystyrene material for use as bedding material under prestressed panels and in the corrugation areas of stay-inplace forms used in forming bridge decks. 1073.2 Preformed Compression Seal. Preformed compression seals shall be in accordance with ASTM D 3542 with the following additional requirements. 1073.2.1 The movement range of the seal as defined in ASTM D 3542 shall be as shown in the contract documents, and the height of seal shall be no less than the nominal width. The seal shall be delivered in containers marked with the manufacturer's name, size of the seal, lot number and date of manufacture. 1073.2.2 The lubricant adhesive applied shall be as recommended by the manufacturer of the seal for installation in accordance with Section 717. The lubricant adhesive shall be delivered in containers marked with the manufacturer's name, lot number, date of manufacture and instructions for storage and use. 1073.3 Strip Seal. Strip seals shall be in accordance with ASTM D 2628 with the following additional requirements. 1073.3.1 The gland lugs of the seal that fasten into the steel extrusion shall be of a type that exerts pressure to the contact surfaces. Glands with snap or arrowhead type lugs shall not be permitted. The seal shall be delivered in containers marked with the manufacturer's name, size of the seal, lot number and date of manufacture. 1073.3.2 The lubricant adhesive applied for bonding the gland to the steel extrusion shall be as recommended by the manufacturer of the seal for installation in accordance with Section 717. The lubricant-adhesive shall be delivered in containers marked with the manufacturer's name, lot number, date of manufacture and instructions for storage and use. 1073.4 Expanded or Extruded Polystyrene Material for Use as Bedding Material for Prestressed Panels. 1073.4.1 Expanded or Extruded Polystyrene Materials. The expanded or extruded polystyrene material shall be in accordance with the following requirements.
1/31/2007
Property
Test
Requirement
Compression Strength
ASTM D 1621
60 psi (minimum)
Water Absorption
ASTM D 2842
2% by Volume (maximum)
Oxygen Index
ASTM D 2863
24 (minimum)
1073-1
Joint Material for Structures
1073.4.2 Adhesive for Expanded or Extruded Polystyrene Materials. The adhesive for use with expanded or extruded polystyrene materials for use as a bedding material for prestressed panels shall be in accordance with manufacturer's recommendations. 1073.5 Expanded Polystyrene Material for Use in Corrugation Areas of Stay-In-Place Forms. The expanded polystyrene materials shall be in accordance with the following requirements. Property
Test
Requirement
Compression Strength
ASTM D 1621
10 psi (minimum)
Water Absorption
ASTM D 2842
2% by Volume (maximum)
1073.6 Manufacturer and Brand Name Approval. Prior to approval and use of this material, the manufacturer shall submit to Construction Division Manager a certified test report showing specific test results in accordance with all requirements of these specifications. The certified test report shall contain the manufacturer's name, brand name of material, lot tested and date of manufacture. In addition, the manufacturer shall submit a sample of the seal or polystyrene material and one-pint (half liter) sample of the adhesive for laboratory testing accompanied by a technical data sheet and a material safety data sheet. With approval by the Engineer of the certified test report and satisfactory results of tests performed on the sample submitted, the brand name and manufacturer will be placed on the appropriate qualified list. The qualified lists are available through Construction Division Manager or MoDOT's web site. New certified test results and samples shall be submitted any time the manufacturing process or the material formulation is changed, and may be required when random sampling and testing of material offered for use indicates nonconformity with any of the requirements herein specified. 1073.7 Acceptance. To obtain final acceptance of this material, the manufacturer shall furnish a certification to the Engineer at destination certifying that the material supplied is in accordance with all requirements specified and stating that the material is the same and is formulated the same as the material tested for manufacturer and brand name approval.
1/31/2007
1073-2
Joint Material for Structures
Section 1075
Centrifugally-Cast Fiberglass-Reinforced Polymer Mortar Pipe
1075.1 Scope. This specification covers centrifugally-cast fiberglass-reinforced polymer mortar pipe to be used in pipejacking and microtunneling for horizontal boring applications under roadways. 1075.2 Acceptance. Acceptance of the material will be based on the manufacturer's certification and upon the results of any tests required by the Engineer. 1075.3 Manufacture. 1075.3.1 Pipe shall be manufactured from polyester resin systems with a proven history of acceptable performance for the particular application. The historical data shall have been acquired from a composite material of similar construction and composition as the proposed product. 1075.3.2 Pipe shall be manufactured from reinforcing glass fibers of commercial grade Eglass filaments with binder and sizing compatible with impregnating resins. 1075.3.3. Pipe shall be manufactured from silica sand, with a minimum of 98% silica, and a maximum moisture content of 0.2%. 1075.3.4 When used, resin additives, such as curing agents, pigments, dyes fillers, thixotropic agents, etc., shall not detrimentally affect the performance of the product. 1075.4 Documentation. The manufacturer shall provide certification to the contractor that the material provided is in accordance with ASTM D 3262 and that pipe joints meet the performance requirements of ASTM D 4161. The certification shall state the manufacturer's name and have attached typical results of tests on the material and pipe joints. 1075.5 Construction Inspection. Pipe will be inspected for defects prior to installation. Damaged pipe will be rejected. Any pipe that appears cracked near the joint will be rejected.
1/31/2007
1075-1
Centrifugally-Cast Fiberglass-Reinforced Polymer Mortar Pipe
(This Page Intentionally Left Blank)
1/31/2007
1075-2
Centrifugally-Cast Fiberglass-Reinforced Polymer Mortar Pipe
Section 1080
Structural Steel Fabrication
1080.1 Scope. This specification covers the fabrication and inspection of bridges and structures made of structural steel and miscellaneous metals. 1080.2 Material. Except as amended by Section 1080.2.4, all material shall be in accordance with Division 1000, Material Details and specifically as follows: Item
Section / Specification
Shear Connectors
1037
Paint for Structural Steel
1045
Coating of Structural Steel
1081
Structural Steel Structural Low Alloy Steel
Quenched and Tempered Alloy Steel
AASHTO M 270, Grade 36 (250) ASTM A 709, Grade 36 (250) AASHTO M 270, Grade 50 (345) ASTM A 709, Grade 50 (345) AASHTO M 270, Grade 50W (345W) ASTM A 709, Grade 50W (345 W) AASHTO M 270, Grade HPS 50W (HPS 345W) ASTM A 709, Grade HPS 50W (HPS 345W) AASHTO M 270, Grade HPS 70W (HPS 485W) ASTM A 709, Grade HPS 70W (HPS 485W) ASTM A 709, Grade 100/100W (690/690W)
Low Carbon Steel Bolts and Nuts
ASTM A 307
High Strength Bolts, Nuts and Washers
ASTM A 325
Cold Finished Carbon Steel Shafting
AASHTO M 169 (ASTM A 108)
Carbon Steel Forgings Alloy Steel Forgings Gray Iron Castings
AASHTO M 102 (ASTM A 668) Class F AASHTO M 102 (ASTM A 668) Class G AASHTO M 105 (ASTM A 48) Class 50
Malleable Iron Castings
ASTM A 47
Carbon Steel Castings
AASHTO M 103 (ASTM A 27) Grade 485-275
Galvanized Coatings
AASHTO M 111 (ASTM A 123)
Lead for Bearing Pads
ASTM B 29
10/1/2012
1080-1
Structural Steel Fabrication
1080.2.1 Galvanized Bolts. Bolts, nuts and washers specified to be galvanized shall be galvanized in accordance with the requirements of AASHTO M 232 (ASTM A 153), Class C or shall be mechanically galvanized in accordance with ASTM B 695, Class 55. Except for anchor bolts, galvanizing thickness shall not exceed 6 mils. Fasteners installed prior to the completion of shop blast cleaning will not require galvanizing. The thickness of the zinc coating for galvanized bolts shall be measured on the wrench flats and top of the bolt head. For mechanically galvanized bolts, the significant surfaces as referenced in ASTM B 695 shall be the entire bolt surface, excluding the underside of the surface of the head and the shank surface between the threaded portion and the underside of the head. The thickness of the zinc coating on the galvanized nuts shall be measured on the wrench flats. For mechanically galvanized nuts, the significant surfaces shall be all surfaces of the nut excluding the threads. The thickness of the zinc coating on galvanized washers shall be measured on both sides. The significant surfaces on mechanically galvanized washers shall be all surfaces of the washer. 1080.2.2 Fit Up Bolts. Fit up and shipping bolts shall be coated to prevent corrosion where a finish coat will not be applied. Shipping bolts for uncoated weathering steel will not require coating. 1080.2.3 Falsework. Falsework material will be subject to the Engineer's approval. All falsework material shall be in good condition such that the material performs as designed. Falsework piling shall be capable of withstanding driving to a depth sufficient to develop adequate bearing. 1080.2.4 Certified Mill Test Reports. For structural steel, the Contractor shall submit a copy of the certified mill test report giving the chemical analysis and results of physical tests on the material furnished. The mill test report shall state the location of the mill where the molten metal was produced. Two copies of the mill test report will be required for material used in railroad structures. If steel is produced outside the United States, the Contractor shall submit a certified test report from a St. Louis County approved U.S. laboratory showing specific results of chemical analysis and physical tests for each heat furnished, and stating that the material meets the specification requirements. Mill tests and laboratory reports shall be submitted for approval before any request is made for shop or field inspection. In addition, the Engineer may take samples for chemical analysis and physical tests from the fabricated steel delivered to the project site. Any time or cost effects caused by obtaining and analyzing samples from delivered steel shall be anticipated by the Contractor as part of the quality assurance process and no compensation or additional time will be allowed for costs or delays associated with this activity. Unless otherwise specified, the supplementary requirements of AASHTO M 270 (ASTM A 709) for Charpy V-notch impact tests in temperature zone 2 shall be mandatory where the contract documents indicate notch toughness is required for fracture critical or non-fracture critical components. Mill test reports shall include the results of Charpy V-notch testing and impact serial numbers for fracture critical components. 1080.2.5 High Strength Fastener Assemblies. In addition to the requirements of Section 712.2.3, high strength bolts, nuts and washers shall meet the following requirements. The Contractor shall furnish a manufacturer's certification showing results of tests performed. Identification in accordance with the appropriate AASHTO/ASTM specifications shall be maintained by container markings which shall match identifying numbers on the certifications and be traceable to the certified mill test reports. High strength fastener assemblies shall be galvanized unless used with unpainted weathering steel or specifically 10/1/2012
1080-2
Structural Steel Fabrication
indicated otherwise by the contract documents. When high strength bolts are used with weathering steel, the fasteners shall be Type 3. All certification testing requirements and mill test reports referenced in the following sections shall be in accordance with Section 106.11. 1080.2.5.1 Bolts. All bolts shall be in accordance with ASTM A 325. If the Contractor elects to use load indicator bolts, only a hex head will be permitted. The type of head used shall be consistent throughout the entire structure, unless otherwise approved by the Engineer. 1080.2.5.1.1 Proof Load Tests. Proof load tests in accordance with ASTM F 606 Method 1 shall be performed. Minimum test frequency shall be in accordance with ASTM A 325. 1080.2.5.1.2 Wedge Tests. Wedge tests on full size bolts, in accordance with ASTM F 606, paragraph 3.5 shall be performed. If bolts are to be galvanized, tests shall be performed after galvanizing. Minimum test frequency shall be in accordance with ASTM A 325. 1080.2.5.2 Nuts. All nuts shall be in accordance with AASHTO M 292 (ASTM A 194) as applicable, or ASTM A 563, except as follows. 1080.2.5.2.1 Nut Grades. Ungalvanized nuts shall be grades 2, C, D or C3 with a minimum Rockwell hardness of 89 HRB or Brinell hardness 180 HB, or heat treated grades 2H, DH or DH3. Nuts that are to be galvanized shall be heat treated grade 2H, DH or DH3. 1080.2.5.2.2 Overtapping. Nuts to be galvanized shall be tapped oversize the minimum amount required for proper assembly. The amount of overtap in the nut shall be such that the nut will assemble freely on the bolt in the coated condition and shall be in accordance with the mechanical requirements ASTM A 563 and the rotational-capacity test. The overtapping requirements of ASTM A 563 will apply, except these limits shall be considered maximum values instead of the minimum, as currently shown. 1080.2.5.2.3 Nut Lubrication. All galvanized nuts, including ASTM A 194 nuts, shall meet the supplementary requirements of ASTM A 563. Galvanized nuts shall be lubricated with a lubricant containing a dye of any color that contrasts with the color of the galvanizing. 1080.2.5.2.4 Proof Load Tests. Proof load tests in accordance with ASTM F 606 shall be performed. Minimum test frequency shall be in accordance with ASTM A 563 or AASHTO M 292 (ASTM A 194). If nuts are to be galvanized, tests shall be performed after lubricating. 1080.2.5.2.5 Weathering Steel. When Type 3 fasteners are specified for use with weathering steel, nuts shall be in accordance with ASTM A 563 and shall be grades C3 or DH3.
10/1/2012
1080-3
Structural Steel Fabrication
1080.2.5.3 Washers. All washers shall be in accordance with ASTM F 436. Hardness testing shall be performed on galvanized washers. The coating shall be removed prior to taking hardness measurements. 1080.2.5.4 Rotational-Capacity Tests. Rotational-capacity tests shall be performed on all bolt, nut and washer assemblies by the manufacturer or distributor prior to shipping. Washers shall be part of the test, regardless if they are required as part of the installation procedure or not. Tests shall be conducted after galvanizing when galvanizing is required. 1080.2.5.4.1 Test Methods. Except as modified herein, the rotational-capacity test shall be performed in accordance with ASTM A 325. 1080.2.5.4.2 Test Lots. Each combination of bolt production lot, nut lot and washer lot shall be tested as an assembly. Where washers are not required as part of the installation procedures, washers need not be included in the lot identification. A rotational-capacity lot number shall be assigned to each combination of lots tested. The minimum frequency of testing shall be two assemblies per rotational-capacity lot. 1080.2.5.4.3 Testing Device. The bolt, nut and washer assembly shall be assembled in a Skidmore-Wilhelm Calibrator or an acceptable equivalent device. 1080.2.5.4.4 Minimum Rotation. The minimum rotation, from a snug tight condition, 10 percent of the specified proof load, shall be as follows: Minimum Bolt Rotation Bolt Length
Rotation
≤ 4 Diameters
240 degrees (⅔ turn)
> 4 Diameters and ≤ 8 Diameters
360 degrees (1 turn)
> 8 Diameters
480 degrees (1⅓ turn)
1080.2.5.4.5 Required Tension. The tension reached at the above rotation shall be equal to or greater than 1.15 times the required installation tension. The installation tension and the tension for the turn test for ASTM A 325 bolts shall be as follows: Required Bolt Tensions Diameter, inches
½
⅝
¾
⅞
1
1⅛
1¼
1⅜
1½
Req. Installation Tension, kips
12
19
28
39
51
56
71
85
103
Turn Test Tension, kips
14
22
32
45
59
64
82
98
118
10/1/2012
1080-4
Structural Steel Fabrication
1080.2.5.4.6 Torque. After the required installation tension has been exceeded, one reading of tension and torque shall be taken and recorded. The torque value shall be as follows: Torque < 0.25 PD Where:
Torque = measured torque, foot-pounds P = measured bolt tension, pounds D = bolt diameter, feet
1080.2.5.4.7 Short Bolts. Bolts that are too short to test in a Skidmore-Wilhelm Calibrator may be tested in a steel joint. The maximum torque requirement shall be computed using a value of P equal to the turn test tension shown in Section 1080.2.5.4.5. 1080.2.5.5 Reporting. The results of all tests, including zinc coating thickness, required herein and in the applicable AASHTO/ASTM specifications, and the location and date of the tests performed, shall be recorded on the appropriate document. The tests need not be witnessed by an inspection agency. The manufacturer or distributor performing the tests shall certify the results are accurate. 1080.2.5.6 Documentation for High Strength Fastener Assemblies. 1080.2.5.6.1 Mill Test Reports. A Mill Test Report (MTR) shall be furnished for all mill steel used in the manufacture of the bolts, nuts or washers. The MTR shall indicate the location where the material was melted and manufactured. 1080.2.5.6.2 Manufacturer Certified Test Reports. The manufacturer of the bolts, nuts and washers shall furnish a Manufacturer Certified Test Report (MCTR) for each item furnished including the following information: 1) The lot number of each of the items tested. 2) The rotational-capacity lot number as required in Section 1080.2.5.4.2. 3) The results of the tests required in Section 1080.2.5.5. 4) The pertinent information required in Section 1080.2.5.4.2. 5) A statement that MCTR for the items are in conformance to this specification and the applicable AASHTO/ASTM specifications. 6) The location where the bolt assembly components were manufactured. 7) Rotational capacity testing if completed by the manufacturer.
10/1/2012
1080-5
Structural Steel Fabrication
1080.2.5.6.3 Distributor Certified Test Reports. The Distributor Certified Test Report (DCTR) shall include MCTR for the various bolt assembly components. The rotational-capacity test may be performed by a distributor in lieu of a manufacturer and shall be reported on the DCTR. The DCTR shall indicate the following if not included in the MCTR: 1) The results of the tests required in Section 1080.2.5.5. 2) The pertinent information required in Section 1080.2.5.4.2. 3) The rotational-capacity lot number as required in Section 1080.2.5.4.3. 4) A statement that the MCTR are in accordance with this specification and the applicable AASHTO/ASTM specifications. 5) Certification of galvanizing from the galvanizing supplier shall be in accordance with Section 1080.2.1. 1080.2.5.7 Shipping of High Strength Fastener Assemblies. Bolts, nuts and washers, where required, from each rotational-capacity lot shall be shipped in the same container in proportionate quantities for use. If there is only one production lot number for each size of nut and washer, the nuts and washers may be shipped in separate containers. Each shipping container shall be permanently marked by the manufacturer or distributor with the rotational-capacity lot number such that identification will be possible at any stage prior to installation. The appropriate MTR, MCTR or DCTR shall be supplied in accordance with the contract documents. 1080.2.6 Machine Bolts. Machine bolted field connections shall be made with machine bolts having American Standard Regular Heads and Nuts of hexagonal shape, and shall be in accordance with ANSI B 18.2.1 and B 18.2.2. Threads shall extend slightly beyond the nut to permit burring. One plain washer in accordance with ANSI B 18.22.1 shall be used at all slotted holes. 1080.2.7 Cast Steel. For cast, the foundry shall furnish a certified copy of foundry reports giving the chemical analysis and results of physical tests on the material from each heat. These reports shall be submitted for approval of material being furnished before any required machine work is done on the castings. 1080.2.8 Cast Iron. For gray iron castings, the foundry shall furnish one finished tension test specimen in accordance with AASHTO M 105 (ASTM A 48) from each heat. The required machine work shall not proceed until material being furnished has been approved. If cast steel is furnished in lieu of gray iron, the minimum tensile strength shall be 50,000 psi. 1080.2.9 Identification of Metals. The steel shall be stamped or stenciled and color striped with paint at the mill. Heat numbers shall be steel stamped or stenciled with paint at the mill. Separate markings and color codes shall be in accordance with AASHTO M 160 (ASTM A 6). The characteristic color stripes shall be placed on each part cut from the mill piece. For steels not covered by AASHTO M 160 (ASTM A 6), the fabricator shall furnish the Engineer the color coding in writing before fabrication begins. Heat numbers shall be painted on all principal pieces, and these pieces shall be so noted on the shop drawings. Principal pieces for this requirement shall include all beams, flanges, webs, splice plates, 10/1/2012
1080-6
Structural Steel Fabrication
cover plates, bearings, bearing stiffener plates, load bearing members of end diaphragms, pin plates, hanger plates and others as may be directed by the Engineer. Principal pieces shall include individual plates of all truss members, truss gusset plates, splice plates and floor beam connection angles. The color code and heat number markings shall be placed on the material such that the markings are visible throughout the work of fabrication. Loss of identification on pieces or items will be cause for rejection of the pieces or items. 1080.2.9.1 Fracture Critical Members. Principal pieces requiring identification shall also include components of fracture critical members. Traceability of both heat numbers and impact serial numbers shall be maintained for fracture critical members and attachments. 1080.2.9.2 Direction of Rolling. Unless otherwise indicated in the contract documents, steel plates for main members and splice plates for flanges and main tension members shall be cut and fabricated such that the primary direction of rolling is parallel to the direction of the principal tensile or compressive stresses. The direction of rolling shall be maintained for all principal pieces during fabrication. 1080.2.10 Steel Stamping. Any metal die stamping of match marks and erection marks in structural steel members shall be limited to a position in the end 1½ inches of flange plates and flange splice plates, the middle third of web plates and the outside edge of the middle third of web splice plates. Metal die stamping at other locations or for other purposes may be approved by the Engineer provided low stress dies are used. Low stress dies will be defined as those manufactured to produce impressions that are rounded at the bottom rather than sharp edged. Metal die stamping on pin plates and hanger plates will not be permitted. 1080.3 Fabrication and Inspection. 1080.3.1 Quality Assurance Inspection. The Engineer will be responsible for QA inspection to assure the quality of the fabricated material. QA inspection by the Engineer will not relieve the Contractor of the responsibility to provide fabricated structural steel items in accordance with the contract documents. Sufficient QC, as necessary to assure work being performed conforms to the contract documents, shall be the responsibility of the Contractor and fabricator. Following adequate notification that QC inspections and testing by the fabricator have been performed, QA inspection will be at the option of the Engineer. Regardless of the location and degree of QA inspection, material and workmanship not meeting specified performance criteria or conforming to the contract documents or recognized good practice may be rejected at any time prior to final acceptance of the work. 1080.3.1.1 Locations of Inspection. QA inspection of fabricated material will ordinarily be made in the shop for fabricating shops within the 48 contiguous States and for shops outside the U.S., but within 1,000 miles of St. Louis County, MO. High strength bolts, nuts and washers shall be presented for sampling at the fabrication shop performing the primary fabrication or at a location agreed to by Construction and Materials. In some cases, QA inspection in the fabrication shop may be waived and inspection made when the fabricated material is delivered to the project site. All costs of QA inspection at fabricating shops located both outside the 48 contiguous States and more than 1,000 miles from St. Louis County, MO, shall be at the Contractor's expense. In such cases, the Contractor will be charged with transportation costs and expenses of QA inspectors for trips made from St. Louis County, MO to locations to which the inspectors must travel 10/1/2012
1080-7
Structural Steel Fabrication
for shop inspection work. These transportation costs and expenses of QA inspectors will be deducted by the Director from monies due the Contractor. 1080.3.1.2 Notification of Inspection. The Engineer shall be notified at least four working days prior to the beginning of the shop fabrication so a QA inspector may be present if so desired and to allow the QA inspector to make travel arrangements. If the fabricator notifies and requests inspection and the QA inspector arrives at the location of inspection to find the material is not ready for inspection as indicated in the request, any travel costs incurred by St. Louis County for additional inspection shall be paid by the Contractor. 1080.3.1.3 Access for Inspection. The Engineer shall have full access to all parts of the shop or project site where material is being fabricated or assembled, and shall be provided with every reasonable facility for determining the character of material and workmanship. 1080.3.1.4 Field Inspection. No increased time or compensation will be allowed for additional work, delays or additional costs as a result of QA inspection at the project site, including required repairs, including where samples were removed, refabrication, securing samples for chemical analysis and physical tests. 1080.3.1.5 Office Space. A suitable office area shall be provided for exclusive use by the Engineer. The office may be enclosed or semi-enclosed as available at the location of QA inspection, but shall be suitable for use as determined by the Engineer. The floor space shall be at least 120 square feet unless otherwise approved by the Engineer, weatherproof, secure, insulated and lighted. The office space shall be adequately ventilated, heated and air-conditioned. Electric outlets with 110-120 volt, 60 Hz current and a telephone with outside line, inter-plant and dial-up computer capabilities shall be provided. Office furniture consisting of a desk (a minimum of 30 inches x 60 inches with drawers), a swivel desk chair with arms and a storage / filing cabinet with lock hardware and key shall be provided. All office furniture will be subject to approval by the Engineer. Should any furniture become unsatisfactory, the furniture shall be promptly repaired or replaced to the satisfaction of the Engineer. Accessible parking shall be provided near the office any time the shop is in operation on St. Louis County projects. No direct payment will be made for furnishing and maintaining an acceptable office area for QA inspection. 1080.3.1.6 Certifications. All structural steel fabricators performing work for the following listed components of steel structures shall be certified prior to the start of fabrication under the appropriate category of the AISC Quality Certification Program as follows: 1) Fabricators of main load-carrying components of welded plate girders, box girders, trusses and arches shall be certified under the AISC Major Steel Bridges category (Cbr). Fabricators of fracture critical members shall be certified under this category, with the additional endorsement for fracture critical capability. 2) Fabricators of main load-carrying components for simple span or continuous rolled beam bridges and POT bearings shall, as a minimum, be certified under the AISC Simple Steel Bridge Structures category (Sbr).
10/1/2012
1080-8
Structural Steel Fabrication
3) Fabricators of overhead sign trusses, temporary bridges and steel bearings shall, as a minimum, be certified under the AISC Conventional Steel Buildings category (Sbd). 4) AISC certification will not be required for manufacturers of simple laminated or elastomeric bearing assemblies. 1080.3.2 Shop Drawings. Shop drawings for structural steel and miscellaneous metals will be required, and shall be prepared in strict accordance with the design details shown on the plans. If details are lacking, the details shall be supplied and shall conform to the design plans and specifications. All drawings shall be clear and complete, and shall be thoroughly checked before submittal. Shop drawings shall be completely titled in accordance with the contract plans and shall pertain to only a single structure. Four sets of the shop drawings shall be submitted to the Bridge Section for approval. The prints submitted shall be legible and shall have distinct details of sufficient contrast to be suitable for microfilming. Prints that do not have the desired clarity and contrast will be returned for corrective action. One set of prints will be returned marked reviewed or approved subject to noted corrections. The Contractor shall promptly make necessary corrections and resubmit six sets for final approval. When shop drawings are approved, the Contractor shall furnish as many additional prints as requested. Reproductions on cloth or film of the original shop drawings will be required for railroad structures and shall be delivered to the Engineer prior to completion of the work. The approval of shop drawings will cover only the general design features, and in no case shall this approval be considered to cover errors or omissions in shop details. The Contractor shall be responsible for the accuracy of the shop drawings, the fabrication of material and the fit of all connections. All changes in the fabrication and erection work caused by errors in shop drawings and any changes in fabrication necessary for satisfactory results0 shall be at the Contractor’s expense. After shop drawings have been approved, no changes in dimensions or substitutions of sections shall be made without written approval from the Engineer. Shop drawings shall be revised to show any authorized changes, and the required number of prints shall be furnished to the Engineer. 1080.3.2.1 Non-Domestic Shop Drawings. Shop drawings from fabricators located outside the 48 contiguous States, whether marked approved or approved subject to the corrections noted, will be returned to the Contractor, and the Contractor shall be responsible for transmitting the drawings to the fabricator for further handling. Should such fabricator also be the Contractor, all prints will be returned to the office located on the project. 1080.3.2.2 Weld Procedures. All welding procedures to be used shall be prepared by the manufacturer, contractor or fabricator as a written procedure specification. For new welding procedures, two copies shall be submitted for approval prior to submitting shop drawings. Approved weld procedures will be kept on file by Bridge and may be considered for use on multiple projects. Any changes to the parameters of an approved welding procedure will require submittal for approval. The shop drawings submitted for approval shall indicate the welding procedure to be used for each joint.
10/1/2012
1080-9
Structural Steel Fabrication
1080.3.2.3 Verification of Work. By submission of shop drawings, the Contractor represents to the Commission that all material, field measurements, construction requirements, performance criteria and similar data have been verified. The Contractor further represents that the shop drawings have been coordinated and verified with the details of the work to be performed by other fabricators and entities on the project. No allowance for additional costs or delays will be made to the Contractor for incorrect fabrication as a result of failure to coordinate or perform these verifications. 1080.3.3 Fabrication. Fabrication of all parts of the structure shall be carefully done in strict accordance with the approved shop drawings. 1080.3.3.1 Straightening. Straightening of any deformed structural material shall be performed by non-injurious methods prior to being worked in the shop. Sharp kinks and bends will be cause for rejection. 1080.3.3.2 Holes. Holes for connections of main members shall be subpunched or subdrilled, and reamed while assembled in the shop, or may be drilled from the solid with main members, and each splice plate fully assembled in their final erected positions. Holes for floor beams and framed stringer connections shall be drilled or reamed to a steel template of sufficient thickness to center the drill accurately, and all members to be secured through the same group of holes shall be drilled or reamed from the same template. Holes may be punched full size in secondary members such as lateral, longitudinal and sway bracing, lacing bars, stay plates and diaphragms. Stacking of web splice plates during drilling or reaming operations on straight girders will be permitted. 1080.3.3.3 Reaming and Finishing of Holes. Reaming or drilling full size from the solid shall be done while the truss, girder, continuous I-beam or other component as noted, is assembled, either in an upright position or on its side, properly adjusted for camber and sweep and after the connecting parts have been firmly fastened together. A minimum of one full span, from bearing to bearing, shall be fully assembled before reaming or drilling full size begins. Connecting parts assembled in the shop for the purpose of reaming or drilling holes for field or shop connections shall not be interchanged or reversed, and shall be match marked. A diagram showing such marks shall be detailed on the shop drawings. Burrs resulting from reaming, drilling or punching shall be removed. All connections shall be disassembled after drilling or reaming to make these holes accessible for deburring. Required cleaning and painting shall be done after disassembly. Reamed, drilled or punched holes shall be round and perpendicular to the member. Any hole out of round more than 1⁄16 inch will be cause for rejection of the plate. Eighty-five percent of the holes in any group shall not show an offset greater than 1⁄32 inch between adjacent thicknesses of metal after reaming or drilling. All holes shall be drilled or reamed and aligned such that a bolt of the specified diameter will enter the hole, and the head and nut will seat on the metal before tensioning. 1080.3.3.4 Applicable Codes. All welding, oxygen cutting, shearing and clipping and dimensional tolerances shall be in accordance with the ANSI/AASHTO/AWS D1.5:2002, Bridge Welding Code. Tubular steel structures shall be governed by the current edition of the AWS D1.1, Structural Welding Code - Steel, in effect at the time of the contract, unless specified otherwise. Aluminum structures shall be governed by the current
10/1/2012
1080-10
Structural Steel Fabrication
edition of the AWS D1.2, Structural Welding Code - Aluminum, except as amended by Section 903, unless otherwise indicated. 1080.3.3.5 Modifications to the Bridge Welding Code. The following modifications to the ANSI/AASHTO/AWS D1.5:2002, Bridge Welding Code (AWS), shall apply: 1080.3.3.5.1 AWS Section 1.3, Paragraph 1.3.4. replaced with the following:
Paragraph 1.3.4 shall be
The gas metal arc welding process shall not be used on any structural components of bridges. Approved gas metal arc processes may be used for incidental, nonstructural components as may be specifically approved by the Engineer. Tack welding with an approved gas metal arc process will be permitted for joints that will subsequently be welded using an approved submerged arc automatic welding process. 1080.3.3.5.2 AWS Section 1.3, Paragraph 1.3.7. A new Paragraph 1.3.7 shall be added as follows: All primary shop welds shall be made by approved submerged arc automatic welding processes. The automatic welding process shall be one in which the wire or electrode feed, speed of travel and guidance are all mechanically controlled. Noncompliance with this requirement will be cause for rejection of the welded material unless prior approval is granted by the Engineer for welding the specified joints by the use of other processes. The automatic welding process requirement for primary shop welds shall be shown on the shop drawings for each joint. Primary shop welds will be defined as flange and web butt welded splices in I-beams, box members and plate girders, plate girder or box flange to web fillet welds and cover plate to flange fillet welds. 1080.3.3.5.3 AWS Section 2.8, Paragraph 2.8.1.1. Paragraph 2.8.1.1 shall be replaced with the following: The minimum fillet weld size, except for fillet welds used to reinforce groove welds, shall be as shown in the following table or as calculated using procedures established to prevent cracking in accordance with Paragraph 4.2.2. In both cases, the minimum size will apply if the size is sufficient to satisfy design requirements. Material Thickness of Thicker Part Joined, inches
Minimum Size of Fillet Weld* inches
To ¾
¼ ** 5
Over ¾ to 2½
⁄16 **
Over 2½
½
* Except that the weld size need not exceed the thickness of the thinner part joined. ** Single pass welds must be used.
10/1/2012
1080-11
Structural Steel Fabrication
1080.3.3.5.4. AWS Section 3.2, Paragraph 3.2.2.2 (4). A new Paragraph 3.2.2.2 (4) shall be added as follows: Quenched and tempered steel plate may be thermally cut provided sufficient preheating is applied according to the steel producer's written recommendations. Procedures for thermal cutting of quenched and tempered steel plate, along with the steel producer's written report, shall be submitted to the Engineer for approval prior to the start of such work. 1080.3.3.5.5 AWS Section 3.2, Paragraph 3.2.3.4. Paragraph 3.2.3.4 shall be replaced with the following: The corrective procedures described in Table 3.1 shall not apply to discontinuities in rolled base-metal surfaces. Such discontinuities may be corrected by the fabricator in accordance with ASTM A 6 (AASHTO M 160), except that repair by welding will be permitted only when approved by the Engineer. Approval will be limited to areas where there will be less than the maximum design stress in the finished structure. When surface imperfections in alloy, low alloy and carbon steel plates are repaired by grinding, the surfaces shall have edges faired to the plate surface with a maximum slope of 1 in 10. 1080.3.3.5.6 AWS Section 3.2, Paragraph 3.2.11. A new paragraph 3.2.11 shall be added as follows: Sheared edges of plates not to be welded that are more than ⅝ inch thick and carrying calculated stress shall be planed to a depth of ¼ inch. 1080.3.3.5.7 AWS Section 3.3.8. Section 3.3.8 shall be replaced with the following: Temporary welds shall be subject to the same WPS requirements as final welds. Temporary welds shall be removed unless otherwise permitted by the Engineer, and the surface shall be made flush with the original surface. Unless previously approved in writing by the Engineer, there shall be no temporary welds for fabrication, transportation, erection or other purposes on main members except at locations more than 1⁄6 the depth of the web from the flanges of beams and girders. There shall be no temporary welds in tension zones of members of quenched and tempered steels. Temporary welds at other locations shall be shown on shop drawings and shall be made with approved consumables. Removal of temporary welds shall conform to Paragraphs 3.3.7.3 and 3.3.7.4. 1080.3.3.5.8 AWS Section 3.4, Paragraph 3.4.6. replaced with the following:
Paragraph 3.4.6 shall be
All shop splices in each component part of a cover-plated beam or built-up member shall be made and all required nondestructive testing completed and approved by the Engineer before the component part is welded to other component parts of the member. Long members or member sections may be made by shop-splicing subsections, each made in accordance with this subsection (see 2.17.6). All shop splices shall be made using full penetration welds that fully develop the capacity of the original member. Additional shop splices required due to length limits of available material may be used if detailed on the shop drawings and placed at 10/1/2012
1080-12
Structural Steel Fabrication
locations approved by the Engineer. No additional payment will be made for any additional shop splices placed in the members at the option of the Contractor, including shop splices that may be required as a result of material limitations. 1080.3.3.5.9 AWS Section 3.5, Paragraph 3.5.1.8.1. A new Paragraph 3.5.1.8.1 shall be added as follows: The maximum permissible variation from specified width for rolled or burned flange plates shall be -⅛ inch to +⅜ inch. 1080.3.3.5.10 AWS Section 3.5, Paragraph 3.5.1.9. Paragraph 3.5.1.9 shall be replaced with the following: The bearing ends of bearing stiffeners shall be flush and square with the web and shall have at least 75 percent of this area in contact with the inner surface of the flanges. The remaining 25 percent of the area of the bearing stiffener shall be within 0.010 inch of the inner surface of the flanges. When bearing against a steel base or seat, all steel components shall fit within 0.010 inch for 75 percent of the projected area of web and stiffeners and not more than 1⁄32 inch for the remaining 25 percent of the projected area. Girders without stiffeners shall bear on the projected area of the web on the outer flange surface within 0.010 inch. The included angle between web and flange shall not exceed 90 degrees in the bearing length. The top surface of a flange or shelf plate supporting a steel bearing rocker shall be considered a flat surface with a tolerance of 0.003 inch per inch in any direction over the projected area of the rocker. The top surface of a flange or shelf plate in direct contact with elastomeric bearings shall not deviate from a true plane surface by more than 1⁄16 inch. 1080.3.3.5.11 AWS Section 3.5, Paragraph 3.5.1.16. A new Paragraph 3.5.1.16 shall be added as follows: Permissible variation in length of assembled beams or girders between the centerline of bearing devices shall not exceed plus or minus ¼ inch for any one span or plus or minus ½ inch for any two or more spans within the assembled unit. The actual centerline of any bearing device shall lie within the thickness of the bearing stiffener. 1080.3.3.5.12 AWS Section 3.7, Paragraph 3.7.2.5. A new Paragraph 3.7.2.5 shall be added as follows: If, after three repairs to the same area of a weld requiring radiographic quality, there is any part of the original defect remaining, or there is a new rejectable indication, the total joint shall be cut apart, all deposited weld metal removed, joint preparation made and the total joint rewelded. 1080.3.3.5.13 AWS Section 3.7, Paragraph 3.7.2.6. A new Paragraph 3.7.2.6 shall be added as follows: The gas metal arc welding process shall not be used for the repair of welds except when repairing welds made with the GMAW process.
10/1/2012
1080-13
Structural Steel Fabrication
1080.3.3.5.14 AWS Section 5.21, Paragraph 5.21.6.2. A new Paragraph 5.21.6.2 shall be added as follows: Any cost involved in qualifying welders, welding operators and tackers, including all material costs, finishing of test specimens, the physical testing of finished specimens and any radiography required shall be borne by the Contractor. Required radiography and physical testing of finished specimens shall be performed at test facilities approved by the Engineer. 1080.3.3.5.15 AWS Section 6.6, Paragraph 6.6.5. replaced with the following:
Paragraph 6.6.5 shall be
If the Engineer subsequently requests nondestructive testing, not specified in the original contract agreement, the Contractor shall perform any requested testing or shall permit any requested testing to be performed. Handling, surface preparation, repair welds and any nondestructive testing requested by the Engineer, as a result of weld repair, shall be at the Contractor’s expense. Payment for any non-destructive testing that does not indicate the need for repair to the tested weld will be in accordance with Section 109.4. 1080.3.3.5.16 AWS Section 6.7, Paragraphs 6.7.1, 6.7.1.1 and 6.7.1.2. Paragraphs 6.7.1, 6.7.1.1 and 6.7.1.2 shall be replaced with the following: Radiographic inspection will be required for areas of both shop and field butt welds as specified herein. One hundred percent inspection will be required for flanges of rolled beams and girders and 100 percent of transverse butt welds in webs for a distance of no less than one-sixth of the web depth from each flange and 25 percent of the remainder of the web depth. At least one-third of the length of all longitudinal web splices shall be radiographed at even intervals throughout the length of the splice. When a rejectable defect is found by radiography in any partially tested joint, either initially or in a later additional radiograph, tests shall be conducted on either side of and adjacent to the rejectable test area. If a rejectable defect is found in any additional areas, then 100 percent of vertical web splices and an additional 10 percent of total weld length in longitudinal web splices shall be tested. The location of these additional test areas shall be as directed by the Engineer. All complete joint penetration groove welds in T and corner joints shall be tested by ultrasonic testing. 1080.3.3.5.17 AWS Section 6.10, Paragraph 6.10.3.4. A new Paragraph 6.10.3.4 shall be added as follows: Edge blocks shall be used when radiographing butt welds greater than ½ inch in thickness. The edge blocks shall have a length sufficient to extend beyond each side of the weld centerline for a minimum distance of 2 inches and shall have a thickness equal to the thickness of the weld, plus or minus 1⁄16 inch. The minimum width of the edge blocks shall be no less than 1 inch. The edge blocks shall be centered on the weld with a snug fit against the plate being radiographed, allowing no more than 1⁄16 inch gap. Edge blocks shall be made of radiographically clean steel and the surface shall have a finish of ANSI 125µin. or smoother (refer to ANSI/AWS D1.1-98 Structural Welding Code - Steel, Section 6.17, Paragraph 6.17.13 and Figure 6.15).
10/1/2012
1080-14
Structural Steel Fabrication
1080.3.3.5.18 AWS Section 6.10, Paragraph 6.10.11.2. Paragraph 6.10.11.2 shall be replaced with the following: If the greatest and least thickness of a weld connecting parts of different thickness cannot be rendered with adequate contrast on a single film with a single exposure, a dual film, or dual exposure technique shall be used to obtain suitable density for both the greatest and the least thickness of the weld. 1080.3.3.5.19 AWS Section 6.12, Paragraph 6.12.4. A new Paragraph 6.12.4 shall be added as follows: After completion of all radiographic inspection, the Contractor shall submit to the Engineer one set of drawing details showing the location and identification numbers of all radiographs taken. 1080.3.3.5.20 AWS Section 6.26, Paragraph 6.26.2.1. Paragraph 6.26.2.1 shall be replaced with the following: For any welds, the greatest dimension of any porosity or fusion type discontinuity that is 1⁄16 inch or larger in greatest dimension shall not exceed the size, B, indicated in Figure 6.8 for the effective throat or weld size involved. The distance from any porosity or fusion type discontinuity described above to another such discontinuity, to an edge or to the toe or root of any intersecting flange-to-web weld shall not be less than the minimum clearance allowed, C, indicated in Figure 6.8 for the size of discontinuity under examination. 1080.3.3.5.21 AWS Section 6.26, Paragraph 6.26.2.2 and Figure 6.9. Delete paragraph 6.26.2.2 and Figure 6.9. 1080.3.3.5.22 AWS Section 6.26, Paragraph 6.26.3.1. Paragraph 6.26.3.1 shall be replaced with the following: Welds subjected to ultrasonic testing in addition to visual inspection shall conform to the requirements of Table 6.3. 1080.3.3.6 Calibrated Tapes. When the contract involves fabrication of a bridge with a bearing-to-bearing span of 100 feet or more, certifications and identifying numbers of calibrated measuring tapes or numbered tapes matched to a calibrated master shall be kept on file for review by the Engineer. Certification of the measuring tape to be used or certification of the master from which the tape was matched shall be traceable to the U.S. National Bureau of Standards. Certification of tapes for shop use shall be renewed at least every two years. 1080.3.3.7 Connection Angles. Connection angles for floor beams and stringers shall be flush and shall be correct as to position and length of member. If milling is required, no more than 1⁄16 inch shall be removed from the thickness of the angles. 1080.3.3.8 Longitudinal Stiffeners. Longitudinal girder web stiffeners shall be a single length if possible. If more than a single length is necessary, such lengths shall be joined by a full penetration butt weld. The location of these butt welds shall be shown on the shop drawings for each joint and shall be subject to approval by the Engineer. Runoff 10/1/2012
1080-15
Structural Steel Fabrication
plates in accordance with AWS Section 3.12 shall be used. The welds shall be radiographically tested and accepted in accordance with AWS Section 6.10 prior to being attached to the web. 1080.3.3.9 Pins. Pins shall be furnished true to size and shall be straight, smooth and free from flaws. Pins shall be provided with hexagonal chamfered nuts. The screw ends shall be sufficiently long to permit burring the threads when members are connected. Pilot and driving nuts shall be furnished for each size of pins where required. Threads for all pins and bolts shall conform with the ANSI B1.1 Free Fit - Class 2 Series except that when recessed nuts are specified, pin ends requiring a threaded diameter of 1⅜ inches or more shall have six threads per inch. If standard nuts are specified for this size pin, a minimum of four threads to the inch shall be used. 1080.3.3.10 Pin Holes. Pin holes shall be bored true to size, smooth and straight, at right angles to the axis of the member, and parallel with each other. The boring shall be done after the member is assembled and welded. The center-to-center distance of pin holes shall be correct within 1⁄32 inch for an individual component or member. The diameter of pin holes shall not exceed that of the pin by more than 1⁄50 inch for pins 4 inches or less in diameter, or no more than 1⁄32 inch for pins larger than 4 inches in diameter. 1080.3.3.11 Casting. Castings shall be free from inclusions of foreign material, casting faults, injurious blow holes or other defects which render the castings unsuitable for the service intended. Castings shall be properly filleted at re-entrant angles. No tolerance will be allowed below the dimensions shown on the plans for thicknesses over an appreciable area of the casting. A reasonable oversize will not be cause for rejection. 1080.3.3.12 Bent Plates. Bent plates shall be cold bent and taken from the stock plates such that the bend line will be at right angles to the direction of rolling. The radius of bends, measured to the concave face of the metal, shall meet the requirements as shown in the table below, in which "T" is the thickness of the plate. If a shorter radius is required, the plates shall be hot bent. Hot bent plates shall be bent at right angles to the direction of rolling. Before hot or cold bending, the corners of the plate shall be rounded to a radius of 1⁄16 inch throughout that portion of the plate at which the bending is to occur. Angle Through Which Plate is Bent
Minimum Radius
61 degrees to 90 degrees
1.0 T
Over 90 degrees to 120 degrees
1.5 T
Over 120 degrees to 150 degrees
2.0 T
1080.3.3.13 Surface Finish. Bearing plates of rolled steel not requiring a surface finish shall be straightened to a plane surface. The surfaces of plates of rolled steel or cast material which are to be in contact shall be finished as shown on the plans, and the final finish shall be prepared in a manner to give at least 50 percent contact as indicated by standard machinist's blue test. Rockers and pedestals made from rolled steel shall be finished after welding. If a flat surface is shown on the plans, the tolerance will be 0.003 inch per inch in any direction. Flat surfaces in full contact shall be finished at right 10/1/2012
1080-16
Structural Steel Fabrication
angles to each other. Bearing plates shall be assembled in sets. The surface finish of bearing and base plates and other bearing surfaces that are to come in contact with each other or with concrete shall meet the following surface roughness requirements as defined in ANSI B 46.1, Surface Roughness, Waviness and Lay, Part I: Surface Roughness Requirements
Micro-inches, Max.
Steel Slabs
2,000
Heavy Plates in Contact in Shoes to be Welded
1,000
Milled Ends of Compression Members, Stiffeners and Fillers
500
Bridge Rollers and Rockers
250
Pins and Pin Holes
125
Sliding Bearings
125
1080.3.3.14 Horizontally Curved Rolled Beams and Plate Girders. If the plans show rolled beams or welded plate girders to be finished to a horizontal curvature, fabrication shall be as follows: 1) Rolled beams shall be curved by the heat curving procedure. 2) Welded plate girders may be fabricated by cutting the flanges to the specified curvature before the girders are attached to the webs or, if not prohibited by the contract, may be curved by the heat curving procedure. 3) If the heat curving procedure is used, the procedure shall comply with the following requirements: a) Material. Heat curving of rolled beams and welded plate girders shall be limited to AASHTO M 270 Grade 36 (ASTM A 709 Grade 36), AASHTO M 270 Grade 50 (ASTM A 709 Grade 50), AASHTO M 270 Grade 50W (ASTM A 709 Grade 50W) and AASHTO M 270 Grade HPS 70W (ASTM A709 Grade HPS 70W). b) Type of Heating. Beams and girders may be curved by either continuous or V-type heating. c) Temperature. The heat curving operation shall be conducted such that the temperature of the steel never exceeds 1,100°F as measured by temperature-indicating crayons or other suitable means applied before heating. The heating of the steel to a temperature greater than 1,200°F will be considered destructive heating and will be conclusive cause for rejection of the steel. Quenching with water or water and air, will not be permitted. Cooling with dry compressed air will be permitted after the steel has cooled to 600°F.
10/1/2012
1080-17
Structural Steel Fabrication
d) Position for Heating. The girder may be heat curved with the web in either a vertical or a horizontal position, unless noted on the contract plans. When curved in the vertical position, the girder shall be braced or supported in such a manner that the tendency of the girder to deflect laterally during the heat curving process will not cause the girder to overturn. When curved in the horizontal position, the girder shall be supported near the ends and at intermediate points, if required, to obtain a uniform curvature. When the girder is positioned horizontally for heating, intermediate safety catch blocks shall be maintained at the mid-length of the girder within 2 inches of the flanges at all times during the heating process. e) Sequence of Operations. Heat curving shall be completed before the girder is painted. The Contractor shall submit a curving procedure addressing the attachment of stiffeners, connection plates and cover plates for review prior to commencement of the heat curving process. 1080.3.3.15 Shop Assembly. 1080.3.3.15.1 If required by the contract, the structural steel for bridges shall be completely shop assembled for inspection, supported only at points of bearing. Long bridges required to be entirely shop assembled may be divided into units for assembly with each unit extending from expansion device to expansion device. 1080.3.3.15.2 Beams and girders of all other bridges shall be assembled for inspection in line assemblies with a minimum length assembled of one complete span, from bearing to bearing. 1080.3.3.15.3 During shop assembly, connecting parts shall be firmly fastened together and held in alignment with a minimum of four drift pins and four make-up bolts per flange splice plate, web splice plate or similar connecting part, until assembly inspection is complete. 1080.3.3.15.4 All trusses, plate girders and continuous I-beams shall be assembled to permit inspection of all parts. QA inspection of the assembly will be at the option of the Engineer. 1080.3.3.16 Shop Measurement of Curvature and Camber. Horizontal curvature and vertical camber will not be measured for QA inspection in the shop until all welding, drilling and heat curving operations have been completed and the flanges have cooled to a uniform temperature. For bridges not requiring complete shop assembly, the vertical camber will be checked with the girder in a horizontal position, and the horizontal curvature will be checked with the girder in either a horizontal or vertical position. The shop drawings shall show the required offsets for both curvature and camber at approximately 10-foot intervals, measured along the girder. The permissible variation in specified sweep for horizontally curved beams and girders, measured in inches, but not to exceed ½ inch, shall be as follows: ⅛ inch x 0.1 x (number of feet from end bearing)
10/1/2012
1080-18
Structural Steel Fabrication
1080.3.4 Shear Connector Studs. Shear connector studs may be attached to the beams or girders either in the fabricating shop or in the field. If the shear connector studs are to be attached in the field, the Contractor shall notify the Engineer no less than one week before the Contractor begins welding shear connectors to the beams or girders so the Engineer may inspect for approval the proposed welding procedure and equipment. Only welding procedures, equipment and operators meeting the requirements of Sections 1080.3.3.4, 1080.3.3.5 and 712.6 shall be used. Areas to which shear connectors are to be attached shall be cleaned of all foreign material, such as oil, grease or paint by a suitable method. Where a shop coat of inorganic zinc primer has been applied, removal shall be limited to the minimum area necessary to apply the studs. After completion of the welding operations, the primed area shall be touched up with a suitable inorganic zinc primer or epoxy mastic paint (non-aluminum). 1080.3.5 Shipping. Fabricated material shall not be shipped before a "Fabrication Inspection Shipment Release" is issued by the Engineer. All parts shall be loaded and protected to prevent damage in transit. Pins, nuts, bolts and other small parts shall be boxed or crated. The "Fabrication Inspection Shipment Release" shall be delivered by the Contractor to the Engineer at destination prior to erection of steel. 1080.4 Weathering Steel. 1080.4.1 Description. This section contains provisions that shall modify, supplement and expand the requirements of the contract plans and other provisions of Section 1080 when the use of weathering steel is specified for structures. Weathering steel will be defined as structural steel specified under AASHTO M 270 (ASTM A 709) Grades 50W, HPS 50W and HPS 70W (Grades 345W, HPS 345W and HPS 485W) that is intended to be primarily used in a bare, uncoated application for the structure. 1080.4.2 High Performance Steels. 1080.4.2.1 Material Requirements. All high performance steel shall be in accordance with the latest edition of AASHTO M 270 (ASTM A 709) and supplements. As an option, HPS 50W (HPS 345W) and HPS 70W (HPS 485W) thermomechanicalcontrolled-processing (TMCP) steel plates available from the manufacturer in limited thicknesses may be directly substituted for the quenched and tempered product. 1080.4.2.2 Fabrication Requirements. All fabrication shall be in accordance with the latest edition of the AASHTO Guide Specifications for Highway Bridge Fabrication with HPS70W Steel, an addendum to be used in conjunction with ANSI / AASHTO / AWS D1.5:2002, except as modified by this section. Only fabricators meeting the requirements of the AISC Quality Certification Program Major Steel Bridges (Cbr) or approved equal may be used to fabricate HPS 50W (HPS 345W) and HPS 70W (HPS 485W) steel. Whenever magnetic particle testing is conducted, only the yoke technique will be permitted as described in Section 6.7.6.2 of AWS D1.5:2002, modified to test using alternating current only.
10/1/2012
1080-19
Structural Steel Fabrication
1080.4.2.3 Welding Requirements for HPS. All welding for high performance steel shall be in accordance with AASHTO / ANSI / AWS D1.5:2002 Bridge Welding Code except as modified herein and by the latest edition of the AASHTO Guide Specifications for Highway Bridge Fabrication with HPS70W Steel. Only submerged arc and shielded metal arc welding processes will be permitted when welding Grade HPS 70W (HPS 485W) steel. The matching submerged arc consumables using the ESAB electrode and Lincoln flux combinations, recommended in Appendix A of the guide specification will not be allowed. Filler metals used for single pass fillet welds or for complete joint penetration groove welds connecting Grade HPS 70W (HPS 485W) plate to ASTM A 709 Grade HPS 50W (HPS 345W) or Grade 50W (345W) may conform to the matching or undermatching requirements from AWS D1.5:2002 as indicated in the guide specification. Moisture resistant coating will be required for all shielded metal arc welding. The Contractor may request approval of alternate consumables in lieu of the filler metals listed in the guide specification for submerged arc welding in accordance with AWS D1.5 Table 4.1. The request for approval shall include documentation of successful welding and shall include diffusible hydrogen tests indicating the levels of diffusible hydrogen to meet the requirements of the guide specifications. Grade HPS 50W (HPS 345W) may be welded under the same requirements as ASTM A 709 Grade 50W (345W). 1080.4.3 Cleaning. Except for the areas of the structure to be partially coated as described in Section 1080.4.4, all surfaces of the structural steel shall be blast cleaned in the fabrication shop to meet the requirements of the Steel Structures Painting Council (SSPC) SSPC-SP6 and may be left uncoated. Faying surfaces of connections to be shop bolted shall be blast cleaned prior to permanent assembly of the connections. After blast cleaning, the steel shall be kept clean of all foreign material. If the steel becomes contaminated, the steel shall be cleaned with a method approved by the Engineer. Girders contaminated with concrete or grout splatters shall be washed off before the material is allowed to dry. 1080.4.4 Partial Coating. The surfaces of all structural steel located under expansion joints, but not in contact with concrete, shall be coated with complete System H within a distance of 1½ times the girder depth, but no less than 10 feet, from the centerline of all deck joints. Within this limit, items to be coated shall include all surfaces of beams, girders, diaphragms, stiffeners, bearings and miscellaneous structural steel items. The prime coat for the specified paint system shall be applied to the structural steel within the above limits in the fabrication shop. The intermediate and finish coats shall be applied in the field in accordance with Section 1081.3.10. The color of the finish coat shall be brown. Portions of the structural steel embedded in or in contact with concrete, including but not limited to the top flanges of girders, shall be coated with no less than 2.0 mils of the prime coat for System H. Shear connectors may not be coated or protected from overspray. 1080.4.4.1 Surface Preparation. All surface preparation and application of the partial coating described herein shall be as specified in Section 1081.3. Required work shall include blast cleaning for all areas to receive the specified prime coat to SSPC-SP-10 (Near White Blast Cleaning) as set forth in Section 1081.3.2.1, except that areas to be primed that will be embedded in concrete may be prepared to no less than SSPC-SP-6. The limits of the areas to be shop and field coated shall be masked to provide crisp, straight lines to prevent overspray on adjacent areas.
10/1/2012
1080-20
Structural Steel Fabrication
1080.4.4.2 Drain Bracket Coating. The galvanized surfaces of drain support brackets shall be prepared according to the coating manufacturer's recommendation and field coated with a gray epoxy mastic primer (non-aluminum) within a distance of 6 inches from the point of connection to the weathering steel structure. 1080.4.5 Bolting and Fasteners. All fasteners, such as bolts, nuts and washers that bolt directly to the weathering grade structural steel, including fasteners located in areas of the structure to be partially coated and fasteners for expansion device supports and similar items shall be high strength weathering fasteners with atmospheric corrosion resistance and weathering characteristics comparable with the A 709 (A 709M) weathering steel. Bolts shall be in accordance with ASTM A 325 (ASTM A 325M), Type 3. Nuts shall be in accordance with the requirements of ASTM A 563 (ASTM A 563M), and shall be Grades C3 or DH3. Washers shall meet the requirements of ASTM F 436, Type 3. All other requirements of Sections 712 and 1080 relating to high strength fastener assemblies and fastener assembly installation will remain in effect. Fasteners for slab drain brackets may be plain uncoated assemblies in accordance with Section 1080.2.5 and coated in accordance with Section 1080.4.5.1. 1080.4.5.1 Coated Connections. Weathering grade fasteners in contact with coated structural steel items or located in areas of the structure to be partially coated, and all fasteners used to attach drain brackets to the structure shall be initially prepared and coated in the field with a gray epoxy mastic (non-aluminum) after the erection of the structure in accordance with the same procedure specified in Section 1081.3.10.1. The epoxy primed fasteners shall be subsequently coated with the System H field coats specified for the structure in areas to be partially coated. 1080.4.5.2 Cleaning. Prior to field bolting connections of high strength fasteners, the faying surfaces shall be cleaned of loose rust by abrasive blast, power hand tools or other approved methods. Tightly adhering rust will not be required to be removed. 1080.4.6 Welding. All welds shall utilize welding processes and electrodes as required that will provide corrosion resistance and weathering characteristics for the welds comparable to the base metal, as set forth in the Section 4 of AWS D1.5:2002 or as modified in Section 1080.4.2.3. 1080.4.7 Bearings and Anchor Bolts. Steel bearings, plate steel for elastomeric and PTFE bearings, structural steel for POT bearings, anchor bolts, sole plates, masonry plates, and associated items shall be in accordance with ASTM A 709 Grade 50W (ASTM A 709M Grade 345W). Anchor bolt nuts shall be heavy hexagon nuts in accordance with ASTM A 563 (ASTM A 563M), Grades C3 or DH3. The exposed surfaces of all bearings for weathering steel structures under expansion joints shall be shop primed and field coated with the complete System H in accordance with Sections 1080.4.4 and 1081.3. 1080.4.8 Protection of Concrete Masonry. All substructure concrete shall be protected from the effects of rust staining during construction in accordance with Section 711.
10/1/2012
1080-21
Structural Steel Fabrication
1080.4.9 Storage of Weathering Steel. Weathering steel shall be stored under conditions that will prevent unsightly, uneven weathering and excessive corrosion. If uneven weathering occurs, the Contractor shall reclean the steel to the satisfaction of the Engineer. If cleaning does not produce satisfactory uniformity in appearance, or if in the judgment of the Engineer, excessive corrosion or chemical contamination has occurred, the Contractor shall replace the material at the contractor's expense. As a minimum, the following conditions shall be avoided and the Contractor shall take additional precautions as deemed necessary: 1) Storage in transit, open cars or trucks for an extended period of time; 2) Standing water on material in storage, or entrapment of moisture; 3) Contact with chemically treated lumber used for blocking or other types of foreign matter; 4) Exposure to chlorides or other chemical contamination. 1080.5 High Strength Bolt Installation. Shop installed high strength bolts shall meet the requirements of Section 712.7. 1080.6 Coating of Structural Steel. requirements of Section 1081.
Shop coating of structural steel shall meet the
10/1/2012
1080-22
Structural Steel Fabrication
Section 1081
Coating of Structural Steel
1081.1 Scope. This specification covers coating new and existing bridges and structures made of structural steel and miscellaneous metals. 1081.2 Systems of Coatings. The required system and color or choice of systems and color will be specified on the plans. Each coat of the specified system shall be applied to all structural steel, unless the contract specifically delineates otherwise. The system and color of coating to be shop-applied shall be shown on the shop drawings. All coatings shall comply with local Volatile Organic Compound (VOC) regulations where the paint is applied. The system and color shall not vary for any portion of the entire structure, including material for field repairs, and shall be compatible products of a single manufacturer. The Contractor shall coordinate the various items of work to ensure compliance with the requirements of this section Approved material specification and dry film thickness for the coating systems shall be as indicated in the following table: Paint Systems for Structural Steel System G (High Solids, Inorganic Zinc Silicate-Epoxy-Polyurethane) Specification
Dry Film Thickness (mils)
Prime Coat
Section 1045.2
3.0 min., -6 max.
Epoxy Intermediate Coat
Section 1045.3
3.0 min., -5 max.
Polyurethane Finish Coat, Gray or Brown
Section 1045.4
2.0 min., -4 max.
Coating
System H (High Solids, Inorganic Zinc Silicate-Waterborne Acrylic IntermediateWaterborne Acrylic Finish) Specification
Dry Film Thickness (mils)
Prime Coat
Section 1045.2
3.0 min., -6 max.
Waterborne Acrylic, Intermediate Coat
Section 1045.5
2.0 min., -4 max.
Waterborne Acrylic, Finish Coat, Gray or Brown
Section 1045.5
2.0 min., -4 max.
Coating
Calcium Sulfonate System Specification
Dry Film Thickness (mils)
Calcium Sulfonate Rust Penetrating Sealer
Section 1045.8.2
1.0 min.
Calcium Sulfonate Primer
Section 1045.8.3
4.0 min.
Calcium Sulfonate Topcoat
Section 1045.8.4
5.0 min.
Coating
1/31/2007
1081-1
Coating of Structural Steel
1081.3 Protective Coating of Structural Steel. 1081.3.1 Scope. This specification covers the preparation of previously uncoated structural steel surfaces, furnishing and applying specified coatings, protection and drying of coatings, furnishing protection from coating spatter and disfigurement, and final cleanup. 1081.3.2 Surface Preparation. 1081.3.2.1 Cleaning. Oil, grease and other contaminants shall be removed in accordance with procedures from Steel Structures Painting Council specification SSPCSP1 prior to blast cleaning. Where high strength bolts are installed prior to blast cleaning or finish coat, the lubricant on high strength bolt assemblies shall also be removed in accordance with SSPC-SP1. Surfaces to be prime coated shall be blast cleaned with abrasives in accordance with SSPC-SP10, producing a height of profile 1.5 mils minimum and 3.0 mils maximum for all systems. The appearance of the final blastcleaned surface shall be in accordance with SSPC-Vis1, Photograph A SP-10, B SP-10, C SP-10, or D SP-10. Conformance with the corresponding SP-5 photographs will also be acceptable. The blast profile shall be assessed with replica tape per ASTM D4417, Method C. The Contractor shall make available to the Engineer access to all SSPC specifications referenced for cleaning and coating operations. 1081.3.2.2 Preparation for Coating. After blast cleaning, all surfaces shall be cleaned to remove any trace of blast products, dust or dirt from the surface, and also from all pockets and corners. The blast-cleaned surfaces shall be given the specified prime coat as soon as practical, but within 24 hours after blast cleaning. If blast cleaned surfaces rust before coating is accomplished, the surface shall be re-blasted by the Contractor at the Contractor's expense. All rusted, damaged or uncoated areas, including ungalvanized nuts, bolts and washers to be prime coated in the field, shall be blast cleaned to the same degree as specified above for the applicable coating system. Care shall be exercised to ensure the blasted steel remains free of grease and oil during handling. 1081.3.2.3 Recleaning. When there is contamination of any blast cleaned surface to be coated, the material shall be re-cleaned to the requirements of SSPC-SP10. 1081.3.3 Limits of Coating Application. Unless otherwise indicated on the plans, the application of the intermediate and finish coats (defined as field coats) for Systems G and H shall be applied to the surfaces of all structural steel, including surfaces of beams, girders, bearings, diaphragms, stiffeners and miscellaneous structural steel items. Areas of steel to be in contact with concrete shall not receive the intermediate and finish coats. 1081.3.4 Coating Thickness Measurement. The dry film thickness of the coatings will be measured by magnetic type gauges in accordance with Steel Structures Painting Council specification SSPC-PA2. At the option of the Engineer, the adhesion of the prime coat will be measured in accordance with ASTM D 3359, Test Method A. When the adhesion is tested, each test result shall equal or exceed scale 3A. Locations for adhesion tests shall be randomly selected. Test locations shall be in areas of least visibility in the completed structure and shall be touched up in an approved manner after completion of the test. When satisfactory test results are not obtained, additional adhesion tests shall be taken to determine the area of insufficient adhesion. For these areas, the surface shall be prepared in accordance with Section 1081.3.2.1 and the area recoated in accordance with these 1/31/2007
1081-2
Coating of Structural Steel
specifications. If additional prime coat is required to provide the specified minimum thickness, the prime coat shall be applied as soon as possible, but within 24 hours of the initial application. 1081.3.5 Coating Material Storage. All coating material shall be stored in accordance with the coating manufacturer's recommendations. Exposure to storage temperatures outside the range recommended in the manufacturer's specifications will be cause for rejection of the coating material. 1081.3.6 Weather Conditions. 1081.3.6.1 Temperature Limitations. The prime coat shall be applied in accordance with the manufacturer's recommendations, except that the minimum air and steel temperature shall not be less than 34°F. Finish and intermediate coats applied over the prime coat shall be applied in accordance with the manufacturer's specifications, which shall be furnished to the Engineer. The minimums and maximums or additional requirements established by the coating manufacturers written specifications for recommended air or metal temperature or relative humidity shall apply if those requirements are more restrictive than those specified in the contract documents. 1081.3.6.2 Moisture Limitations. Coatings shall not be applied in rain, snow, fog or mist, or when the steel surface temperature is less than 5°F above the dew point. The dew point shall be determined in accordance with MoDOT Test Method T 38. Coatings shall not be applied to wet, damp, frosted or ice-coated surfaces. 1081.3.6.3 Application in Protected Areas. When coatings are applied in a protected area to eliminate the weather conditions, the coated steel shall remain in the protected area until the coatings are cured. 1081.3.6.4 Damaged Coatings. Any uncured coatings exposed to freezing, excess humidity, rain, snow, condensation or curing temperatures outside the range recommended by the manufacturer will be considered damaged. Damaged coatings shall be permitted to dry, then shall be removed and the surface blast cleaned and recoated at the Contractor's expense. 1081.3.7 Thinning. Thinners will be permitted as recommended by the manufacturer's written specifications, provided VOC limits are not exceeded. 1081.3.8 Application. Coatings shall be applied in accordance with the Steel Structures Painting Council specification SSPC-PA1 unless otherwise specified by the product manufacturer. The manufacturer's written specifications for application, upon request, shall be submitted to the Engineer for review. 1081.3.8.1 Application Repairs. If deficiencies in the quality of work or material result in rejection, the Contractor shall submit a repair proposal for approval by the Engineer. 1081.3.8.2 Curing of Coatings. Curing time for recoating shall be within the limits of the manufacturer's recommendations. Application of the finish coat over the intermediate coat shall be accomplished within the recoat time for proper adhesion established by the manufacturer's written specifications.
1/31/2007
1081-3
Coating of Structural Steel
1081.3.9 Shop Coating. All surfaces of fabricated structural steel, including areas which will be inaccessible after assembly, contact surfaces of high strength bolted connections, and all surfaces to be in contact with concrete in the completed structure shall be coated in the shop with the prime coat. The primer shall be of the type and thickness specified, except as modified by Section1081.3.9.1 and Section 1081.3.9.2. Structural steel sway bracing for substructure may be prepared and coated in the field. 1081.3.9.1 Contact Surfaces. Contact surfaces of high strength bolted field splice and diaphragm connections shall be prime coated to produce a dry film thickness no less than 1.5 mils or more than 2.5 mils. The limits of the coating thickness for these surfaces shall be shown on the shop drawings. The maximum limit of 2.5 mils may be increased provided acceptable test results in accordance with the Testing Method to Determine the Slip Coefficient for Coatings Used in Bolted Joints (AISC "Specification for Structural Joints Using ASTM A 325 or A 490 Bolts", Appendix A) are submitted and approved by the Engineer. Revised shop drawings will not be required upon acceptance of the test results. The tests shall meet the requirements for the slip coefficient and creep resistance for Class B coatings and shall be performed by a nationally recognized independent testing laboratory. Any change in the formulation of the coating will require retesting, except when thinned within the limits of manufacturer's written specifications. At the Contractor's option, the contact surfaces of connections for all non-slab bearing diaphragms on non-curved girders may be prime coated with a dry film thickness of no less than 3.0 mils or no more than 6.0 mils, unless noted otherwise on the plans. 1081.3.9.2 Inaccessible Surfaces. Surfaces which will not be in contact, but which will be inaccessible after assembly, shall be prime coated to produce a dry film thickness of no less than 3.0 mils and no more than 6.0 mils. Dry film thickness on surfaces which will be in contact with concrete may be reduced to 2.0 mils provided thorough and complete coverage is obtained. Although shear connectors need not be coated, protection of the connectors from overspray when coating other parts of the beam or girder will not be necessary. Coating thickness measurements will not be made on shear connections. 1081.3.9.3 Touch-up of Galvanized Bolts. The galvanized coating of nuts, bolts and washers damaged during shop installation shall be shop repaired in accordance with Section 1081.3.10.1 and Section 1081.3.10.1.1. 1081.3.9.4 Inspection Prior to Coating. No coatings shall be applied before shop inspection of fabrication has been completed. Surfaces of steel within 2 inches of edges to be field welded shall not be coated in the shop. 1081.3.9.5 Erection Match Marks. Erection match marks shall not be visible in the completed structure. 1081.3.10 Field Coating. Intermediate and finish coats for the specified coating system shall be applied in the field. The Contractor shall be responsible for final cleanup and field touch-up of any shop applied coating, including surface preparation and coating of field connections, welds or bolts, areas masked in the shop, and all damaged or defective coating and rusted areas. Surface preparation for field touch-up shall be performed in accordance with Section 1081.3.2, unless otherwise approved by the Engineer. The touchup field coat shall consist of the same coating used for the shop applied coat. Contact surfaces of high strength bolted connections shall be protected from the intermediate and 1/31/2007
1081-4
Coating of Structural Steel
finish coats. Damage to the coating of galvanized bolts, nuts and washers where bare steel is exposed shall be repaired in accordance with these specifications or, the connection may be prepared as specified in Section 1081.3.2, followed by a touch-up field coat application of the required coating system. 1081.3.10.1 Field Touch-up of Galvanized Bolts. The galvanized coating of nuts, bolts and washers damaged during installation shall be repaired. Lubricants shall be removed in accordance with SSPC-SP1. Rust shall be removed in accordance with SSPC-SP-2 or SSPC-SP-3. Touch-up shall consist of the application of an approved gray epoxy mastic. The touch-up material shall be compatible with and from the same manufacturer as the coating system to be used for the structure. Prior to field coating operations, the Contractor shall submit information on the specific products to be used, including compatibility data and applicable recoating times to the engineer for review. Subsequent coatings shall be applied within the recoat time recommended by the manufacturer. 1081.3.10.1.1 Touch-up Color. For areas of the structure that will not receive a field coat, the color of the touch-up material for bolts specified in Section 1081.3.10.1 shall be similar to galvanized metal. 1081.3.10.1.2 Previously Repaired Material. If repairs to the galvanized coating of shop-installed nuts, bolts and washers have previously been performed in accordance with Section 1081.3.9.3 or if epoxy mastics are otherwise shop-applied to structural steel, the Contractor shall be responsible for any special field preparation required for proper adhesion of subsequent field coats to the epoxy coating. Prior to field coating operations, the Contractor shall submit manufacturer's recommendations to the Engineer. 1081.3.10.1.3 Masking. Previously coated or adjacent areas shall be masked or otherwise protected from material used to touch-up the galvanized coating of fasteners. 1081.3.10.2 Sequence of Work. Field coatings, except for touch-up and coating of inaccessible surfaces, shall not be applied until the concrete deck has been placed, the forms removed, and all concrete spatter, foreign material and contaminants are removed from existing coatings unless otherwise approved by the Engineer. Prior to submittal of alternative application methods, the Contractor shall present methods to be used to prevent damage to the intermediate and final field coatings. The sequence of work shall be arranged to provide ample time for each coat to cure before the next coat is applied. The intermediate field coats shall be free of all oil, grease, dust or dirt prior to application of the next coat. Intermediate or prime coats that have been exposed to chlorides used in snow removal operations shall be cleaned by power washing as defined in Section 1081.5.3.2.2 prior to application of the subsequent intermediate or final coats. In no case shall a coat be applied until the previous coat has been approved by the Engineer. Excessive rust streaks or coatings on concrete masonry shall be removed by sandblasting or by other approved methods without damage to the masonry.
1/31/2007
1081-5
Coating of Structural Steel
1081.3.10.3 Work Under Stage Construction Contracts. If complete field coating is not included in the contract for erection of structural steel, the touch-up coating of newly erected work and the coating of surfaces which will be inaccessible after erection shall be included as part of the work to be performed under the contract for erection. Field coating under any contract that does not include the erection shall include cleaning, preparation of any previously applied coatings, repairs and spot application of coatings required at the time the work is performed. Prior to field coating of structural steel that was erected under a previous contract, the Contractor shall submit the manufacturer's recommendations to the Engineer, outlining requirements for cleaning and preparation of all existing coatings. The manufacturer's recommendations shall include requirements for preparation of epoxy mastics previously applied for touch-up or other purposes. 1081.3.10.4 Partial Applications. If partial application of the field finish coats to a structure as provided in Section 1081.3.3 is required or permitted, the Contractor shall perform field touch-up coating to areas of the structural steel outside the limits to receive the intermediate and finish coats. Touch-up shall be in accordance with in Section 1081.3.10 and at the Contractor's expense. 1081.3.11 Identification. The Contractor shall, at the completion of the coating application, stencil in black paint on the structure the number of the bridge, the word "COATED", the system used and the month and year the coating was completed. The letters shall be capitals approximately 3 inches high. The legend shall be stenciled on the outside face of an outside stringer or girder near each end of the bridge as directed by the Engineer. 1081.3.12 Property and Traffic Protection. The Contractor shall protect pedestrian, vehicular, railroad and other traffic, persons and property, upon, beneath and in the vicinity of the structure, and all portions of the bridge against damage or disfigurement by blast media, blast residue, coatings, coating material, equipment or by any other operations. 1081.4 Recoating of Structural Steel (System G or H). 1081.4.1 Scope. This specification covers the field preparation of structural steel surfaces to be recoated, furnishing and applying specified coatings, protection and drying of coatings, furnishing protection from coating spatter and disfigurement, and final cleanup. 1081.4.2 Systems of Protective Coatings. All structural steel shall be recoated by the Contractor in the field using one of the complete systems, including prime coats in accordance with Section 1081.2, unless noted otherwise. Recoating of structural steel, including surface preparation, weather conditions, application, touch-up and protection, shall be in accordance with all requirements of Section 1081.3. 1081.4.3 Surface Preparation. Cleaning and painting of the structural steel shall proceed in areas or sections as approved by the Engineer, usually consisting of one or more complete spans. The cleaning and application of the coatings for each specified section shall be entirely completed and accepted by the Engineer prior to proceeding with additional cleaning or coating. Surface preparation shall be in accordance with Section 1081.3.2. All existing coatings and paint shall be removed by blast cleaning unless specifically indicated otherwise in the contract.
1/31/2007
1081-6
Coating of Structural Steel
1081.4.3.1 Environmental Regulations. The paint removal operation shall comply with all local, state and federal regulations, including but not limited to the Environmental Protection Agency (EPA), Occupational Safety and Health Administration (OSHA) Standards 29 CFR 1910 and 1926.62, and the Missouri Code of State Regulations, including 10 CSR 10 Air Conservation Commission, 10 CSR 20 Clean Water Commission, 10 CSR 25 Hazardous Waste Commission, and 10 CSR 80 Solid Waste Management. 1081.4.3.2 Collection of Non-Lead Based Residue. The Contractor shall collect the residue from the cleaning operations for disposal. The residue from cleaning operations shall be stored in Contractor furnished, watertight containers free from rust, paint or other structural defects. Containers shall remain closed at all times, except when necessary to add additional residue, and shall be labeled to indicate the contents. Material, other than the residue from the cleaning operations, shall not be placed in the containers. Clothing, tarps, hoses and other waste material shall be properly disposed of by the Contractor at the Contractor's expense. At the end of each day's work, the containers shall be stored outside the flood plain in a secure area for bridges over streams or near the bridge site in a secure area for other bridges. The Contractor shall properly dispose of all non-hazardous residues. Any testing required for the disposal of residues shall be the responsibility of the Contractor. Hazardous residues shall be disposed of in accordance with Section 1081.4.3.3. 1081.4.3.3 Collection of Lead Based Residue. The Contractor shall collect the heavy metal contaminated residue from the cleaning operations for disposal. All residues shall be considered hazardous waste until tested to verify otherwise. The residue shall be stored in containers and locations as described in Section 1081.4.3.2, and the containers shall be labeled to indicate hazardous material storage with approved labels. Heavy metal contaminated residue shall be transported to a lead smelter or hazardous waste disposal facility by a Missouri licensed hazardous waste transporter. For more information concerning approved smelters or hazardous waste disposal facilities, the Contractor shall contact the Missouri Department of Natural Resources, Hazardous Waste Program. The Contractor shall be responsible for contacting the Engineer to coordinate the paperwork required for shipping of the heavy metal contaminated material. Clothing, tarps, hoses and other cleaning material shall be tested for heavy metal contamination and shall be disposed of in accordance with all local, state or federal regulations. The Contractor shall maintain an inventory of the quantity of heavy metal contaminated residue delivered to the storage site and either to the lead smelter or the hazardous waste disposal facility. Copies of the inventory shall be provided to the Engineer. 1081.4.4 Joints. All seams and joints which cannot be satisfactorily sealed or coated shall be adequately caulked with compounds compatible with the coating system being applied. Caulking material shall be in accordance with the coating manufacturer's recommendations and shall meet the approval of the Engineer. Caulking shall be satisfactorily completed for an entire joint or seam after application of the prime coat and before application of any specified finish or intermediate coats.
1/31/2007
1081-7
Coating of Structural Steel
1081.4.5 Identification. The Contractor shall, at the completion of recoating, stencil in black paint on the structure the number of the bridge, the word "RECOATED", the system used and the month and year the coating was completed. The letters shall be capitals approximately 3 inches high. The legend shall be stenciled on the outside face of an outside stringer or girder near each end of the bridge as directed by the Engineer. 1081.4.6 Property and Traffic Protection. The Contractor shall provide protection in accordance with Section 1081.3.12. 1081.5 Overcoating of Structural Steel (Calcium Sulfonate System). 1081.5.1 Scope. This specification covers the field preparation of structural steel surfaces to be recoated, disposal of paint residues and power washing water, furnishing and applying the specified coatings, protection and drying of the coatings, furnishing protection from coating spatter or disfigurement and final cleanup. 1081.5.2 System of Protective Coatings. All exposed and accessible surfaces of structural steel and steel bearings shall be coated with the Calcium Sulfonate paint system in accordance with Section 1081.2 unless otherwise noted. The color of the topcoat shall be as shown on the contract plans. Recoating of the structural steel shall be in accordance with all requirements of Section 1081.3. 1081.5.3 Surface Preparation. Surface preparation shall be in accordance with Section 1081.4.3, except that blast cleaning will not be required. 1081.5.3.1 Removal of Existing Paint. The existing steel shall be cleaned by a combination of approved mechanical methods and power washing in accordance with Section 1081.5.3.2. 1081.5.3.1.1 Water for Power Washing. The water used for power washing shall be clean, potable water free from contaminants. The wastewater shall be collected and disposed of in accordance with all applicable state, local and federal clean water regulations. The wastewater shall not be discharged onto the ground or into waters of the state without a permit. Water that is collected from the power washing operation shall not be reused in the power washing operation. 1081.5.3.1.2 Environmental Regulations. The paint removal operation shall comply with all local, state and federal regulations including those defined in Section 1081.4.3.1. 1081.5.3.1.3 Collection of Non-Lead Based Residue. The residue from both the mechanical and power washing operations shall be stored in containers and locations as described in Section 1081.4.3.2. The containers shall remain closed at all times except when necessary to add additional residue or wastewater. The containers shall be labeled to indicate the contents. Material other than the residue or wastewater from the cleaning operations shall not be placed in the containers. Clothing, tarps, hoses and other waste material, non-hazardous, filtered wastewater and remaining non-hazardous residues shall be properly disposed of by the Contractor. Any testing required for the disposal of the wastewater or residues shall be the responsibility of the Contractor. Copies of all testing data, required certifications and shipping manifests shall be provided to the Engineer. 1/31/2007
1081-8
Coating of Structural Steel
1081.5.3.1.4 Collection of Lead Based Residue. All residue and wastewater shall be considered hazardous waste until tested to verify otherwise. The residue shall be stored in containers and locations as described in Section 1081.4.3.2, and the containers shall be labeled to indicate hazardous material storage with approved labels. Heavy metal contaminated residue shall be transported to a lead smelter or hazardous waste disposal facility by a Missouri licensed hazardous waste transporter. For more information concerning approved smelters or hazardous waste disposal facilities, contact the Missouri Department of Natural Resources, Hazardous Waste Program. The Contractor shall be responsible for contacting the Engineer to coordinate the documentation required for shipping of the heavy metal contaminated material. Clothing, tarps, hoses and other cleaning materials shall be tested for heavy metal contamination and disposed of in accordance with all local, state or federal regulations. Wastewater collected during cleaning operations, that test results indicate as a hazardous waste as determined by 40 Code of Federal Regulations 261.24 (Methods for Determining Hazardous Waste Characteristics of Toxicity), shall be filtered to remove as much heavy metal contamination as possible. If further tests indicate the wastewater is still considered contaminated, the wastewater shall be transported to a hazardous waste disposal facility in accordance with all applicable regulations. Wastewater that has been tested and determined to be non-hazardous shall be discharged in accordance with Section 1081.5.3.1.1. The Contractor shall maintain an inventory of the quantity of heavy metal contaminated residue delivered to the storage site and either to the lead smelter or the hazardous waste disposal facility. The Contractor shall also keep an inventory of the quantity of heavy metal contaminated water generated and delivered to the storage site and the quantity of heavy metal contaminated water, which has been disposed. Copies of the inventory shall be provided to the Engineer. 1081.5.3.1.5 Testing of Water Samples. At the conclusion of the power washing operation, the Contractor shall obtain samples of the filtered wastewater in the presence of the Engineer. The samples shall be analyzed by an independent testing laboratory for total metals, oil and grease, biochemical oxygen demand, total suspended solids, pH and Toxicity Characteristic Leaching Procedure (TCLP) heavy metals. Samples shall be collected and analyzed in accordance with EPA approved methods. Copies of all test reports shall be supplied to the Engineer. Additional testing required to comply with any federal, state or local regulations shall be provided by the Contractor. 1081.5.3.2 Cleaning of Structural Steel. All exposed steel surfaces shall be mechanically cleaned and power washed prior to application of the coating. 1081.5.3.2.1 Mechanical Cleaning. Exposed structural steel where mechanical cleaning is required shall be cleaned in accordance with SSPC-SP2 or SSPC-SP3. Mechanical cleaning will be required for areas of rusted steel, loose, cracked or brittle paint or areas indicated by the Engineer. The cleaning shall be performed 2 inches beyond the areas of rust or defective paint in all direction or until tightly adhered paint is obtained with no rust or blisters. Edges between the bare steel and the paint shall be feathered. Collection of the material removed shall be in accordance with Section 1081.5.3.1.
1/31/2007
1081-9
Coating of Structural Steel
1081.5.3.2.2 Power Wash Cleaning. After completion of the mechanical cleaning to the satisfaction of the Engineer, the steel shall be cleaned by a low-pressure power wash to remove loose paint, dirt and other loose deleterious material. The maximum pressure for the power washing shall be 1500 psi. If necessary, solvent cleaning in accordance with SSPC-SP1 shall be employed to augment the power washing. Collection of the wastewater, solvents and other residues from the power washing operation shall be in accordance with Section 1081.5.3.1. After the power washing operation, areas that have remaining rust or loose paint shall be re-cleaned in accordance with Section 1081.5.3.2.1, except that vacuum power tools will be required for power tool cleaning. All surfaces washed shall be completely free of all foreign matter, surface dry and approved by the Engineer prior to application of the coating. 1081.5.4 Application. The coating shall be applied in accordance with Section 1081.3 and the manufacturer's recommendations. The steel shall be free of all cleaning residues prior to coating. Areas that have been cleaned to bare steel shall be prime coated on the same day as the cleaning. Any areas that rust prior to application of the prime coat shall be recleaned. The prime coat and topcoat shall be applied to all steel surfaces with the exception of steel encased in concrete. Any existing paint that curls or lifts after application of the Calcium Sulfonate system shall be removed, the area re-cleaned and the coating reapplied. Application of the rust penetrating sealer will only be required if specified in the contract documents or as determined by the Engineer. Application of the rust penetrating sealer shall be in accordance with the rust penetrating sealer manufacturer’s recommendations. 1081.5.5 Identification. The Contractor shall, at the completion of the final coating application, stencil in black paint on the structure the number of the bridge, the word "RECOATED - Calcium Sulfonate" and the month and year the coating was completed. The letters shall be capitals approximately 3 inches in height. The legend shall be stenciled on the outside face of an outside girder near each end of the bridge as directed by the Engineer. 1081.5.6 Property and Traffic Protection. The Contractor shall provide protection in accordance with Section 1081.3.12. 1081.6 Galvanized Metal. Galvanizing shall be applied after fabrication. Galvanized material on which the galvanizing has been damaged will be rejected or may, with approval of the Engineer, be repaired in the field by the zinc alloy stick method. Required field welds and adjacent areas on which galvanizing has been damaged shall be galvanized by this same method. The area to be regalvanized shall be thoroughly cleaned, including the removal of slag on welds. Touch-up of galvanizing of sheet material less than 3⁄16 inch may be completed by the use of an approved aluminum epoxy mastic coating if the material will not be in direct contact with concrete or with an approved non-aluminum epoxy mastic coating if the material will be in direct contact with concrete.
1/31/2007
1081-10
Coating of Structural Steel