Reinstated KT-61: Raveling Test on Recycled Asphalt Specimens. Added KT-82: Determination of Excessive Moisture in Concrete Surfaces

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1 s to the 2014 version of Part V of the Construction Manual This document is intended as a guide to the changes that occurred between the 2014 to the 2015 versions of Part V of the Kansas Department of Transportation Construction Manual. Use this guide in conjunction with the published manual for context. This document may not reflect all changes that occurred. Refer to the official published version. Table of Contents Reinstated KT-61: Raveling Test on Recycled Asphalt Specimens Reinstated KT-69: Relative Density HMA: CONTRACTOR S QUALITY CONTROL PLAN Added KT-81: Sampling Cold Plastic Pavement Marking, Patterned Cold Plastic Pavement Marking Tape and High Durability Pavement Marking Tape Added KT-82: Determination of Excessive Moisture in Concrete Surfaces Added KT-83 Strand Bond in Prestressed Concrete Memebers Added KT-84: Sampling Nuts, Bolts and Washers Table 2 Gyratory Compactor KT (6 for large Pine Models AFGC125X) CONCRETE: CONTRACTOR S QUALITY CONTROL PLAN Table 1 Test Thermometers KT-17, KT-22 & AASHTO T 231 KT-73 Compression Testing Machine KT-22, KT-23 & AASHTO T 22, KT-49 & KT-76 Capping Material AASHTO T 231 KT-77

2 EXAMPLE OF A LABORATORY QUALITY MANUAL FOR CONCRETE TABLE OF CALIBRATION/VERIFICATION DATES Test Thermometers KT-17, KT-22 & AASHTO T 231 KT-73 Compression Testing Machine KT-22, KT-23 & AASHTO T 22, KT-49 & KT-76 Capping Material AASHTO T 231 KT CEMENT TREATED BASE: CONTRACTOR S QUALITY CONTROL PLAN Table 1 Capping Material AASHTO T 231 KT EXAMPLE OF A LABORATORY QUALITY MANUAL FOR CEMENT TREATED BASE TABLE OF CALIBRATION/VERIFICATION DATES Capping Material AASHTO T 231 KT CONCRETE MIX DESIGN Note 3.1. the various components of the mix, i.e.: the absolute volumes of cementitious (plain, blended or fly ash modified), aggregate, water and air in one cubic yard of concrete. Since the quantities of cementitious, water and air are limited by specifications, 3.1. Secure one or more copies of KDOT Form No. 694, WORK SHEET CONCRETE MIX DESIGN. (See Example.) 3.2. Complete Part I of the form. This includes the class of concrete, the aggregate designation, the water cement ratio,

3 When designing concrete mixes composed of sweetened mixed aggregate, the percentage of each aggregate may be determined by specification requirements, or the contractor may elect to use certain aggregate combinations to produce the required gradation. When designing a "coarse fine" mix, equal parts of coarse aggregate and fine aggregate are normally used. This portion has proven to be satisfactory and should be changed only to improve the characteristics of the mix and not as a convenience to the producer or contractor. Deviation from these proportions shall not be made without prior approval from the District Materials Engineer Complete Part II of the form by calculating the volume, in cubic feet, occupied by the cementitious materials, water and air in a cubic yard of the mixture. NOTE: If the specific gravity of Type II cement is not known, a value of 3.20 will be assumed. For Type I cement use a value of At the option of the contractor, fly ash from an approved source and meeting the specified requirements may be used as a partial replacement for Portland Cement. Calculations for fly ash substitution are to be made on the back of KDOT Form No Complete the last page to determine the combined aggregate gradation. Include the percent retained for each sieve and the cumulative percent retained as determined in accordance with KT-2. Calculate the gradation parameters of the mixture. Pg 3-5 Pg 6 New mix design form New CMS screenshot MIX DESIGN PROCEDURES FOR CIR (COLD-IN-PLACE RECYCLING) MATERIAL 1.9. KTMR-37 to KT KTMR-38 to KT-61 Table A1 KTMR-37 to KT-60 KTMR-38 to KT REQUIRED SAMPLE SIZES Durable One 36 (915 mm) piece (all widths). One 36 (900 mm) for materials less than 12 (300 mm) in width. One 24 (600 mm) piece for materials of 12 (300 mm) and greater in width.

4 Cold Plastic One 36 (900 mm) piece (4 [100 mm], 6 [150 mm], 8 [200 mm] widths).for materials less than 12 (300 mm) in width. One 24 (600 mm) piece for materials of 12 (300 mm) and greater in width Delete entry for Durable and Temporary Pavement Marking Tape Add Patterned Cold Plastic and High Durability Note Note: For the fasteners of (above), the number of specimens listed are per each individual lot as and identified by the individual bolt length, diameter, and head marking (strength and type); or nut marking SIEVE ANALYSIS OF AGGREGATE (Kansas Test Method KT-2) 5.2. NOTE: For lightweight aggregate cover material: Dry-screen lightweight aggregate cover material according to KT-4 instead of washing. Remove and discard all deleterious material from the sample including clay lumps retained on the No.4 (4.75 mm) sieve before the mass of the sample after dry-screening is determined. 6.6 determined by that method to the mass passing the No. 200 (75 μm) sieve by dry sieving of the same sample in this method. 7.3.x Renumber Sect. 7.3 to 7.2.xx SPECIFIC GRAVITY AND ABSORPTION OF AGGREGATES (Kansas Test Method KT-6) Footnote 4 Pg New Scet AASHTO T uses the cone test The portion selected should be of sufficient size to yield a sample weighing approximately 1,000 g all of which passes the No. 4 (4.75 mm) sieve and retained on the No. 100 (150 µm) sieve Determine the mass of the empty flask. Record the value as F.

5 Immediately split out and weigh a sample of the saturated surface-dry material weighing not less than 500 g. Record this value as B. Place the sample in the flask Weigh the flask and its contents to the nearest 0.1 g. Record the value as K Cool the sample to room temperature and weigh. Record the value as A Cool the sample to room temperature and weigh. Record the value as A FIELD DENSITY TESTS OF SOILS, TREATED BASE COURSES AND WATER BOUND BASE COURSES (Kansas Test Method KT-13) 2.7 AASHTO T 191; Density of Soil In-Place by the Sand-Cone Method (DELETED) ( ) MARSHALL TESTS OF BITUMINOUS MIXES (Kansas Test Method KT-14) Pg. 6 Foot note [1] The aging process reflects information found in the proposed AASHTO PP2, Short and Long Term Aging of Bituminous Mixes R30-02 Standard Practice for Mixture Conditioning of Hot-Mix Asphalt (HMA) AIR CONTENT OF FRESHLY MIXED CONCRETE BY THE PRESSURE METHOD(Kansas Test Method KT-18) 8. Remove 8, Yield Cement Factor 9. Renumber to FLEXURAL STRENGTH OF CONCRETE (THIRD-POINT LOADING METHOD) (Kansas Test Method KT-23) New Draw lines on the beam at 6 intervals equally spaced from the end of the beam representing the support and load applying block locations. Use these marks when installing the beam in the test fixture If the fracture occurs at a capped section, include the cap thickness in the measurement

6 SAMPLING AND SPLITTING PLANT MIXED ASPHALT MIXTURES (Kansas Test Method KT-25) 2.1. AASHTO T 168; Sampling Asphalt Paving Mixtures Standard Method of Test for Sampling Bituminous Paving Mixtures METHOD OF TESTING THE STRENGTH OF PORTLAND CEMENT CONCRETE USING THE MATURITY METHOD (Kansas Test Method KT- 44) The beams specimens shall be cast The beams specimens shall be cast METHOD FOR OBTAINING AND TESTING DRILLED CORES FROM PCCP AND PRECAST GIRDERS (Kansas Test Method KT-49) With cores from pavements placed over open-graded aggregate bases the foregoing provisions frequently cannot be met because of the great number of projections or voids on the bottom surface Measurement - Prior to testing, measure the length of the capped specimen to the nearest 0.01 inch (0.25 mm) and use this length to compute the length-diameter ratio. Take three caliper measurements at 120 degree intervals along the circumference of the circle to determine the average length.prior to testing, measure the length of the capped specimen to the nearest 0.01 inch (0.25 mm) and use this length to compute the length-diameter ratio. Determine the average diameter Compressive strength (corrected) calculated to the nearest 10 psi (0.01 MPa) FIELD DENSITY AND MOISTURE TESTS OF SOILS BY NUCLEAR GAUGE(Kansas Test Method KT-51) 4.2. A Determination* by the nuclear method is to be compared with moisture quantities described under KT-11, , CONSTANT WEIGHT MASS METHOD 5.1. KT-11, 6 9. GAS PRESSURE SPEEDY METHOD TEST PROCEDURE FOR SPEEDY METHOD can be used if the Speedy was calibrated PLASTIC FINES IN COMBINED AGGREGATES BY USE OF THE SAND EQUIVALENT TEST (Kansas Test Method KT-55)

7 3.1 described in AASHTO T 176, A mechanical shaker as described in AASHTO T 176, Pg. 3 Note 1 Pg. 3 Note 1 AASHTO T and provides alternative means of the sample; the Manual and Hand Method. In removing the Manual and Hand Method, AASHTO T 176, 8. OPERATOR QUALIFICATIONS is not necessary and not included within KT Working calcium chloride solution: Prepare the working calcium chloride by diluting oz ( ml) one measuring tin full of the stock calcium chloride solution to 1 gal (3.78 L) with water Prepare the desired number of two test samples using the following method For each test sample: Siphon in 7.3. If it is desired to average a series of sand equivalent values, Average the whole number values determined as described above Record and report to the nearest whole number RESISTANCE OF COMPACTED ASPHALT MIXTURE TO MOISTURE INDUCED DAMAGE (Kansas Test Method KT-56)

8 3.7. Freezer maintained at F ( C) place the plastic bag containing the specimens in a freezer at F ( C) Pg. 2 Note 1 AASHTO T requires the material to be cured in an oven at 60 C for 16 hours prior to curing METHOD FOR PREPARING AND DETERMINING THE DENSITY OF HOT MIX ASPHALT (HMA) SPECIMENS BY MEANS OF THE SUPERPAVE GYRATORY COMPACTOR (Kansas Test Method KT-58) 7. Title 7. MIXING AND COMPACTION PROCEDURE 7. Added language describing incorporation of recycled materials FLAT AND ELONGATED PARTICLES IN COARSE MATERIAL TEST (Kansas Test Method KT-59) Table pp 4 Added identifiers for variables "e" and "f" INDIRECT TENSILE TEST (Kansas Test Method KT-60) Reinstated KT RAVELING TEST ON RECYCLED ASPHALT SPECIMENS (Kansas Test Method KT-61) Reinstated KT SAMPLING EPOXY PAVEMENT MARKING (Kansas Test Method KT-66) 2.2 Typo correction: tape Relative Density (Kansas Test Method KT-69)

9 New Reinstated KT DENSITY, ABSORPTION AND VOIDS IN HARDENED CONCRETE(Kansas Test Method KT-73) 5. Testing is usually scheduled so that the boiling of the samples takes place when the samples are between 27 and 29 days of age. Other timeframes may be required in the contract documents = Density of water New REPORT 7.1. Record absorptions to the nearest 0.01 % Record densities to the nearest 0.01 g/cm Record the volume of permeable pore space (voids) to the nearest 0.01 % and report to the nearest 0.1% Surface Resistivity Indication of Concrete s Ability to Resist Chloride Ion Penetration (Kansas Test Method KT-79) 6. Note: Testing is scheduled at 28 days. However, as this is a nondestructive test and is likely to be run on samples cast for other testing purposes, resistivity testing shall occur as close to 28 days as possible before the sample is altered in any way for a different test; i.e., resistivity testing will occur on day 27 or 28 before the samples are tested for strength, KT- 76. The samples are to be tested no earlier than 27 days, or no later than 32 days of age. Therefore, samples tested for KT-73 cannot be used for surface resistivity testing. Samples used for KT-73 cannot be used for KT-79 due to timing of the tests Note provided that the samples are still processed according to 5.1.

10 6.4.. Randomly assign one of the marks as 0, then rotate either clockwise or counterclockwise the sample and assign the next mark 90, and so on If specimens were cured in a moist room, multiply set average by Sampling Cold Plastic Pavement Marking, Patterned Cold Plastic Pavement Marking Tape and High Durability Pavement Marking Tape (Kansas Test New Determination of Excessive Moisture in Concrete Surfaces (Kansas Test Method KT-82) New STRAND BOND IN PRESTRESSED CONCRETE MEMBERS (Kansas Test Method KT-83) New SAMPLING NUTS, BOLTS AND WASHERS (Kansas Test Method KT-84) New

11 Appendix A Division 200 SPECIAL FILL Sec. 209 Field Density Tests (0.1 lb/ft3 [1 kg/m3] or 0.1% of optimum density) MECHANICALLY STABILIZED EARTH FILL Sec. 214 Field Density Tests (0.1 lb/ft3 [1 kg/m3] or 0.1% of optimum density) DIVISION 300 LIME TREATED SUBGRADE Sec. 302, 2000 & 2400 Percent Solids of Lime Slurry (WPG 0.01 g, Slurry Solids 0.1%) Field Density Tests (0.1 lb/ft3 [1 kg/m3] or 0.1% of optimum density) KT-13 or KT-51 ACI 1 per lift per 300 feet (100 meters) of wall or once daily KT-13 or KT-51 ACI 1 per lift per 300 feet (100 meters) of wall or once daily See Appendix B.1 per day or batch, whichever is greater. KT-13 or KT-51 ACI 1 per 500 feet (150 meters) CEMENT OR FLY ASH TREATED SUBGRADE

12 Sec. 303, 2000, & 2400 Field Density Tests (0.1 lb/ft3 [1 kg/m3] or 0.1% of optimum density) Div. 400 KT-13 or KT-51 ACI 1 per 500 feet (150 meters) PORTLAND CEMENT CONCRETE STRUCTURES AND MISCELLANEOUS CONSTRUCTION (continued) Sec. 401, 703 and 717 DIV. 400 PORTLAND CEMENT CONCRETE STRUCTURES AND MISCELLANEOUS CONSTRUCTION Sec. 401 and 717 Permeability Cylinders Divison 400 Div. 500 PORTLAND CEMENT CONCRETE PAVEMENT Sec. 502 and 503 Permeability (0.01%, KT-73 or 10 coulomb, AASHTO T 277 or nearest 0.1 kω-cm, KT-79) KT-73 or AASHTO T 277 or KT-79 Code: l Cylinders (1 lbf [1 N], 0.1 in [1 mm], 1 psi [0.01 MPa]) Resistivity to the nearest 0.1 kω-cm. KT-22 and KT-76 and KT-79 Remove Low Cracking High Performance Concrete Structures Permeability Code: l Removed line for KT-3 VERIFICATION SAMPLES & TESTS (Note f) Vibrator Frequency Per Standard Specifiction 154.2e Daily by KDOT

13 Divison Field density Tests Removed coring and nuclear denstiy as options. Removed note on thickness. Sec. 603, 611, 614, & 1103 Completed Road Work Field Density Tests Note: If specified [plan] lift thickness is less than 1.5 (40 mm) or less, none required. Divison 700

14 POST-TENSIONING (Haunched Slab Bridges) Divison 700 MULTI-LAYER POLYMER CONCRETE OVERLAY Prepared Bridge Deck Surface Sec. 716, 1732 Sec. 729 and Polymer Binder Resins ASTM D 4263 KT-82 MULTI-LAYER POLYMER CONCRETE OVERLAY SLURRY POLYMER CONCRETE OVERLAY REPAIR OF EXISTIN POLMER CONCRETE BRIDGE DECK OVERLAY Sec. 729, 739, 740 and 1730 (New ) Division 1700 ABUTMENT STRIP DRAIN Sec ANTI-GRAFFITI COATING Sect per source, per District per year Infrared Spectroscopy 1 per project, per manufacturer, per District DIVISION 2200 Thermoplastic Sprayed Thermoplastic Epoxy Traffic Line Paint 2 for each type of bead. 2 for each type of bead. 2 for each type of bead. Traffic Line Paint Pavement Marking Paint 2 for each type of bead. DIVISION , 2208 and 2209 Except for symbols, 1 on each per lot per color. New Multi-component Sec Pg. 24 Code a Pg. 24 Code VER ACC 1/2 pint per each component lot per color per project. Written justification shall be made to the Chief of the Bureau of Construction & Materials & Research l. Verification method must be the same test method as used for mix design approval.

15 Appendix B Pg. 9 Code Code o: Verification method must be the same test method as used for mix design approval. PORTLAND CEMENT CONCRETE PAVEMENT Sec. 501 & 503 (continued) Concrete (continued) Permeability Code: Pg. 9 Code l Division 500 PORTLAND CEMENT CONCRETE PAVEMENT Concrete (New) Vibrator Frequency Quality Control by Contractor Verification by KDOT o Uncompacted Void Content of Coarse Aggregate (UVA) value of 45 when tested in accordance with AASHTO T 326, Method A KT-80. Cores (1 lbf [1 N], 0.01 in [1 mm], 1 psi [0.01 MPa]) Vibrator Frequency Per Standard Specifiction 154.2e Every 4 hours Daily Code j. Provide access to Contractor owned forced air ignition furnace, ovens, and Superpave Gyratory compactor, as required, for the Sate Inspector to perform verification tests. Division 600 ULTRATHIN BONDED ASPHALT SURFACE (UBAS) Sec. 613 & 1103 Individual Aggregates