MANUAL OF INSTRUCTIONS MATERIALS DIVISION COMMONWEALTH OF VIRGINIA DEPARTMENT OF TRANSPORTATION

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Edgar Bryant
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1 MANUAL OF INSTRUCTIONS MATERIALS DIVISION COMMONWEALTH OF VIRGINIA DEPARTMENT OF TRANSPORTATION

2 TABLE OF CONTENTS Chapter I - GENERAL INSTRUCTIONS...1 SECTION 101 PURPOSE AND SCOPE OF MANUAL...1 SECTION 102 MISSION AND GOALS OF MATERIALS DIVISION...1 SECTION 103 INPUT CONCERNING MATERIALS DIVISION POLICY AND INSTRUCTIONS...1 SECTION 104 RELATION OF MATERIALS DIVISION EMPLOYEES...1 Sec With Suppliers and Contractors...1 Sec With the Public...1 SECTION 105 SAFETY PRECAUTIONS...1 Sec Department Employees Visiting Plants...2 Sec Nuclear Safety Precautions...2 Sec Nuclear Moisture-Density Gauges General Adminiatration...3 Sec Nuclear Moisture-Density Gauges Operating and Emergency Precautions...4 SECTION 106 GENERAL INFORMATION...5 Sec Information Required...5 Sec Sampling of Materials in the Field...7 Sec Compliance with Specifications SCALE PROGRAM...7 Sec Certification of Batch Test Weights...7 Sec Certification of Scales...8 Sec Deleted...10 Sec General Scale Requirements and Check Points...10 Sec Recordkeeping and Scale Certification Data System...12 SECTION 108 BONDED WEIGHPERSON PROGRAM...12 Sec Surety Bond...12 Sec Certification of Weighperson...13 Sec General Guidelines for Weighperson...14 Sec Duties of Certified (Bonded) Weighperson...14 Sec Reconciling Weigh Documents...16 Sec Department Monitoring...16 SECTION 109 LEGAL LOAD DETERMINATION...17 Sec Administration...17 Sec Responsibilities...17 SECTION 110 THE DISTRICT MATERIALS ENGINEER...19 SECTION 111 DUTIES OF MATERIALS TECHNICIAN SUPERVISORS AND TECHNICIANS...20 SECTION 112 OPERATIONS OF THE MATERIALS DIVISION...20 Sec Plant Testing and Inspection...20 Sec Laboratory Testing...21 Sec Visual Inspection...21 SECTION 113 MATERIALS...21 Sec General...21 Sec Material Arriving Bearing Inspection Seals...23 Sec Material Arriving Without Evidence of Inspection...23 Sec Handling of Materials on Job...23 Sec Proper Sampling in the Field...24 Sec Information to be Submitted with Samples...24

3 Sec Procedure to be Followed when Material is Rejected...24 SECTION 114 REQUESTS FOR TESTS AND SERVICES...26 Sec Performing Materials Tests and Services for Other State Agencies, Local Governmental Units, Other States, and Federal Agencies...26 Sec Reciprocal Agreements where the Service is Performed Without Charge...26 Sec Reciprocal Agreements for Services in which the Cost is Recovered/Paid...27 Weighing Inspection Report...1 VDACS Report VDACS Report Nuclear Moisture - Density Gauges...1 Chapter II - METHODS AND FREQUENCIES OF SAMPLING...1 SECTION 201 GENERAL...1 SECTION 202 DEFINITION OF SAMPLES...2 Sec Investigation Samples...2 Sec General Samples...2 Sec Acceptance Samples...2 Sec Independent Assurance Samples...3 Sec New Products...4 Sec Materials Notebook Submittal...5 Sec Materials Project Records Retention...5 SECTION 203 SUBMISSION OF SAMPLES...5 Sec Packing of Samples...6 Sec Material Safety Data Sheet...6 Sec Identification of Samples...6 Sec Shipment of Samples...7 SECTION 204 SAMPLING MATERIALS...7 Sec Admixtures, Concrete...7 Sec Aggregates...7 Sec Aluminum Alloys...13 Sec Bearing Pads and Bedding Materials...14 Sec Asphalt Material, Liquid...14 Sec Asphalt Mixtures...19 Sec Brick...19 Sec Bronze and Copper Alloy...19 Sec Cement, Hydraulic...19 Sec Snow and Ice Control Materials...21 Sec Concrete, Hydraulic Cement...23 Sec Copper Sheet and Strip...23 Sec Curing Materials and Protective Coatings for Concrete...23 Sec. 204.l4 Electrical Conduits, Fittings, and Boxes...24 Sec Epoxy Resins...26 Sec Fencing...26 Sec. 204.l7 Fly Ash...27 Sec Guardrail, Steel Beam...28 Sec Joint Materials...29 Sec Landscape Materials (Roadside Development)...31 Sec Lime...33 Sec Masonry Units, Concrete...34 Sec Monuments, Right-of-Way...37

4 Sec Paint...38 Sec Piling...38 Sec Pipe...39 Sec Reserved...49 Sec Poles and Posts...49 Sec Preservatives, Timber...51 Sec Reflective Materials...52 Sec Soils and Granular Materials...56 Sec Steel...56 Sec Structural Timber and Lumber...64 Sec Water...64 Sec Waterproofing and Dampproofing Materials...64 Sec Wire Rope and Wire Strand...65 SECTION 205 SUMMARY OF MINIMUM ACCEPTANCE SAMPLING REQUIREMENTS...65 SECTION 206 SUMMARY OF MINIMUM INDEPENDENT ASSURANCE SAMPLING REQUIREMENTS Sec Definitions Sec Project Site Testing Sec Plant Site Testing SECTION 207 SUMMARY OF MATERIALS SUBJECT TO MODIFIED INSPECTION AND ACCEPTANCE PROCEDURES Sec l Manufacturers and Producers Certifications Sec Materials for General or Routine Construction Sec Materials for Rest Area Construction Sec Materials for Signalization and Electrical System Installation SECTION 208 MATERIALS CERTIFICATION AND DOCUMENTATION PROCEDURES FOR SPECIAL PROJECTS Sec General Sec Preliminary Documentation Sec Rest Area and Signalization Work Sec Determination of Materials Acceptance Program Sec Acceptance Procedures During Course of Project Sec Corrective Actions and Price Adjustments Sec Handling of Materials and Reports Sec Checking Records at Project Completion Sec Special Materials Acceptance Guidelines SECTION 209 CHAPTER II - APPENDIX A...1 Concrete Pipe Plant Monitor Report...2 Corrugated Metal Pipe Plant Monitor Report...1 Reinforcing Steel Fabrication Shop...1 Reinforcing Steel Epoxy Coating Plant Review...1 Precast Concrete Plant Monitor Report...1 Pavement Marking Materials Inventory Ledger...3 Polyethylene Pipe Plant Monitor Report...1 Chapter III - GEOTECHNICAL ENGINEERING...1 SECTION 301 GENERAL...1 SECTION 302 TYPES OF INVESTIGATIONS...2

5 SECTION 303 INVESTIGATION PROCEDURES...2 Sec General...2 Sec Permission to Enter Property...2 Sec Staking the Line...4 Sec Preliminary Field Inspection / Inspection of the Site...4 Sec Location of Drill Holes...4 SECTION 304 SOIL SURVEY...4 Sec General...4 Sec Initial Preliminary Survey...4 Sec Final Soil Survey...4 SECTION 305 INVESTIGATION OF SOILS FOR FOUNDATION DESIGN...8 Sec General...8 Sec Field Classification of Soils...10 Sec Cased Borings...13 Sec Ordinary Dry Samples (Standard Penetration Test)...14 Sec Undisturbed Dry Samples...14 Sec Vane Shear Test...15 Sec Cone Penetrometer Test...15 Sec Flat Dilatometer Test...16 Sec Scour Investigation...16 SECTION 306 BEDROCK INVESTIGATIONS...16 Sec General...16 Sec Rock Classification...17 Sec Coring Equipment...17 Sec Procedure...17 Sec Factors Affecting Recovery of Core...19 SECTION 307 BORING RECORDS...20 Sec General Information...20 Sec Cased Borings...20 Sec Core Borings...21 SECTION 308 PACKING AND DELIVERY OF SAMPLES...21 SECTION 309 SUBMITTAL OF REPORTS...22 SECTION 310 SPECIAL DESIGNS...22 Sec Wick Drains...22 Sec Stone Columns...22 Sec Geotextiles...23 Sec Settlement Plates...24 SECTION 311 PLANT SAMPLING, TESTING, AND INSPECTION OF CENTRAL-MIXED AGGREGATE BASE, SUBBASE, AND SELECT MATERIAL...24 Sec General...24 Sec Equipment...24 Sec Approval of Job-Mix...26 Sec Documentation of Tonnage Material...26 Sec Sampling Central-Mixed Aggregates...26 Sec Sampling Material from the Road...29 SECTION 312 SAMPLING SOILS AND GRANULAR MATERIALS FOR CEMENT, ASPHALT, OR LIME STABILIZATION...29 SECTION 313 IDENTIFICATION AND SIZE OF SAMPLE TO BE SUBMITTED...30 SECTION 314 ROAD SAMPLING, TESTING, AND INSPECTION...30 Sec Density Control...31

6 Sec Depth Control...36 SECTION 315 UNIFORM GUIDE FOR CENTRAL-MIXED AGGREGATE QUALITY ASSURANCE AND CONTROL...38 Sec Responsibility of Materials Division...38 Sec Responsibility of Central-Mixed Aggregate Producer...41 SECTION 316 STABILIZED OPEN GRADED BASE MATERIAL...42 Sec General...42 Sec Frequency of Tests...42 Sec Reports...42 SECTION 317 SUMMARY OF MINIMUM ACCEPTANCE SAMPLING REQUIREMENTS...42 C. M. A. Pugmill Plant Inspection Report...1 Chapter IV - SAMPLING AND CONTROL OF HYDRAULIC CEMENT CONCRETE 1 SECTION 401 GENERAL...1 Sec Equipment...1 Sec Materials...3 SECTION 402 AGGREGATE MOISTURE...3 Sec Physical Characteristics...3 Sec Methods of Determining Water Content...4 SECTION 403 WATER-CEMENT RATIO...5 SECTION 404 FINENESS MODULUS...6 SECTION 405 PROPORTIONING OF AIR-ENTRAINED CONCRETE...7 Sec General...7 Sec ACI Concrete Mix Design Utilizing Conventional Materials...7 Sec ACI Concrete Mix Design Utilizing Fly Ash...8 Sec ACI Concrete Mix Design Utilizing Granulated Iron Blast-Furnace Slag...9 Sec Allowable Field Adjustments...9 Sec Batch Weight Adjustments...9 Sec Remediation of Alkali Silica Reaction...10 SECTION 406 USE OF ADMIXTURES...10 SECTION 407 PLACEMENT AND CURING OF CONCRETE...12 Sec Adequate Moisture...12 Sec Proper Temperature...13 SECTION 408 CONSISTENCY OF CONCRETE...15 SECTION 409 DETERMINATION OF AIR CONTENT...16 SECTION 410 YIELD OF MIX...19 Sec Definition of Yield...19 Sec Method...19 Sec Sample...19 Sec Calculations...19 Sec Significance of Yield...20 SECTION 411 STRUCTURAL AND MISCELLANEOUS CONCRETE...20 Sec General...20 Sec Compressive Strength Specimens...20 SECTION 412 PAVEMENT CONCRETE...23 Sec General...23 Sec Flexural Strength Specimens...23

7 Sec Depth Tests...25 SECTION 413 PRESTRESSED CONCRETE...26 Sec General...26 Sec Pretensioning Strand and Use of Typical Curve...26 Sec Forming...26 Sec Sampling and Control of Concreting Operations...27 Sec Curing, Moist and Steam...28 Sec Stress Release...28 Sec Handling Precast Units...28 Sec Reports...29 Sec Shop Drawings and Special Requests...29 Sec Summary of General Outline of Duties of Prestressed Plant Inspector...29 SECTION 414 OVERLAY CONCRETE...31 Sec General...31 Sec Mobile Mixer Calibration Latex Modified Concrete...32 Sec Testing...34 Sec Placement Procedures...36 SECTION 415 SUMMARY OF IMPORTANT FACTORS...38 SECTION 416 UNIFORM GUIDE FOR CONCRETE CONTROL...39 Sec Responsibility of Materials Division...39 Sec Responsibility of Concrete Producer...44 SECTION 417 SUMMARY OF MINIMUM ACCEPTANCE SAMPLING REQUIREMENTS...45 Inspection Report of Hydraulic Cement Concrete Plants...1 Inspection Report on Plastic Concrete Testing Equipment, Procedures, and Records...1 Strength Evaluation Graphic...3 Concrete Mobile Calibration Data Sheet...5 Chapter V - SAMPLING AND CONTROL OF ASPHALT CONCRETE...1 SECTION 501 GENERAL...1 Sec Equipment...1 Sec Materials...2 SECTION 502 PLANT SAMPLING, TESTING, AND INSPECTION OF ASPHALT MIXTURES...3 Sec Approval of Job-Mix...3 Sec Documentation of Tonnage Material...3 Sec Sampling Composite Materials...3 Sec Sampling Asphalt Mixtures...3 Sec Cold Asphalt Mixtures...7 Sec Reports...10 SECTION 503 ROAD SAMPLING, TESTING, AND INSPECTION OF ASPHALT PAVEMENTS..10 Sec General...10 Sec Density Control...10 Sec Depth Control...13 Sec Duties of the Project Inspector...15 SECTION 504 UNIFORM GUIDE FOR ASPHALT CONCRETE QUALITY ASSURANCE AND CONTROL...16 Sec Responsibility of Materials Division...17 Sec Responsibility of Asphalt Concrete Producer...23 SECTION 505 SUMMARY OF MINIMUM ACCEPTANCE SAMPLING REQUIREMENTS...24

8 Asphalt Concrete Plant Inspection Report...1 Chapter VI - PAVEMENT DESIGN AND EVALUATION...1 SECTION 601 FUNDAMENTAL CONCEPTS OF PAVEMENT DESIGN...1 Sec Pavement Design...1 Sec Pavement Components...2 Sec Axle Loads...3 Sec Tire Pressure...4 Sec Load Equivalency...4 SECTION 602 VIRGINIA'S PAVEMENT DESIGN METHODS...5 Sec General Sequence of Events...5 Sec Pavement Design Methods...6 Sec Final Recommendations...6 Sec Follow-Up and Problem Identification...7 Sec Computer Database...7 Sec Future of Pavement Design in Virginia...7 Sec Metric Conversion...7 SECTION 603 PAVEMENT TESTING AND EVALUATION...7 Sec Pavement Evaluation...7 Sec Roughness...7 Sec Deflection Testing and Analysis...8 Sec Skid Testing...8 Sec Visual Rating...9 Sec Video Inspection of Underdrains and Outlets...9 SECTION 604 APPENDIX...10 Figure 1. Typical Section for Rigid and Flexible Pavement Systems...1 Flowchart Depicting the Sequence of Events as Utilized in Virginia Pavement Design Approach...2 Guidelines for Asphalt Concrete Application Rates...3 Density of Base Asphalt Mixes for Approximate Quantity Calculations...4 Skid Testing Request Instructions...5 Request for Falling Weight Deflectometer Testing...6 Request Form for Non-Destructive Testing...8 Life Cycle Cost Analysis...9 SECTION 801 GENERAL...1 Sec Description...1 Sec Distribution...1 Sec Numbering Reports...1 SECTION 802 STOCKING AND ORDERING OF FORMS...2 SECTION 803 USE OF FORMS (BY NUMBER)...3 Sec Form TL-3, Tag Envelope (For Sample Cards)...3 Sec Form TL-9, Notice of Shipment of Pipe, Brick, Block, Etc...3 Sec Form TL-10, Notice of Shipment of Sample for Test (Commercial)...3 Sec Form TL-11, Notice of Shipment of Sample for Test (Soil and Local Materials)...4 Sec Form TL-13, Notice of Shipment of Concrete Cylinder...4 Sec Form TL-13A, Notice of Shipment of Concrete Cylinder...4 Sec Form TL-15, Notice of Transfer of Material...4 Sec Form TL-18, Geological Specimen Label...5

9 Sec Form TL-21, Report of Hydraulic Cement...5 Sec Form TL-22, Report on Sample of Coarse Aggregate...5 Sec Form TL-22A, Report on Sample of Concrete Aggregate...5 Sec Form TL-22B, Report on Sample of Fine Aggregate...5 Sec Form TL-23, Report on Neoprene Elastomers...5 Sec Form TL-24, Report on Sample of Liquid Membrane Seal...5 Sec Form TL-25, Report on Sample of Steel...5 Sec Form TL-26, Report on Structural Concrete...6 Sec Form TL-26A (TL-26), Coding Form Report of Structural Concrete...6 Sec Form TL-27, Statement of Hydraulic Cement Concrete Mix Design...6 Sec Form TL-28A Coding Form Concrete Batch Report...7 Sec Form TL-29, Report on Sample of Concrete Pipe...7 Sec Form TL-30, Report on Epoxy Products...7 Sec Form TL-31, Report on Particle Size Analysis...7 Sec Form TL-32, Report on Sample of Soil...8 Sec Form TL-33, Report on Soil, Direct Shear Test...8 Sec Form TL-34, Report on Soil, Unconfined Compression Test...8 Sec Form TL-35, Report on Sample of Soil Cement...8 Sec Form TL-36, Report on Soil Consolidation Test...8 Sec Form TL-37, Report on Soil Triaxial Test...8 Sec Form TL-38, Report of Profile Evaluation...8 Sec Form TL-39, Report on Sample of Geotextile Fabrics...8 Sec Form TL-43, Report on Sample of Bituminous Materials...9 Sec Form TL-44, Laboratory Data Sheet Tensile Strength Ratio...9 Sec Form TL-47, Report on Sample of Miscellaneous Material...9 Sec Form TL-50, Report on Asphalt Concrete Mixtures...9 Sec Form TL-51, Report on Coefficient of Permeability...9 Sec Form TL-52, Report on Dense Graded Aggregate...9 Sec Form TL-52A, Central Mix Aggregates Test Results Input Form...9 Sec Form TL-52C, Central Mix Aggregates Test Results Input Form Monitor Phase...10 Sec Form TL-53, Report of Nuclear Control Strip Roller Pattern...10 Sec Form TL-54, Report of Nuclear Control Strip Field Density...10 Sec Form TL-55, Report of Nuclear Test Section Field Density...10 Sec Form TL-56, Asphalt Nuclear Density Thin Lift Worksheet, Roller Pattern...10 Sec Form TL-58, Asphalt Nuclear Density Thin Lift Worksheet, Control Strip Target Density10 Sec Form TL-59, Asphalt Nuclear Density Test Section...10 Sec Form TL-60, Asphalt Nuclear Density Worksheet, Roller Pattern/Sawn Plugs, and Control Strip Target Density...11 Sec Form TL-61, Quarterly Inventory and Evaluation of Safety Procedures...11 Sec Form TL-100A, Asphalt Concrete Test Results Input Form...11 Sec Form TL-100C, Asphalt Concrete Test Results Input Form Monitor Phase Form TL-100C11 Sec Form TL-101A, Report on Legal Load Determination...11 Sec Form TL-102A, Weighpersons Daily Summary...11 Sec Form TL-103, Surety Bond Form...12 Sec Form TL-105, Report of Job Acceptance Depth Tests...12 Sec Form TL-106, Report on Concrete Cores...13 Sec Form TL-107, Confirmation of Test Results...13 Sec Form TL-109, Inspection Report...13 Sec Form TL-121, Equipment Reciept...14 Sec Form TL-122, Nuclear Gauge Transferral Reciept...14 Sec Form TL-124, Report of Nuclear Embankment Densities...14 Sec Form TL-125, Report of Field Density of Soil...14 Sec Form TL-125A, Worksheet for One-Point Proctor...14 Sec Form TL-127, Statement of Asphalt Concrete or Central-Mix Aggregate Job Mix Formula...15 Sec Form TL-127A, Job Mix Input Form Central-Mix Aggregate...15

10 Sec Form TL-127B, Asphalt Concrete Job Mix Input Form...15 Sec Form TL-131, Certification of Materials...16 Sec Form TL-136, Report of Independent Assurance Depth and Density Tests...16 Sec Form TL-137, Report for Settlement Plate...16 Sec Miscellaneous Materials Records and Reports...17 SECTION 804 REPORTS BY COMMERCIAL TESTING LABORATORIES...20 SECTION 805 SAMPLE FORMS...20 Chapter IX - TECHNICAL TABLES AND RELATED DATA...1 Technical and Related Abbreviations...2 Signs and Symbols...10 Temperature Conversion Table...11 U.S.A. Standard Sieve Series...12 Weights and Measures...13 Lineal Feet Covered by One Ton at Various Application Rates...15 Lineal Meters Covered by One Meteric Ton at Various Application Rates...16 Distance in Lineal Feet Covered by 1000 Gallons...17 Distance in Meters Covered by 1000-Liters...18 Dry Weight per Square Yard of Aggregate Base Materials...19 Dry Weight per Square Meter of Aggregate Base Materials...20 Volume Correction Table for Liquid Asphalt...21 Weight/Volume Relations of Asphaltic Materials at 60ºF (16ºC)...22 Lineal Feet Covered by One Ton of Aggregate at Various Rates of Application...23 Lineal Meters Covered by One Metric Ton of Aggregate at Various Rates of Application...23 Specific Gravity Ranges of Some Common Virginia Aggregates...24 Reinforcing Steel...25 AASHTO Classification of Soil and Soil Aggregates...26

MANDATORY SUPPLEMENTAL SPECIFICATIONS FOR CONTRACTOR QUALITY CONTROL Contractor Quality Control - is replaced with the following:

MANDATORY SUPPLEMENTAL SPECIFICATIONS FOR CONTRACTOR QUALITY CONTROL EFFECTIVE DATE: OCTOBER 14, 2011 200.07 Contractor Quality Control - is replaced with the following: (a) (b) (c) Scope: These requirements