Student Manual Lesson 6- Specifications. Version /

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3 The QC Manager must be knowledgeable of the requirements for sampling and testing for these materials. This lesson is not intended to provide detailed in-depth review of specifications, but a snap shot of how and when QC and VT interact during sampling and testing for various materials. Version /

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5 Minimum Process Control Testing Requirements: Include as a minimum, the following testing frequencies in the Quality Control Plan: Asphalt Plant 1. Hot Mix Asphalt 2. Aggregate (Including RAP) 3. Mix temperature 4. Aggregate moisture content from stockpiles or combined cold feed aggregate 5. Other tests (as determined necessary by the Contractor) Roadway 1. Monitor the pavement temperature and the roadway density 2. Mix temperature 3. Monitor the pavement smoothness 4. Monitor the pavement cross slope 5. Monitor the mix spread rate If the Contractor fails to maintain the construction process in accordance with the approved Quality Control Plan, the Engineer may elect to stop the construction operation at any time until the deficiencies are corrected. Version /

6 Minimum Quality Control System Requirements: Personnel Qualifications: Provide Quality Control Technicians in accordance with Section Hot Mix Asphalt Testing Laboratory Requirements: Furnish or have furnished a fully equipped asphalt laboratory (permanent or portable) at the production site. The Laboratory must be qualified under the Department s Laboratory Qualification Program, as described in Section 6. In addition, the laboratory shall meet the following requirements: 1. Area - The effective working area of the laboratory shall be a minimum of 180 ft2 [17 m2], with a layout of which will facilitate multiple tests being run simultaneously by two technicians. This area does not include the space for desks, chairs and file cabinets. Any variations shall be approved by the Engineer. 2. Lighting - The lighting in the lab must be adequate to illuminate all areas of the work. 3. Temperature Control - Equip the lab with heating and air conditioning units that provide a satisfactory working environment. 4. Ventilation - Equip the lab with fume hoods and exhaust fans that will remove all hazardous fumes from within the laboratory in accordance with OSHA requirements. 5. Equipment and Supplies - Furnish the lab with the necessary sampling and testing equipment and supplies for performing contractor Quality Control and Department Verification Sampling and Testing. A detailed list of equipment and supplies required for each test is included in the appropriate FDOT, AASHTO, or ASTM Test Method. 6. Calibration of the Superpave Gyratory Compactor: Calibrate the Superpave Gyratory Compactor in accordance with the manufacturer s recommendations. Identify in the Quality Control Plan the established frequencies and document all calibrations. 7. Personal Computer - Provide a personal computer capable of running a Microsoft ExcelTM spreadsheet program, along with a printer. 8. Communication - Provide a telephone and fax machine (with a private line) for the use of the testing facility s quality control personnel. Version /

7 334-4 Contractor Process Control. Assume full responsibility for controlling all operations and processes such that the requirements of these Specifications are met at all times. Perform any tests necessary at the plant and roadway for process control purposes. The Engineer will not use these test results in the acceptance payment decision. Address in the Quality Control Plan how Process Control failures will be handled. Investigate, at a minimum, the production process, testing equipment and/or sampling methods to determine the cause of the failure, and make any necessary changes to assure compliance with these Specifications. Obtain a follow up sample immediately after corrective actions are taken to assess the adequacy of the corrections. In the event the follow-up Process Control sample also fails to meet Specification requirements, cease production of the asphalt mixture until the problem is adequately resolved to the satisfaction of the QC Manager. Version /

8 See Specification requirements for sampling and testing requirements. The official FDOT in-depth flow diagrams can be found on the FDOT State Materials Office website under Publications, Specifications, Flowcharts. Version /

9 The Verification inspector should be sampling from his own wheel barrow. He should not be taking his samples from the same wheel barrow as the QC inspector. Remember, that the reason for this is to establish if there was a difference in the sampling if a resolution issues develops. The sampling process starts when the concrete comes down the chute of the concrete truck. From there the inspector is required to take a sample of concrete from two different portions in the load. He is required to remix the concrete in the wheelbarrow. He is required to cover the wheel barrow while tests are conducted and samples are prepared. All of these steps should occur for every LOT by QC and for every fourth LOT by VT. When there is a resolution issue, this is one of the ways that we can determine why there was a difference in the strengths of the cylinders. That is, if the steps were not followed as identified in the test methods then we can understand the reason for the difference and the sampling process is a key to identifying these deviations. Version /

10 346-1 Description. Obtain concrete from a plant that is currently on the list of Producers with Accepted Quality Control Program and Chapter 9.2 of the Materials Manual Concrete Production Facilities Guidelines, which may be viewed at the following URL: If the concrete production facility s approval is suspended, the Contractor is solely responsible to obtain the services of another approved concrete production facility or await the re-approval of the affected concrete production facility prior to the placement of any further concrete on the project. There will be no changes in the contract time or completion dates. Bear all delay costs and other costs associated with the concrete production facility approval or re-approval. Materials Manual Quality Control Program The QCP of any concrete producer shall meet the requirements of Specifications Section 105. The production facility shall be on the Department s approved list prior to production of concrete for Department projects. The approved Quality Control Plan shall be the minimum required control of concrete on all Department projects. The State Materials Office will assign a Concrete Plant Number for each facility. Version /

11 General: Develop a Quality Control Plan (QCP) as specified in 105. Meet the requirements of the approved QCP and Contract Documents. Ensure the QCP includes the necessary requirements to control the quality of the concrete. Perform QC activities to ensure materials, methods, techniques, personnel, procedures and processes utilized during production meet the specified requirements. For precast/prestressed operations, ensure that the QC testing is performed by the Producer. Accept the responsibility for performing QC inspections on all phases of work. Ensure all materials and workmanship incorporated into the project meet the requirements of the Contract Documents. When concrete plastic properties (slump, air content and temperature) could be significantly affected by handling between the point of delivery and the point of final placement, including the use of pumps, conveyor belts, troughs, chutes, barge transport or other means, provide in the QCP provisions to sample the plastic concrete for all testing at the point of final placement, as a minimum. Ensure the QCP includes any anticipated requirements for adjusting the concrete at the placement site. Include the testing procedures that will be implemented to control the quality of the concrete and ensure that concrete placed is within the target range. Also, include provisions for the addition of water to concrete c delivered e ed to the placement pace e site ste at designated level eareas, to ensure ethe allowable ao abe amount of water stated on the concrete delivery ticket or the maximum water/cementitious materials ratio on the approved design mix are not exceeded. Ensure the anticipated ranges of jobsite water additions are described and the proposed methods of measuring water for concrete adjustments are included. Failure to meet the requirements of this Specification or the QCP will automatically void that portion of the QCP. To obtain QCP re-approval, implement corrective actions as approved by the Engineer. The Engineer may allow the Contractor to continue any ongoing g concrete placement but the Engineer will not accept concrete for any new placement until the QCP reapproval is given by the Engineer. Version /

12 The official FDOT in-depth flow diagrams can be found in the FDOT State Materials Office website under Documents/Publications, Specifications, Flowcharts. Version /

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14 Contractor QC, Department Verification, and Resolution Procedures for: 1. Maximum Density (Proctor) 2. Soil Classification (Embankment ONLY) 3. Density (Nuclear) 4. Surface testing (Base ONLY) 5. Thickness (Base ONLY) 6. LBR (Stabilized Subgrade ONLY) 7. Mixingi Depth Checks (Stabilized Subgrade ONLY) will be reviewed for Excavation and Embankment (120), Excavation for Structures and Pipe (125), Stabilizing (160) and Rock Base (200). Version /

15 The official FDOT in-depth flow diagrams canbefoundinthefdotstate Materials Office website under Publications, Specifications, Flowcharts. Contractor QC Testing Frequency One (1) per soil type Dept. Verification Testing Frequency One (1) per soil type Independent Verification (IV) testing will be performed and will be used in the same manner as Verification testing (VT) Engineer will verify that the QC and VT results compare within 4.5 pcf Resolution Procedure If not w/in 4.5 pcf, Eng. will take an additional sample of that soil type and State Materials Office (SMO) or designee will test the sample. If Resolution compares with QC, then QC results will be used for material acceptance purposes for each LOT with that soil type If Resolution doesn t compare with QC, then VT results will be used for material acceptance purposes Version /

16 The official FDOT in-depth flow diagrams can be found in the FDOT State Materials Office website under Publications, Specifications, Flowcharts. Contractor QC Testing Frequency One (1) per Maximum Density Dept. Verification Testing Frequency One (1) per Maximum Density Independent Verification (IV) testing will be performed and will be used in the same manner as Verification testing (VT) Engineer will verify the Quality Control results if the Verification results identify matching soil classifications Resolution Procedure Otherwise, the Engineer will take one additional sample of material from the soil type in question and SMO or an AASHTO accredited laboratory designated by the SMO will perform Resolution testing. If Resolution matches QC classification, then QC results will be used for material acceptance purposes If Resolution doesn t match QC classification, then VT results will be used for material acceptance purposes Version /

17 The official FDOT in-depth flow diagramscanbefoundinthefdot State Materials Office website under Publications, Specifications, Flowcharts. Contractor QC Frequency One (1) per two (2) consecutive LOTs Split each Proctor sample for Verification and Resolution (3-way split) Test locations (Stations and offsets) are determined using a random number generator provided by the Engineer Dept. Verification Frequency One (1) per eight (8) consecutive LOTs Sample is randomly selected from the 4 split samples, remaining 7 samples (3-VT and 4-RT) are retained by Contractor until the 8 LOTs are accepted Engineer will verify the QC results of the 8 consecutive LOTs if the VT result compares within 4.5 pcf of the QC result for the corresponding LOTs. Resolution Procedure If QC & VT are not within 4.5 pcf: RT sample for that corresponding VT sample will be tested If QC and RT are w/in 4.5 pcf use QC for each pair of LOTs If QC and RT are not w/in 4.5 pcf: Engineer will collect & test 3 remaining VT samples and VT results will be used for the 8 LOTs in question Version /

18 The official FDOT in-depth flow diagrams canbefoundinthefdot State Materials Office website under Publications, Specifications, Flowcharts. Contractor QC Frequency One (1) per two (2) consecutive LOTs Test locations (Stations and offsets) are determined using a random number generator provided by the Engineer Contractor notifies Engineer after each passing QC test Dept. Verification Frequency One (1) per eight (8) consecutive LOTs Test location (Stations and offsets) are determined using a random number generator Resolution Procedure If VT does not meet minimum specified, Engineer will take an additional random sample, Resolution (RT), w/in 8 LOTs Test location (Stations and offsets) are determined using a random number generator State Materials Office (SMO) or designee will test the RT sample If the RT results meet the minimum requirements, the the Engineer will accept the 8 LOTs Otherwise, the Contractor will reprocess and retest all 8 LOTs Version /

19 The official FDOT in-depth flow diagrams canbefoundinthefdot State Materials Office website under Publications, Specifications, Flowcharts. Contractor QC Frequency Three (3) per LOT Test locations (Stations and offsets) are determined using a random number generator provided by the Engineer Dept. Verification Frequency One (1) per LOT Determine test locations (Stations and offsets) using a random number generator Resolution Procedure If VT does not meet specified depth, Contractor retest within 5 radius of VT If QC retest passes, Engineer will accept that LOT If QC retest confirms shallow depth, Contractor will remix & re-measure and the Engineer may re-verify If QC retest confirms extra deep mixing, after compaction, the Contractor will density test the bottom 12, in addition to the QC density test on the top 12 and both must pass specification requirement Version /

20 The official i FDOT in-depth flow diagrams can be found in the FDOT Statet Materials Office website under Publications, Specifications, Flowcharts. Contractor QC Frequency One (1) per eight (8) consecutive LOTs Split each sample for Verification or Resolution Test locations (Stations and offsets) are determined using a random number generator provided d by the Engineer Dept. Verification Frequency One (1) per sixteen (16) consecutive LOTs Sample is randomly selected from the 2 split samples, remaining sample is retained by Contractor Resolution Procedure If not within 4.5 pcf: Verification results will be used for those 8 LOTs, Engineer will collect the remaining split sample and State Materials Office (SMO) or designee will test samples If the Resolution Test result is within 4.5 pcf of QC, then QC results will be used for the corresponding 8 LOTs If the Resolution Test results is not w/in 4.5 pcf of QC, then RT results will be used for remaining 8 LOTs Version /

21 Frequency The official FDOT in-depth flow diagrams can be found in the FDOT State Materials Office website under Publications, Specifications, Flowcharts. Test Name Quality Control Verification Roadway Surface 10 per LOT 3 per LOT Shoulder/widening* Surface 5 per LOT 1 per LOT Roadway Thickness 3 per LOT 3 per four LOTs Shoulder/widening* Thickness 3 per 2 consecutive LOTs 3 per 8 consecutive LOTs * Note = for widening less than or equal to 5 ft Contractor QC Cores for thickness (Deficient if over 1/2 less than specified thickness) Template & 15 straightedge for surface (Deficient if irregularities are greater than 1/4 ) Test locations (Stationsti and offsets) are determined dusing a random number generator provided d by the Engineer Dept. Verification If the VT test results are not deficient, the QC test data will be considered verified. Resolution Procedure If the VT results are deficient, Contractor retest within 5 of VT If QC re-test meets requirements, LOT will be accepted If the QC re-test confirms deficient thickness or surface irregularity, the Contractor will rework and retest that LOT by scarifying and adding additional base material. The Department will re-verify the group of those LOTs. As an exception, if authorized by the Engineer, such areas may be left in place without correction and with no payment. Version /

22 Acceptance Program General Requirements: Initial Equipment Comparison: Before initial production, perform a comparison test using the Quality Control, Verifications and Independent Assurance gauges. Unless the Engineer instructs, do not perform the initial equipment comparison more than once per project. When comparing the computed dry density of one nuclear gauge to a second gauge, ensure that the difference between the two computed dry densities does not exceed 2 PCF [32 kg/m3] between gauges from the same manufacturer, and 3 PCF [48 kg/m3] between gauges from different manufacturers. Repair or replace any Quality Control gauge that does not compare favorably with the IA gauge. Perform a comparison analysis between the Quality Control nuclear gauge and the Verification nuclear gauge any time a nuclear gauge or repaired nuclear gauge is first brought to the project. Repair and replace any Quality Control gauge that does not compare favorably with the Verification gauge at any time during the remainder of the project. Calibrate all Quality Control gauges annually. Version /

23 The official i FDOT in-depth flow diagrams can be found in the FDOT Statet Materials Office website under Publications, Specifications, Flowcharts. Version /

24 It is the Contractor s responsibility to report QC sampling and testing results. In some instances, such as Earthwork and Class 1 Non-Structural Concrete, there is also a Certification completed by the Contractor. Version /

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26 To insure good communications on projects, Contractor will provide QC test data directly into the Department s LIMS (Laboratory Information Management System). The Dept. provides training in setting up the system, entering data, and understanding the report. Version /

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29 NOTES Version /