PART ONE FIELD TESTING FOR PROJECT AND IA

Transcription

1 PART ONE FIELD TESTING FOR PROJECT AND IA

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3 TABLE OF CONTENTS Overview... 1 Testing... 1 Prject Acceptance Testing... 1 Infrmatinal Testing... 1 Retests... 2 Miscellaneus Samples and Tests... 2 Acceptance f Small Quantities... 2 Nuclear Testing Prgram... 2 Testing Perfrmed by Other Divisins... 2 Testing Disputes, Reslutin... 3 Independent Assurance Prgram... 4 Respnsibilities f the IA Lab... 4 Independent Assurance Samples and Tests... 5 Independent Assurance Frms... 6 Independent Assurance Files and Recrds... 7 Sampling and Testing Frequencies... 7 Tester Qualificatin Prgram... 8 Field Lab Facilities and Equipment... 8 Lab Remval and Setup... 8 Lab Calibratin Lab Equipment Repair, Maintenance and Replacement Inventries Field Lab Recrd-Keeping Field Tester Safety i

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5 OVERVIEW This resurce has established the field testing guidelines t maintain cmpliance with 637B Title 23 Cde f Federal Regulatins (CFR) while assisting Cnstructin Field Crews and the Cnstructin Divisin in administering a quality cnstructin prject as it relates t field testing. Sampling and testing n radway cnstructin cntracts ensures that materials and cnstructin methds cnfrm t plans and specificatins. Cnsistent sampling and testing prcedures are necessary t ensure quality materials and cnstructin techniques are prvided t the Department. NOTE: Fr mre infrmatin regarding the Department s Quality Assurance Prgram, refer t Chapter 4, Sampling and Testing, f the Cnstructin Manual. TESTING P ROJECT ACCEPTANCE TESTING Prject acceptance testing (field testing) is perfrmed during the prgress f cnstructin n the materials t be permanently incrprated int the cntract t ensure quality and cnsistency. In additin, sme materials are accepted by the Department with submissin f Certificates f Cmpliance frm the Cntractr and/r prducer f the material r prducts listed n the Qualified Prducts List (QPL). The Department is respnsible fr all acceptance testing; with few exceptins. These exceptins include the measurement f pavement smthness and the measurement f retr-reflectivity fr striping. Prject acceptance tests (field tests) are perfrmed by cnstructin crew testers and/r the Materials Divisin using the Synpsis f Materials Divisin Testing Manual fr Field Testing r the Materials Divisin Testing Manual. T determine which test methd revisin t use n a cntract, refer t the cntract advertised date fund in the e-bidding prtal and use the test methd revisin dated n r befre the cntract advertised date. Tests are t be cnducted at the apprpriate lcatins and times using methds as defined in the specificatins. The Materials Checklist Letter prvided by the Materials Divisin identifies materials acceptance details fr each cntract. The Acceptance Test Summary Sheet (ATSS) shws all knwn, at the time f publicatin, applicable minimum required tests needed fr each cntract. Unfreseen changes t existing materials and/r the additin f new materials requiring testing will need t be addressed by the Resident Engineer. The Minimum Required Samples and Tests: Prject and Minimum Required Samples and Tests: Independent Assurance (IA) list the minimum required frequencies fr each material n each cntract. T determine which set f Prject Testing Frequencies t use n a cntract, refer t the cntract advertised date fund in the e-bidding prtal and use the Prject Testing Frequencies that are dated n r befre the cntract advertised date. Refer t Field Lab Recrd-Keeping fr specific requirements n reprting test results. INFORMATIONAL TESTING Sme materials will require infrmatinal testing utside the regular cntract acceptance testing frequencies. Infrmatinal testing is perfrmed after the Cntractr has submitted their test results t the Resident Engineer. Examples f infrmatinal testing cnducted by NDOT testers include but are nt limited t: Aggregates t be submitted fr mix designs. Aggregates prduced fr stckpile. Misture cntent f aggregates. Hydrated lime in marinated aggregate. State f Nevada Department f Transprtatin Cnstructin Divisin 1

6 Cement treated base mixtures. Cncrete cylinders ther than the 28-day curing perid. Material taken utside the specified acceptance pint. RETESTS Fr materials nt cmplying with the specificatins, the first retest f the unaccepted material shuld be run t determine if the sampling and testing methds were crrectly perfrmed. Any retest must be taken frm the same acceptance pint and be taken n the same material. If the retest prduces cmparable results, the Cntractr shall use an apprpriate methd t crrect the unacceptable material. Per Sectin 106, Cntrl f Material, f the Standard Specificatins, the Cntractr is respnsible fr prviding a quality material that meets the specificatins and cmplete their wn infrmatinal testing t ensure cnfrmance. Befre cmpleting further retests, the Resident Engineer will make sure the Cntractr made a cnstructive effrt t crrect the unacceptable material. Repetitive testing, in an effrt, t get a passing test, will nt be allwed and is against the NDOT Rights and Respnsibilities dcument signed by each qualified tester. After the secnd re-test, the Resident Engineer shuld be cmmunicating with the Cntractr, regarding, nt incrprating the failing material int the cntract r remving the failing material frm the cntract. MISCELLANEOUS SAMPLES AND TESTS The Cnstructin Divisin, District Engineer r FHWA may request sampling and testing f materials r wrk that may be in questin. ACCEPTANCE OF SMALL QUANTITIES Small quantities are defined as 10 percent f the minimum required tests fr that material. EXAMPLE: Bit. Rati is required every 1,000 tns: 1000 x.10 = 100 tns If the cntract quantity is less than 100 tns, the minimum required frequencies can be waived by the Resident Engineer. If a material meets this criterin, the Resident Engineer can accept the material n substantial cmpliance and nt require the minimum required tests. If the material is 10 percent r mre f the minimum required testing frequency, then all applicable tests shall be cmpleted per the Minimum Required Samples and Tests: Prject frequency table. Ntify the District IA Lab if tests are waived based n this criterin. This will allw the Lab t update its prtin f the Acceptance Testing Summary Sheet (ATSS). NUCLEAR TESTING PROGRAM The Department s Radiatin Safety Class is taught by the Crprate Radiatin Safety Officer (CRSO) and cvers all plicies and prcedures required fr string and transprting f the Department s nuclear density gauges. Each District Radiatin Safety Officer (DRSO) prvides the Nuclear Gauge Operatin Class giving prper training and qualificatins fr the peratin f the Department s nuclear density gauges. The Radiatin Safety Class and Nuclear Gauge Operatin Class must be taken and passed prir t transprting, string r perating the Department s nuclear density gauges. TESTING PERFORMED BY OTHER DIVISIONS MATERIALS DIVISION Testing perfrmed by the Materials Divisin is cmpleted in accrdance with the applicable sectin(s) f the Standard Specificatins and can be either surce acceptance r prject cntrl, depending n the type f material and the required tests needed t be run. 2 State f Nevada Department f Transprtatin Cnstructin Divisin

7 When submitting samples and/r material certificatins t the Materials Divisin, verify they are accmpanied with the apprpriate cmpleted transmittal. (Incmplete/inaccurate transmittals will result in delayed test results.) G t the Frms library n the Cnstructin Divisin SharePint site [ fr transmittal frms. An accurately cmpleted transmittal frm can be fund in the Part 3. The fllwing list shws the different Labs within the Materials Divisin and which materials are tested by each ne: AGGREGATE LAB Brrw, select brrw, aggregate base, backfill, granular backfill, MSE backfill, drain backfill, riprap, riprap bedding, tp sil, screenings, deicing sand, plantmix bituminus surface aggregates, Prtland cement cncrete aggregates ASPHALT LAB Refinery samples, asphalt cement, bituminus emulsin, bituminus cutback BITUMINOUS LAB Dense-graded and pen-graded plantmix bituminus surface mix designs, dense-graded plantmix bituminus surface behind the paver samples CHEMICAL LAB Paint, traffic beads, water, hydrated lime, guidepsts, metal fence psts, chain link fence, sign psts, crrugated metal pipe, wire mesh, fly ash, cement GEOTECHNICAL LAB Brrw, select brrw, aggregate base, granular backfill, MSE backfill PAVEMENT ANALYSIS SECTION Final cncrete pavement samples f Prtland cement cncrete pavement STRUCTURAL LAB Cncrete cylinders, reinfrcing steel, metal fence psts, guidepsts, chain link fence, crrugated metal pipes, tensining strand, cncrete aggregates, slurry backfill, cncrete cres STRUCTURES DIVISION, NON-DESTRUCTIVE TESTING SECTION Structural steel: Inspectin and testing during fabricatin, welding, erectin and/r paint applicatin Pst tensining: Strand installatin and testing, gruting TESTING DISPUTES, RESOLUTION The Cntractr and Resident Engineer shuld discuss the apprpriate crrective actins when materials r cnstructin methds d nt cnfrm t the plans and/r specificatins. When a test result is questined r disputed: 1. The Resident Engineer shuld first cnduct the test using a different tester n the same crew. If the results are still in dispute, then the Resident Engineer will immediately request an audit frm the District IA Lab. 2. If the results f the District IA Lab and field tester d nt match, then each party will perfrm an additinal audit. This secnd audit will cnsist f the District IA Lab and field tester running the test, side-by-side and with their wn equipment. The District IA Lab inspectr will then review audit findings and prvide recmmendatins t the Resident Engineer and field testers fr implementatin. State f Nevada Department f Transprtatin Cnstructin Divisin 3

8 3. If the first tw steps d nt reslve the dispute, then the Resident Engineer and District IA Lab will cntact the Quality Assurance Engineer t arrange fr a three-way split that includes the Materials Divisin fr referee testing. INDEPENDENT ASSURANCE PROGRAM The Independent Assurance (IA) Prgram is federally mandated by FHWA in accrdance with 23 CFR 637B. The IA sampling and testing prgram independently verifies the reliability f the results f field sampling and acceptance testing fr all NDOT persnnel assciated with NDOT cntracts. The Cnstructin Divisin manages and runs the IA Labs which are in each District facility. Each District IA Lab is respnsible fr perfrming independent assurance testing n all cntracts within the District. T ensure an independent check f the field crew testing prcedures, the District IA Lab and its staff are nt assciated with any field crew testing persnnel. IA Lab test results are nt used fr acceptance testing n any cntract nr t determine the quality and acceptability f the materials and/r wrkmanship. RESPONSIBILITIES OF THE IA LAB The IA Lab is respnsible fr auditing field testers in accrdance with the Minimum Required Samples and Tests: Independent Assurance (IA) frequency table. This includes but is nt limited t the fllwing: Maintain testing cnsistency thrughut the state by verifying that NDOT s testing prcedures are utilized and perfrmed crrectly by testing persnnel. Perfrm visual audits. Perfrm direct split audits. Reprt the audit findings. Discuss the audit with the individual(s) whse testing is being audited and with the Resident Engineer befre leaving the jb site (if crrective actin is necessary). Perfrm fllw-up audits as necessary. Additinal respnsibilities f the IA Lab include but are nt limited t the fllwing: Verify that all persnnel perfrming tests n NDOT cntracts pssess the necessary Nevada Field Sampling and Testing Qualificatin Prgram (NFSTQP), Nevada Alliance fr Quality Transprtatin Cnstructin (NAQTC) r Western Alliance fr Quality Transprtatin Cnstructin (WAQTC), and Nevada Cncrete Qualificatin Prgram (NCQP) r American Cncrete Institute (ACI) qualificatins. Prvide annual training and qualificatin fr field crew testers fr the NFSTQP/NCQP written and perfrmance exams. Verify that field lab safety prcedures are being fllwed. Perfrm annual field lab: Safety inspectins, n NDOT Frm (Field Lab Safety Equipment Inspectin) by July 1 f every calendar year. Inspectins n field labs t verify equipment meets the requirements f the test methds and is in gd wrking cnditin. Dcument n NDOT Frm (Field Labratry Inspectin Reprt) by July 1 f every calendar year. Fixed asset inventries cnducted in January r February f every calendar year. Perfrm DRSO respnsibilities. 4 Review field crew test reprts fr accuracy and cmpleteness. State f Nevada Department f Transprtatin Cnstructin Divisin

9 Assist in annual equipment budget requests. Acquire and distribute testing equipment t field testers as needed. Prvide equipment repair and maintenance. INDEPENDENT ASSURANCE SAMPLES AND TESTS The Minimum Required Samples and Tests: Independent Assurance (IA) frequency tables utline the materials t be sampled, sample lcatins, tests t be perfrmed by the IA Lab and the minimum frequency requirements. Use these frequencies when field testing prcedures (audits) are bserved t be crrect. Whenever these cnditins d nt exist, increase the frequency f IA samples and tests t prvide greater cntrl. District IA Lab inspectrs sample each cntract unifrmly thrughut the cnstructin perid. Since sampling depends n hw much material has been prduced r prcessed since the previus sampling, IA inspectrs stay infrmed f the wrk n each cntract using clse crdinatin with the field crew testers t rganize their wrk efficiently. The Resident Engineer shall keep the District IA Lab infrmed f any schedule changes and crdinate cmpletin f testing requirements thrughut the duratin f the cntract. SPLIT SAMPLES Split sample tests are the same tests that are run n regular cntract samples. As a part f the regular IA sampling and testing prgram, mst samples are split regularly between the field testers and the District IA Labs (tw-way splits) r amng the field testers, District IA Labs and a third party (three-way splits). The District IA Lab s test results prvide an additinal way t check the accuracy f the field testing prcedures. OBTAINING SAMPLES Take split samples at the same lcatins as regular cntract samples r btain the split frm the field testers. The sample shuld be large enugh s that each lab will have enugh material fr each required test. Crdinate with the field testers t either btain the sample frm their field lab lcatin r have the field testers deliver the split sample t the District IA Lab. REPORTING REQUIREMENTS The crew field lab shall prvide their cmpleted test reprts n direct split samples t their District IA Lab within 24 hurs f test cmpletin. Audit results shall be reprted by the IA Lab within 14 calendar days f receiving each split sample. TEST Sieve Analysis TABLE 1: IA AUDIT TOLERANCES CONTROL Percent Passing 3 in. t 1 in. sieves Percent Passing 3/4 in. t 3/8 in. sieves Percent Passing N. 4 sieve Percent Passing N. 8 t N. 16 sieves Percent Passing N. 20 t N. 50 sieves Percent Passing N. 60 t N. 200 sieves TOLERANCE RANGE (PLUS OR MINUS) 7% 6% 5% 4% 3% 2% Fractured Face Percent Fractured Faces 7% Sand Equivalent Sand Equivalent Value 4% Plasticity Index Plasticity Index 3 Density Calculated Maximum Density 3 lbs./cu.ft. Slump Slump f Cncrete 1 inch Air Cntent Percent f Air in Cncrete 0.5% Unit Weight Punds per Cubic Ft 1.5 lbs. T.M.D. (Rice) Density 3 lbs./cu.ft. Ignitin Oven Bitumen Rati 0.3% Absrptin Percent Absrptin 0.5% CV Cleanliness Value 4.0% State f Nevada Department f Transprtatin Cnstructin Divisin 5

10 When split samples vary mre than the allwable tlerances, the IA Lab will cnfirm that tester(s) are fllwing prper testing prcedures. The IA Lab inspectrs will btain and test an additinal fllw-up audit (if available). If the fllw-up audit still cnfirms unsatisfactry results, a meeting with the tester, Resident Engineer, the District IA Lab and the Cnstructin Divisin s Quality Assurance Engineer will ccur. If deficiencies cntinue, the Cnstructin Divisin s Quality Assurance Engineer will meet with all parties t determine the apprpriate reslutin. RECORDS The IA Lab maintains accurate recrds t cnfirm: Prper frequency f splits. Splits are reprted immediately. Crrective actin is taken when necessary. Testing dcumentatin is maintained. VISUAL AUDITS OF FIELD TESTING PROCEDURES The District IA Lab will visually audit field sampling and testing prcedures t verify the accuracy f field methds. Audits include: Inspecting any r all f the fllwing: Sampling prcedures Sample splitting prcedures Sample preparatin Testing prcedures Calculatins Reprts Equipment use and prcedures Field bks and files (lab) Discussing the audit with the tester(s) wh is/are being bserved and with the Resident Engineer befre leaving the jb site (if crrective actin is necessary). Reprting the visual audit n NDOT frms (Visual Audit Reprt Frm), (Visual Audit fr Nuclear Density Gauge - Plantmix) r A (Visual Audit fr Nuclear Density Gauge - Sils). Verifying that field lab safety prcedures are being fllwed. A fllw-up audit (if available) is required fr any failing r unsatisfactry audit, visual r prcedural, t verify cnditins have been crrected. If the fllw-up audit still cnfirms unsatisfactry results, a meeting with the tester, Resident Engineer, the District IA Lab and the Cnstructin Divisin s Quality Assurance Engineer will ccur. If deficiencies cntinue, the Cnstructin Divisin s Quality Assurance Engineer will meet with the Resident Engineer and the Materials Divisin t determine the apprpriate reslutin. INDEPENDENT ASSURANCE FORMS Cmplete IA audit reprts daily. Cnsecutively number inspectin IA audits fr all types f material fr each cntract. Use the fllwing infrmatin when numbering audit tests: 6 State f Nevada Department f Transprtatin Cnstructin Divisin

11 Fr Cmpactins and Sieves: District number, abbreviatin (IA), the material cde (1B) and the cnsecutive number f the test. Fr example, test number 1-IA-1B-40 n an audit reprt indicates District One, IA, Type 1 Class B Aggregate and the frtieth audit fr this cntract. Numbering will cntinue fr each material type regardless f the surce. Fr Cncrete: District number, abbreviatin (IA), and the cnsecutive number f the test. Fr example, test number 1- IA-40 n an audit reprt indicates District One, IA and the frtieth audit fr this cntract. Numbering will cntinue fr each material type regardless f the surce. INDEPENDENT ASSURANCE FILES AND RECORDS Keep all IA audit reprts n file in the electrnic filing system chrnlgically by the type f material r audit. Distribute them t all apprpriate divisins within 14 calendar days f the receipt f audit material. Submit the IA audit results even if the field tester has nt submitted their test results t the IA Lab fr cmparisn. Frward all cmpleted audit reprts electrnically t the Cnstructin Divisin s Quality Assurance Sectin, the Resident Engineer, the Assistant Resident Engineer, the District Engineer and the Assistant District Engineer. Refer t Appendix C f the Dcumentatin Manual fr a list f inspectin audit reprts and the crrespnding distributin. SAMPLING AND TESTING FREQUENCIES Every material must be tested and accepted based n sampling frequencies fr each cntract. These frequencies have been established t help ensure cnsistency f the quality f materials and t meet federal requirements. If these frequencies are nt met, federal funding fr the cntract may be withheld. Prcesses t assist the Resident Engineer in meeting the required frequencies are handled by the Materials Divisin and the Cnstructin Divisin. The Materials Divisin prepares a Materials Sampling and Testing Checklist which shuld include all materials required fr sampling and testing and identifies prducts and/r materials that may be accepted by a Certificate f Cmpliance fr each cntract. The Cnstructin Divisin s Quality Assurance Sectin receives the Materials Checklist Letter and generates the Acceptance Testing Summary Sheet (ATSS) which defines the minimum required number f tests fr each material listed n the Materials Checklist. Bth dcuments are distributed t the Resident Engineer befre cnstructin begins. The ATSS is a wrking dcument t be updated mnthly by the District IA Lab and the Resident Engineer until the cntract wrk is cmplete. The District IA Lab frwards the updated ATSS (mnthly) t the Resident Engineer, and this infrmatin must be included in the Resident Engineer s mnthly updates. Fr mre infrmatin, refer t the ATSS prcess mem lcated in the Cnstructin Divisin SharePint site s Quality Assurance Dcuments library [ The Minimum Required Samples and Tests: Prject and Minimum Required Samples and Tests: Independent Assurance (IA) frequency tables define the minimum requirements fr sampling and testing f materials. The sampling frequency may be increased t ensure adequate cntrl and may vary n sme cntracts accrding t unique cnditins. Any changes t the frequencies defined in the ATSS must be discussed with the Quality Assurance Engineer prir t making changes. The Resident Engineer must address the reasn fr nt meeting the frequencies n the ATSS apprpriately in the ntes (e.g., small quantity). Except as prvided in Sectin , (Cntrl f Material) Certificates f Cmpliance, f the Standard Specificatins, all materials are inspected and/r tested fr acceptance befre incrprating int the wrk. TESTER QUALIFICATION PROGRAM In accrdance with 23 CFR 637B, NDOT testers perfrming wrk n a cntract shall be certified under an apprved prgram. The Department utilizes the fllwing prgrams: NFSTQP State f Nevada Department f Transprtatin Cnstructin Divisin 7

12 NCQP The NDOT qualificatin prgrams include written and perfrmance examinatins. Emplyees must successfully cmplete the entire qualificatin prgram t becme qualified testers. These qualificatins are valid fr 5 years. All qualificatins carry inherent rights and respnsibilities. These respnsibilities include perfrming and reprting test results with accuracy and precisin in accrdance with the required NDOT test prcedures utlined in the Synpsis f Materials Divisin Testing Manual fr Field Testing. Each tester will sign the NDOT Respnsibilities Agreement fr Field Testing agreement when qualifying fr NFSTQP and NCQP qualificatin. Failure t fllw the testing requirements may result in suspensin frm testing duties r ther penalties. Cnsultants and Cntractrs qualify/certify their testers under the fllwing prgrams: NAQTC WAQTC ACI FIELD LAB FACILITIES AND EQUIPMENT The field labs belng t the Equipment Divisin and are assigned by the Cnstructin Divisin t each individual cnstructin crew. The lab trailers are n a 20-year replacement prgram thrugh the Equipment Divisin. The Equipment Divisin, the Cnstructin Divisin and the Architecture Divisin wrk clsely t make sure acceptable lab facilities are prcured thrugh the Equipment Divisin s Annual Budget. The Resident Engineer uses, and is respnsible fr maintaining, their assigned lab trailer alng with the equipment assigned t the lab. Only apprpriate materials and apprved equipment are authrized in the field lab. The Resident Engineer is respnsible fr enfrcing this plicy. The District Engineer is respnsible fr the security f the field lab when stred by the District. The Cntractr is respnsible fr the field lab security at the jb site. A list f apprved equipment utilized in a field lab can be fund n NDOT Frm (Inventry f Standard Testing Equipment - Cnstructin Field Labs). LAB REMOVAL AND SETUP It is the respnsibility f the Resident Engineer t prepare the lab trailer fr site re-lcatin and setup nce it arrives at the new site. The fllwing list will assist with this prcess if the lab trailer is being mved internally by the NDOT Equipment Divisin: the Equipment Divisin Superintendent with sufficient ntice and cc: Cnstructin Divisin s Quality Assurance Engineer and the lcal District IA Lab. In the request include: The address where the lab is being picked-up. The address where the lab is being delivered. Any sheds r carg cntainers that need t be transprted at the same time. The date the mve needs t be cmpleted. The cntact persn wh will meet the transprt driver at the pick-up lcatin and fllw t the delivery lcatin. 8 State f Nevada Department f Transprtatin Cnstructin Divisin

13 Cntact the lcal equipment shp via phne, r the lcal wrk rder prcess. Ntify them that the lab is being mved by the fllwing date and request a safety check f the trailer t verify it has wrking brakes, brake lights, tires, etc., befre the transprt driver arrives. Remve and discnnect the pwer, water and prtable hlding tank either by the Cntractr in accrdance with Sectin 628, Mbilizatin, f the Standard Specificatins, r the lcal District Services via phne, r the lcal wrk rder prcess. This needs t be cmpleted prir t the arrival f the transprt driver. Remve heavy equipment frm inside the lab trailer and secure any light equipment left inside the lab trailer frm falling and breaking during the mve. Ensure all equipment - stairs, jack-stands, tie dwns r chains, etc., utside f the lab trailer are remved prir t the transprt driver arriving. Meet the transprt driver at the existing lab trailer lcatin. Fllw the transprt driver t the new lab trailer lcatin, assisting the transprt driver and t verify the lab trailer is delivered t the crrect lcatin. After the lab trailer has been remved frm the frmer lcatin, ensure all garbage and cnstructin material has been dispsed f prperly, leaving the ld lab site in the same r better cnditin than it was fund while satisfying any strm water requirements. Once the transprt driver delivers the lab trailer t the new lcatin, set up the lab trailer. This includes but is nt limited t: Placing the jack stands in the apprpriate lcatins, leveling the lab trailer and securely tying dwn the lab trailer with tie-dwns r chains. Placing the stairs, s they are level and flush with the lab trailer. Set up all lab equipment in the apprpriate places inside and utside f the lab trailer. Ensure that the lab trailer has water, gas and electricity either by the Cntractr in accrdance with Sectin 628, Mbilizatin, f the Standard Specificatins, r the lcal District Services via phne, r the lcal wrk rder prcess. The fllwing list will assist with this prcess if the lab trailer is being transprted and setup by a hired certified manufactured husing cmpany: If the lab is mved thrugh mbilizatin n an active cntract using a letter f authrizatin r cntract mdificatin the Cntractr is a certified manufactured husing cmpany r will hire a certified manufactured husing cmpany t btain all necessary permits required by the State f Nevada Husing Divisin - Manufactured Husing. If the lab is mved thrugh a service prvider wh is a certified manufactured husing cmpany hired by District - the certified manufactured husing cmpany will btain all necessary permits required by the State f Nevada Husing Divisin - Manufactured Husing. The certified manufactured husing cmpany hired will: Remve tie-dwns r chains, jack stands and stairs. Transprt lab trailer, tie-dwns r chains, jack stands and stairs t new lab lcatin. Setup level lab trailer, place tie-dwns r chains, jack stands and stairs. Occupancy will d what is necessary (repairs) t btain the permitted ccupancy f the lab trailer The Resident Engineer is still respnsible fr: State f Nevada Department f Transprtatin Cnstructin Divisin 9

14 Cntacting the lcal equipment shp via phne, r the lcal wrk rder prcess. Ntify them that the lab is being mved by the fllwing date and request a safety check f the trailer t verify it has wrking brakes, brake lights, tires, etc., befre the transprt driver arrives. Remving and discnnecting the pwer, water and prtable hlding tank either by the Cntractr in accrdance with Sectin 628, Mbilizatin, f the Standard Specificatins, r the lcal District Services via phne, r the lcal wrk rder prcess. This needs t be cmpleted prir t the arrival f the transprt driver. Remving heavy equipment frm inside the lab trailer (if required) and secure any equipment left inside the lab trailer frm falling and breaking during the mve. Meeting the transprt driver at the existing lab trailer lcatin. Fllwing the transprt driver t the new lab trailer lcatin, ensuring the lab trailer is delivered t the crrect lcatin. After the lab trailer has been remved frm the frmer lcatin, ensuring all garbage and cnstructin material has been dispsed f prperly, leaving the ld lab site in the same r better cnditin than it was fund while satisfying any strm water requirements. Ensuring that the lab trailer has water, gas and electricity either by the Cntractr in accrdance with Sectin 628, Mbilizatin, f the Standard Specificatins, r the lcal District Services via phne, r the lcal wrk rder prcess. Once the ccupancy permit is btained, setting up all lab equipment in the apprpriate places inside and utside f the lab trailer. Fr assistance r mre infrmatin, cntact the lcal District IA Lab r the Cnstructin Divisin s Quality Assurance Engineer. LAB CALIBRATION The Materials Divisin is respnsible fr scheduling an annual equipment calibratin f the field labs with the Resident Engineer. The calibratin will be cmpleted at the field lab site. Any time a lab is mved, the Resident Engineer is respnsible t cntact the Materials Divisin s Lab Services Sectin t recalibrate the lab trailer equipment. The lab trailer must be setup, fully equipped and peratinal befre the scheduled calibratin. Failure t setup the lab trailer prperly will result in the calibratin being rescheduled. Once the calibratin is cmplete, a reprt will be sent t the Resident Engineer and the Cnstructin Divisin s Quality Assurance Sectin. Any equipment nt passing calibratin will be repaired r replaced in crdinatin with the District IA Lab. L AB EQUIPMENT REPAIR, MAINTENANCE AND REPLACEMENT The Resident Engineer is respnsible fr maintaining a clean and safe lab facility. Fr any necessary structural r mechanical repairs n the lab trailers, cntact the lcal District Services via phne, r lcal wrk rder prcess. Fr repair r replacement f equipment, cntact the lcal District IA Lab. INVENTORIES An inventry f all testing equipment fr each lab trailer is cnducted nce a year (by June) by the Resident Engineer assigned t the lab trailer and reprted n NDOT Frm (Inventry f Standard Testing Equipment - Cnstructin Field Labs). Equipment assigned t the lab trailer shall nt be transferred t anther trailer withut permissin f the District IA Lab. Fr equipment ver $5,000, the District IA Lab will schedule and cmplete the fixed asset inventries fr the Equipment Divisin nce a year. 10 State f Nevada Department f Transprtatin Cnstructin Divisin

15 FIELD L AB RECORD- KEEPING FILES AND RECORDS Befre each cntract begins, setup the lab files in accrdance with Chapter 2, Cntract Start Up, f the Dcumentatin Manual. Use the Materials Sampling and Testing Checklist, ATSS and Estimate f Quantities t aid in this preparatin. When daily testing is cmplete, file a cpy f the cmpleted field test reprt(s) in the apprpriate field labratry files, then submit the riginal field test(s) t the Office Persn. Staple a cpy f any retest t their crrespnding riginal failed field test. FIELD LAB BOOKS All field lab bks will be written with pencil r red pencil. N pens, markers r highlighters shall be used. Befre each cntract begins, set up the three required field lab bks. Cmpactin Bk Sieve Bk Cncrete Bk Infrmatinal Bk (if required by Resident Engineer) Number each page in the bk, 1 thrugh 80, n the tp right crner. Include a title page (this can be typed, r hand written if it has the fllwing infrmatin: State f Nevada, Department f Transprtatin, Lcatin Descriptin, Cntract Number, Prject Number, Bk Title and number and Name f Resident Engineer), a cmplete index and an initial key as shwn in the fllwing field bk examples. Use the Materials Sampling and Testing Checklist, ATSS and The Estimate f Quantities t cmplete setup f the field lab bks. If the cntract is small and all three bks with the required infrmatin will fit, cmbine these bks int ne field bk. When daily testing is cmplete, keep a summary f all cntract acceptance tests in the apprpriate field bks. This will allw quick access t test results and frequencies. Circle all failing tests and areas t retest in red. Submit all cmpleted field lab bks t the field ffice when the cntract is cmplete. These bks will be submitted t the Cnstructin Divisin s Administrative Services Sectin upn cntract clseut. State f Nevada Department f Transprtatin Cnstructin Divisin 11

16 COMPACTION BOOK Set up Cmpactin Bks accrding t the examples in Figure 1, 2 and 3. Recrd remarks such as an audit, an ccasinal check f quantities placed r additin f testing frequencies. Circle all failing tests in red. Dcument each material in chrnlgical rder fr test numbering. 12 Figure 1: Cmpactin Bk Example State f Nevada Department f Transprtatin Cnstructin Divisin

17 Figure 2: Cmpactin Bk Example State f Nevada Department f Transprtatin Cnstructin Divisin 13

18 Figure 3: Cmpactin Bk Example 14 State f Nevada Department f Transprtatin Cnstructin Divisin

19 SIEVE BOOK Keep summaries f cntract sieve analysis and ther test results fr aggregate materials in a field Sieve Bk in the fllwing manner: 1. Dcument each material as its wn subsectin. (Refer t Figure 4, 5 and 6 fr examples) Divide each bk int sectins fr each type f material, such as: Type 1 Class B Aggregate Base. Aggregate fr Plantmix Bituminus Base, Surface, Open-graded, Permeable Base and Pre-Mix. Type 2 Plantmix Bituminus Surface. Plantmix Bituminus Surface Open-Graded. Shulder Material. Aggregate fr Prtland Cement Cncrete Pavement. Cncrete Aggregates. Any ther materials required n the cntract. Althugh ther types f material will have different tests listed, fllw the same basic arrangement fr all materials. 2. Include the fllwing in each subsectin: Test Identificatin: Cnsecutively list tests and identify each with the date and sample lcatin. Results: List numerical results f all acceptance tests; hwever, d nt list sieve analysis results screen-byscreen. If all screens are within the specificatin range, nte the results as P (passing). Cntrarily, if any ne screen is ut f specificatin range, nte the results as F (failing). Explain all failures in the remarks. Retests and Remarks: Include the date and test number f the failing test(s) with an explanatin f the crrective actin taken n the passing r failing re-tests. 3. List nly acceptance tests in the Sieve Bk. Keep summaries f infrmatinal samples in a separate bk (Infrmatinal Bk), if required by the Resident Engineer. 4. Circle all failing test results in red pencil. State f Nevada Department f Transprtatin Cnstructin Divisin 15

20 Figure 4: Sieve Bk Example 16 State f Nevada Department f Transprtatin Cnstructin Divisin

21 Figure 5: Sieve Bk Example State f Nevada Department f Transprtatin Cnstructin Divisin 17

22 Figure 6: Sieve Bk Example 18 State f Nevada Department f Transprtatin Cnstructin Divisin

23 CONCRETE BOOK Set up Cncrete Bks accrding t Figure 7 belw. Recrd remarks such as an audit, an ccasinal check f quantities placed r additin f testing frequencies. Circle all failing tests in red fr quick identificatin. Figure 7: Cncrete Bk Example State f Nevada Department f Transprtatin Cnstructin Divisin 19

24 INFORMATIONAL BOOK If required by the Resident Engineer, the Infrmatinal Bk captures infrmatin like the ther bks, except the test number is indicated by an I (instead f T ) and is cmbined int a single bk. TEST NUMBERING All cnstructin materials incrprated int the cntract that are required t be tested will be labeled with a test number. Utilize the fllwing infrmatin t crrectly label each test cmpleted n the cntract. COMPACTION REPORTS Cnsecutively number sil cmpactin tests fr a material regardless f the surce. Cde sil cmpactin tests as fllws: The first number represents the test number. The grup f letter(s) indicates the material used. Use nly the cdes listed in Table 2. Use f additinal cding will be apprved by the Cnstructin Divisin s Quality Assurance Sectin. The next grup f numbers indicates the minimum cmpactin requirement as per the Standard Specificatins fr the applicable material. When retests are required, a furth grup is added with the letter R fllwed by a number. This number represents the retest number. EXAMPLE: If the test number is 218-S-90-R1, the cde indicates test number 218, subgrade material, 90 percent minimum cmpactin as required by the Standard Specificatins, and the first retest f the area represented by test number 218. Cnsecutively number plantmix cmpactin tests fr a material fr all surces and mix designs. Cde plantmix cmpactin tests as fllws: The first number represents the test sectin being tested. The next grup f letters indicates the material used. Use nly the cdes listed in Table 2. Use f additinal cding will be apprved by the Cnstructin Divisin s Quality Assurance Sectin. The next grup f numbers indicates the subsectin f the test sectin. There are nt any re-tests n plantmix cmpactins. EXAMPLE: If the test number is 25-PM-1, 25-PM-2, 25-PM-3, 25-PM-4 and 25-PM-5 (this is ne full test sectin, 1001 yd 2 t 13,000 yd 2 f plantmix n ne frm), the cde indicates the test sectin number 25, plantmix material, test subsectin number 1 thrugh 5. If the test number is 26-PM-1 (this is a small test sectin, under 1000 yd 2 f plantmix, n ne frm), the cde indicates the test sectin number 26, plantmix material, test subsectin number State f Nevada Department f Transprtatin Cnstructin Divisin

25 TABLE 2: CONSTRUCTION MATERIAL CODES TYPE OF MATERIAL CODE SPECIFICATION REFERENCE Original Grund OG Subgrade (includes Radway Excavatin and Cmmn Brrw in the Embankment) S Select Brrw XB Pipe Backfill PB Structure Backfill SB Drain Backfill DB Type 1, Class B Aggregate Base 1B Type 2, Class B Aggregate Base 2B Type 3, Class B Aggregate Base 3B Type 1, Class A Aggregate Base 1A Type 2, Class A Aggregate Base 2A Type 3, Class A Aggregate Base 3A Prtland Cement Treated Base CTB Radbed Mdificatin RBM Plantmix Bituminus Surface PM Mechanically Stabilized Earth Backfill MSE SIEVES SOILS, CONCRETE AND INFORMATIONAL REPORTS Fr NDOT frms (Daily Reprt f Tests Made in Field) and (Reprt f Field Tests f Carse and Fine Aggregate fr Cncrete), cnsecutively number test reprts regardless f the surce. Cnsecutively number each f the tw types f samples, infrmatinal r acceptance, daily. Cde test numbers as fllws: The first letter is T fr acceptance test r I fr infrmatinal test. The secnd set f numbers represents the daily test number. The third set f numbers represents the reprt number. When retests are required, the furth set f numbers represents the retest number. The fllwing are examples f test cde numbers: Acceptance Test Number T-1-31 represents the first test taken that day at the acceptance pint n Reprt Number 31. Acceptance Test Number T-1-31-R2 represents the secnd retest, taken at the acceptance pint f material previusly tested and pertains t Acceptance sample number 1, Reprt Number 31. Infrmatinal Test Number I-1-31 represents the first infrmatinal test taken n Reprt Number 31. PLANTMIX BITUMINOUS SURFACE REPORTS Fr NDOT Frm (Daily Plant Reprt f Asphalt Mixtures), cnsecutively number reprts fr all surces and mix designs (PBS Type II, PBS Type 2C with RAP, PBS Type 3, Open Grade, etc.). Cnsecutively number each f the tw types f samples, infrmatinal r acceptance, daily. There are n retests n any types f plantmix. Cde test numbers as fllws: State f Nevada Department f Transprtatin Cnstructin Divisin 21

26 The first letter is T fr acceptance test r I fr infrmatinal test. The secnd set f numbers represents the daily test number. The last set f numbers represents the reprt number. The fllwing are examples f test cde numbers: Acceptance Test Number T-1-31 represents the first sample taken at the acceptance pint n Reprt Number 31. Infrmatinal Test Number I-1-31 represents the first infrmatinal sample taken n Reprt Number 31. REPORTING OF DAILY TESTING FORMS Cmplete daily reprts f test results fr the day the respective wrk is perfrmed. Refer t Table 3 fr the applicable reprt frms fr varius materials and tests. Cmpleted test reprts will be turned int the Resident Engineer daily allwing them t see the material testing results. Within 24 hurs f cmpleting the test, ntify the Cntractr f the preliminary test results. The Resident Engineer s ffice persn checks the daily test reprts. Then, the Resident Engineer reviews and signs the daily test reprts. The Resident Engineer s signature cnfirms the daily test results are accurate and cmpleted in accrdance with NDOT prcedures. Once the daily test reprts have been cmpleted, distribute them as detailed in Appendix C f the Dcumentatin Manual. Distribute all test reprts within 7 calendar days f test cmpletin. Give the final test results t the Cntractr as sn as pssible but n later than 7 calendar days after the test has been cmpleted. Submit riginal field test reprts t the District IA Lab. The District IA Lab will review the test reprts and return any cntaining errrs r missins t the Resident Engineer fr crrectins within 7 calendar days f receipt. Upn satisfactry cmpletin, the IA Lab will frward the riginal test reprts t the Cnstructin Divisin within 7 calendar days fr final review and filing. 22 State f Nevada Department f Transprtatin Cnstructin Divisin

27 TABLE 3: REQUIRED REPORTING OF DAILY TESTING FORMS FORM NUMBER REPORT AND USE Misture-Density Determinatin, Cmpactin Reprt Nuclear Cmpactin Reprt fr Sils and Aggregates * * * Daily Reprt f Tests Made in Field * Select Brrw * Backfill * Selected Material r Base * A Drain Backfill Aggregate Base Curses Screenings Sand Bltter Plantmix Aggregate Infrmatinal Open-grade Aggregate Infrmatinal * * * A * A * B * * * * * (Aggregate stckpiles ther than cncrete) Daily Plant Reprt f Asphalt Mixtures Plantmix Bituminus Base Plantmix Bituminus Surface Plantmix Bituminus Open-Graded Surface Nuclear Thin Layer Cmpactin Reprt fr Plantmix Bituminus Pavements Density n Bituminus Mix Pavements Reprt f Field Tests f Carse and Fine Aggregate fr Cncrete Cncrete Pavements Cncrete Structures Cncrete Field Summary Reprt Reprt f Tests f Prtland Cement Cncrete Pavement Flexural Strength Beams * If required TRANSMITTALS When submitting samples t the Materials Divisin, verify they are accmpanied by a cmpleted passing test reprt frm (if required) and the apprpriate transmittal. Incmplete/inaccurate transmittals will result in delayed test results. G t the Cnstructin Divisin SharePint site s Frms library [ fr transmittal frms. The fllwing are the three transmittal frms: NDOT Frm (Transmittal fr Asphalt Samples) NDOT Frm (Transmittal fr Cncrete Samples) NDOT Frm (Transmittal fr Test Samples and Certificatins) The fllwing are the standard sample cntainers available frm the Equipment Divisin s Headquarters Stckrm: Aggregate and stne: Sack, sample large cttn canvas, 19 in. x 32 in. Slurry backfill, plantmix bituminus surface and Prtland cement cncrete (when the maximum aggregate particle size exceeds 1 in.): Mld, cylinder plastic, 6 in. x 12 in. Prtland cement cncrete fr structures: Mld, cylinder plastic, 4 in. x 8 in. Cutback asphalts: Can, rectangular metal, 1 qt., sample with lid State f Nevada Department f Transprtatin Cnstructin Divisin 23

28 Fly ash, hydrated lime and Prtland cement: First bag, sample plyethylene 10 in. x 20 in. pen end. Place plyethylene bag inside a sack, sample small cttn canvas Water and emulsified asphalt: Bttle, plastic wide muth with lid, 1 qt. Asphalt cement, traffic paint and traffic beads: Can, paint rund 1 qt. with lid FIELD TESTER SAFETY All sampling, testing and equipment peratins will adhere t the safety requirements f Federal and State Occupatinal Safety and Health Administratin (OSHA) standards, which can be fund at 24 State f Nevada Department f Transprtatin Cnstructin Divisin