02.A02_Gravel_Crushing_Submittal_REV.pdf

United States Department of Agriculture

Forest Service

Region 2

Rio Grande National Forest

Divide and Conejos Peak Ranger District

March 2018

Black Mountain, Red Lake, and Chicken Foot Gravel Crushing Contract

Rio Grande National Specification List Black Mountain and Red Lake Gravel Crushing

Standard Specifications for Construction of Roads and Bridges

On Federal Highway Projects. FP-03

BLACK MOUNTAIN, RED LAKE, AND CHICKEN FOOT

GRAVEL CRUSHING

Spec. No. Title Latest Rev. Date

FSSS 101-109 General Requirements 1/2009

FSSS 153 Contractor Quality Control 10/2007

FSSS 154 Contractor Sampling and Testing 05/2005

FSSS 155 Schedules for Construction Contracts 05/2004

FP-03 156 Public Traffic 2003

FSSS 157 Soil Erosion Control 02/2005

FSSS 171 Weed and Disease Prevention 03/2005

FSSS 204 Excavation and Embankment 03/2005

FSSS 205 Rock Blasting 05/2004

FSSS 320 Stockpiled Aggregates 12/2008

FSSS 703 Aggregate 11/2008

NIST 2.21 NIST Handbook 44, Sections 2.20 and 2.21

Belt-Conveyor Scale Systems

FSSS –Black Mountain, Red Lake, and Chicken Foot Gravel Crushing

Table of Contents

Preface

101 - Terms, Format, and Definitions

103 - Scope of Work

104 - Control of Work

105 - Control of Material

106 - Acceptance of Work

107 - Legal Relations and Responsibility to the Public

108 - Prosecution and Progress

109 - Measurement and Payment

153 - Contractor Quality Control

154 - Contractor Sampling and Testing

155 - Schedules for Construction Contracts

157 - Soil Erosion Control

171 - Weed and Disease Prevention

204 - Excavation and Embankment

205 - Rock Blasting

320 - Stockpiled Aggregates

703 - Aggregate

Preface

Delete all but the first paragraph and add the following:

Preface_wo_03_15_2004_m

The Forest Service, US Department of Agriculture has adopted FP-03 for construction of National Forest System Roads.

101 - Terms, Format, and Definitions

101.01 Meaning of Terms

101.01_nat_us_01_22_2009

Delete all references to the TAR (Transportation Acquisition Regulations) in the specifications.

101.03_nat_us_06_16_2006

101.03 Abbreviations.

Add the following to (a) Acronyms:

AFPA American Forest and Paper Association MSHA Mine Safety and Health Administration NIST National Institute of Standards and Technology NESC National Electrical Safety Code WCLIB West Coast Lumber Inspection Bureau

Add the following to (b) SI symbols:

mp Milepost ppm Part Per Million

101.04_nat_us_03_29_2007

101.04 Definitions.

Delete the following definitions and substitute the following:

Bid Schedule--The Schedule of Items.

Bridge--No definition.

Contractor--The individual or legal entity contracting with the Government for performance of prescribed work. In a timber sale contract, the contractor is the “purchaser”.

Culvert--No definition.

Right-of-Way--A general term denoting (1) the privilege to pass over land in some particular line (including easement, lease, permit, or license to occupy, use, or traverse public or private lands), or (2) Real property necessary for the project, including roadway, buffer areas, access, and drainage areas.

Add the following:

Adjustment in Contract Price--“Equitable adjustment,” as used in the Federal Acquisition Regulations, or “construction cost adjustment,” as used in the Timber Sale Contract, as applicable.

Change--“Change” means “change order” as used in the Federal Acquisition Regulations, or “design change” as used in the Timber Sale Contract.

Design Quantity--“Design quantity” is a Forest Service method of measurement from the FS-96 Forest Service Specifications for the Construction of Roads and Bridges. Under these FP specifications this term is replaced by the term “Contract Quantities”.

Forest Service--The United States of America, acting through the Forest Service, U.S.

Department of Agriculture.

Neat Line--A line defining the proposed or specified limits of an excavation or structure.

Pioneer Road--Temporary construction access built along the route of the project.

Purchaser--The individual, partnership, joint venture, or corporation contracting with the Government under the terms of a Timber Sale Contract and acting independently or through agents, employees, or subcontractors.

Protected Streamcourse--A drainage shown on the plans or timber sale area map that requires designated mitigation measures.

Road Order--An order affecting and controlling traffic on roads under Forest Service jurisdiction. Road Orders are issued by a designated Forest Officer under the authorities of 36 CFR, part 260.

Schedule of Items--A schedule in the contract that contains a listing and description of construction items, quantities, units of measure, unit price, and amount.

Utilization Standards--The minimum size and percent soundness of trees described in the specifications to determine merchantable timber.

Add Figure 101-1—Illustration of road structure terms:

Figure 101-1—Illustration of road structure terms.

102.00_nat_us_02_16_2005

102 Bid, Award, and Execution of Contract

Delete Section 102 in its entirety.

103 - Scope of Work

103.00_nat_us_02_16_2005

Deletions

Delete all but subsection 103.01 Intent of Contract.

104 - Control of Work

Deletions Delete Sections 104.01, 104.02, and 104.04.

104.00_nat_us_06_16_2006

Add the following subsection:

104.06 Use of Roads by Contractor

104.06_nat_us_02_17_2005

The Contractor is authorized to use roads under the jurisdiction of the Forest Service for all activities necessary to complete this contract, subject to the limitations and authorizations designated in the Road Order(s) or described in the contract, when such use will not damage the roads or national forest resources, and when traffic can be accommodated safely.

105 - Control of Material

105.02_nat_us_01_18_2007

105.02 Material Sources.

105.02(a) Government-provided sources.

Add the following:

Comply with the requirements of 30 CFR 56, subparts B and H. Use all suitable material for aggregate regardless of size unless otherwise designated.

105.05 Use of Material Found in the Work.

105.02_nat_us_03_29_2005

Delete 105.05 (a) and (b) and the last sentence of the second paragraph and substitute the following:

Materials produced or processed from Government lands in excess of the quantities required for performance of this contract are the property of the Government. The Government is not obligated to make reimbursement for the cost of producing these materials.

106 - Acceptance of Work

106.01_nat_us_07_31_2007

106.01 Conformity with Contract Requirements.

Delete Subsection 106.01 and substitute the following:

Follow the requirements of FAR Clause 52.246-12 Inspection of Construction.

References to standard test methods of AASHTO, ASTM, GSA, and other recognized standard authorities refer to the methods in effect on the date of solicitation for bids.

Perform all work to the lines, grades, cross-sections, dimensions, and processes or material requirements shown on the plans or specified in the contract.

Incorporate manufactured materials into the work according to the manufacturer’s recommendations or to these specifications, whichever is more strict.

Plan dimensions and contract specification values are the values to be strived for and complied with as the design values from which any deviations are allowed. Perform work and provide material that is uniform in character and reasonably close to the prescribed value or within the specified tolerance range. The purpose of a tolerance range is to accommodate occasional minor variations from the median zone that are unavoidable for practical reasons.

The Government may inspect, sample, or test all work at any time before final acceptance of the project. When the Government tests work, copies of test reports are furnished to the Contractor upon request. Government tests may or may not be performed at the work site. If Contractor testing and inspection is verified by the Government, the Contractor’s results may be used by the Government to evaluate work for acceptance. Do not rely on the availability of Government test results for process control.

Acceptable work conforming to the contract will be paid for at the contract unit bid price. Four methods of determining conformity and accepting work are described in Subsections 106.02 to

106.05 inclusive. The primary method of acceptance is specified in each Section of work.

However, work may be rejected at any time it is found by any of the methods not to comply with the contract.

Remove and replace work that does not conform to the contract, or to prevailing industry standards where no specific contract requirements are noted, at no cost to the Government.

(a) Disputing Government test results. If the accuracy of Government test results is disputed, promptly inform the CO. If the dispute is unresolved after reasonable steps are taken to resolve the dispute, further evaluation may be obtained by written request. Include a narrative describing the dispute and a proposed resolution protocol that addresses the following:

Sampling method;

1. Number of samples;

2. Sample transport;

3. Test procedures;

4. Testing laboratories;

5. Reporting;

6. Estimated time and costs; and

7. Validation process.

If the evaluation requires additional sampling or testing be performed, mutually agree with the Government on witnessing procedures and on sampling and testing by a third party laboratory. Use a third party laboratory accredited by the AASHTO accreditation program.

Provide proof of the laboratory’s accreditation for the test procedures to be used. Do not use the same laboratory that produced the disputed Government test results or that produced the test results used as a basis for the dispute.

The CO will review the proposed resolution protocol and may modify it before final approval and execution.

The Government will use the approved resolution protocol test results to determine the validity of the disputed testing. If the Government test results are validated, the Contractor will be responsible for all costs associated with developing and performing the resolution protocol. If the Government test results are not validated, the Government will be responsible for all costs associated with developing and performing the resolution protocol.

If the validity of the Government test results cannot be determined, the Contractor and

Government will equally share all costs associated with developing and carrying out the resolution protocol.

(b) Alternatives to removing and replacing non-conforming work. As an alternative to removal and replacement, the Contractor may submit a written request to:

(1) Have the work accepted at a reduced price; or

(2) Be given permission to perform corrective measures to bring the work into conformity.

The request must contain supporting rationale and documentation. Include references or data justifying the proposal based on an evaluation of test results, effect on service life, value of material or work, quality, aesthetics, and other tangible engineering basis. The CO will determine disposition of the nonconforming work.

106.07_nat_us_05_11_2004

106.07 Delete

Delete subsection 106.07.

107 - Legal Relations and Responsibility to the Public

107.05 Responsibility for Damage Claims.

Delete the entire subsection.

107.06 Contractor’s Responsibility for Work.

Delete the following from the first paragraph.

“except as provided in Subsection 106.07”.

107.05_nat_us_05_11_2004

107.06_nat_us_06_16_2006

107.09 Legal Relationship of the Parties.

Delete the entire subsection.

107.10 Environmental Protection.

Add the following:

107.09_nat_us_06_16_2006

107.10_nat_us_06_16_2006

Design and locate equipment repair shops, stationary refueling sites, or other facilities to minimize the potential and impacts of hazardous material spills on Government land.

Before beginning any work, submit a Hazardous Spill Plan. List actions to be taken in the event of a spill. Incorporate preventive measures to be taken, such as the location of mobile refueling facilities, storage and handling of hazardous materials, and similar information. Immediately notify the CO of all hazardous material spills. Provide a written narrative report form no later than 24 hours after the initial report and include the following:

Description of the item spilled (including identity, quantity, manifest number, and other identifying information).

Whether amount spilled is EPA or state reportable, and if so whether it was reported, and to whom.

Exact time and location of spill including a description of the area involved.

Containment procedures.

Summary of any communications the Contractor had with news media, Federal, state and local regulatory agencies and officials, or Forest Service officials.

Description of clean-up procedures employed or to be employed at the site including final disposition and disposal location of spill residue.

When available provide copies of all spill related clean up and closure documentation and correspondence from regulatory agencies.

The Contractor is solely responsible for all spills or leaks that occur during the performance of this contract. Clean up spills or leaks to the satisfaction of the CO and in a manner that complies with Federal, state, and local laws and regulations.

108 - Prosecution and Progress

108.00_nat_us_02_16_2005

108 Delete.

Delete Section 108 in its entirety.

109 - Measurement and Payment

109.00_nat_us_02_17_2005

109 Deletions

Delete the following entire subsections:

109.06 Pricing of Adjustments.

109.07 Eliminated Work.

109.08 Progress Payments.

109.09 Final Payment.

109.02_nat_us_06_16_2006

109.02 Measurement Terms and Definitions.

(b) Contract quantity.

Add the following:

Contract quantities will be adjusted only when there are errors in the original design of 15% or more.

Change the following:

“(b) Cubic yard” to “(c) Cubic yard”.

109.03_nat_us_03_29_2005

109.03 Weighing Procedures and Devices.

(c) Project weighing system.

Add the following:

For aggregates weighed for payment, adjust scale weights of material to deduct the daily average moisture content in excess of 2 percentage points over optimum moisture as determined by AASHTO T 99 or the designated compaction method. If moisture determination is necessary, determine the daily average moisture content in accordance with AASHTO T 255, from not less than three representative samples of aggregate taken at random intervals each day that aggregate is being weighed.

153 - Contractor Quality Control

153.04_nat_us_10_24_2007

153.04 Records.

Delete all but the first sentence

154 - Contractor Sampling and Testing

154.01_nat_us_05_24_2005

154.01 Description

Delete the last sentence of the first paragraph.

155 - Schedules for Construction Contracts

155.00_nat_us_05_11_2004

155 Delete.

Delete Section 155 in its entirety.

157 - Soil Erosion Control

157.03_nat_us_02_24_2005

157.03 General

Delete the entire subsection and replace with the following:

Prior to the start of construction, submit a written plan that provides permanent and temporary erosion control measures to minimize erosion and sedimentation during and after construction.

Do not begin work until the necessary controls for that particular phase of work have been implemented. Do not modify the type, size, or location of any control. An alternate erosion control plan with all necessary permits may be submitted 30 days before intended use.

Incorporate all permanent erosion control features into the project at the earliest practicable time, as outlined in the approved plan.

When erosion control measures are not functioning as intended, immediately take corrective action.

171 - Weed and Disease Prevention

Description

171.00_nat_us_03_30_2005

171.01 This work consists of washing and treating construction equipment to remove seeds, plants, and plant fragments from the equipment before the equipment is used on National Forest System lands.

Construction Requirements

171.03 General. Notify the CO in writing at least 15 days before moving any construction equipment onto National Forest System lands. Construction equipment does not include cars, pickup trucks, and other vehicles that regularly travel between the construction site and areas outside of National Forest System lands.

Provide the CO with an opportunity to monitor the washing and inspection.

Equipment. Use a high pressure washing system.

171.05 Washing. Wash the sides, tops, and undercarriages of all construction equipment.

Remove all seeds, plants, plant fragments, dirt, and debris from the construction equipment.

171.06 Inspection. Inspect the washed construction equipment, including the undercarriage, to ensure that the washing removed the dirt, debris, and seeds from the construction equipment.

Rewash the construction equipment as necessary or as directed.

171.07 Acceptance. Weed prevention will be evaluated under Subsection 106.02.

Measurement

171.08 Do not measure weed prevention for payment.

Payment

171.09 Include all costs associated with the Section 171-Weed Prevention in the unit price for Section 151-Mobilization.

204 - Excavation and Embankment

204.05 Conserved Topsoil

Delete the entire paragraph.

204.05_nat_us_02_18_2005

204.06 Roadway Excavation

(b) Rock Cuts.

Add the following:

When blasting rock, use blasting methods according to Subsection 205.08.

204.06_nat_us_03_02_2005

204.11 Compaction.

Add the following compaction methods:

Place material by end dumping to the minimum depth needed for operation of spreading equipment. Level and smooth each embankment layer before placing the next layer. Operate hauling and spreading equipment uniformly over the full width of each layer. Construct a solid embankment with adequate compaction by working smaller rock and fines in with the larger rocks to fill the voids and by operating hauling and spreading equipment uniformly over the full width of each layer as the embankment is constructed. Make at least three complete passes.

204.14_nat_us_03_02_2005

204.14 Disposal of Unsuitable or Excess Material.

Delete the text of the first paragraph and substitute the following:

Dispose of unsuitable or excess material at designated sites or legally off of the project.

205 - Rock Blasting

205.03 Regulations

Add the following:

(e) Forest Service Manual (FSM) 6745 Explosives and Blasting Materials.

205.07 Test Blasting.

Add the following:

205.02_nat_us_05_13_2004

205.06_nat_us_05_12_2004

Test blast at all new sources, when rock type changes, and when blast layout changes due to slope or other changes.

205.08_nat_us_05_12_2004

205.08 Blasting.

Delete the following:

Place a stake next to each hole with hole number and total depth drilled.

Do not stem the hole with drill cuttings.

Add the following:

(8) Halt blasting operations when any of the following conditions exist:

Precipitation exceeds 1 inch in any 24 hour period.

Precipitation exceeds 3 inches in any 96 hour period.

Precipitation exceeds 4 inches in any 144 hour period.

A landslide occurs within 300 feet of a blast site under any precipitation conditions.

320 - Stockpiled Aggregates

Description

320.00_nat_us_12_19_2008

320.01 This work consists of furnishing and placing aggregate in a stockpile at an existing site or constructing a new site and placing the aggregate at the new site.

Material

320.02 Conform to the following Section:

Aggregate 703

Provide the gradation and quality requirements specified in the Section identified in the pay item.

Construction Requirements

320.03 Stockpile Site. Prepare existing sites as necessary to accommodate the quantity of aggregate to be stockpiled.

For new sites, clear and grub according to Section 201. Grade and shape the site to a uniform cross-section that drains. Compact the floor of the site with at least three passes using compaction equipment conforming to Subsection 204.11. Place, compact, and maintain a minimum 6 inches of crushed aggregate over the stockpile site and access roads. Prevent contamination of the stockpiles.

320.04 Stockpile. After a representative quantity of aggregate is produced, submit proposed target values for the appropriate sieve sizes along with a representative 350-pound sample.

Set target values within the gradation ranges shown in Table 703-3 for the required grading.

Request site approval before stockpiling aggregates. Make the stockpiles neat and regular in shape. Make the side slopes no flatter than 1:1.5.

Build the stockpiles in layers not exceeding 3 feet thick. Complete each layer before depositing aggregates in the next layer. Do not allow aggregates from the one layer to run down over lower layers of the stockpile. Do not drop aggregates from a bucket or spout in one location to form a cone-shaped pile.

Construct stockpile layers by spreading aggregates with trucks or other approved pneumatic-tired equipment. Do not push aggregates into piles.

When operating trucks on stockpiles, avoid tracking dirt or other deleterious material onto the stockpiled material.

Space stockpiles far enough apart or separate stockpiles by suitable walls or partitions to prevent the mixing of the different aggregate gradations.

320.05 Acceptance. Aggregate for stockpiling will be evaluated under Subsection 301.08 and Table 301-1. The point of sampling will be the belt or stockpile.

Preparation of stockpile sites and construction of stockpiles will be evaluated under Subsections

106.02 and 106.04.

Measurement

320.06 Measure the 320 items listed in the bid schedule according to subsection 109.02.

Payment

320.07 The accepted quantities, measured as provided in subsection 109.02 and above, will be paid at the contract price per unit of measurement.

703 - Aggregate

703.05_0213_us_11_25_2008

703.05 Subbase, Base, & Surface Course Aggregate.

Replace (1) and (2) and add (3) under 703.05(c) with the following:

(1) Gradation Table 703-3

(2) Liquid Limit, AASHTO T 89 Table 703-3

(3) Plasticity index, AASHTO T 90: Not to exceed 6

Replace Table 703-3 with the following:

Handbook 44 – 2012 2.21. Belt-Conveyor Scale Systems

2-55

Table of Contents

Section 2.21. Belt-Conveyor Scale Systems .................................................................... 2-57

A. Application ...................................................................................................................................................2-57 A.1. General. ...............................................................................................................................................2-57 A.2. Exceptions. ..........................................................................................................................................2-57 A.3. Additional Code Requirements. ..........................................................................................................2-57

S. Specifications ................................................................................................................................................2-57 S.1. Design of Indicating and Recording Elements. ...................................................................................2-57

S.1.1. General. .................................................................................................................................2-57 S.1.2. Units. .....................................................................................................................................2-57 S.1.3. Value of the Scale Division. .................................................................................................2-57 S.1.4. Recording Elements and Recorded Representations. ...........................................................2-58 S.1.5. Rate of Flow Indicators and Recorders. ...............................................................................2-58 S.1.6. Advancement of Primary Indicating or Recording Elements. ..............................................2-58 S.1.7. Master Weight Totalizer. ......................................................................................................2-58 S.1.8. Power Loss. ...........................................................................................................................2-58

S.2. Design of Weighing Elements. ...........................................................................................................2-58 S.2.1. Speed Measurement. .............................................................................................................2-58 S.2.2. Adjustable Components. .......................................................................................................2-58 S.2.3. Overload Protection. .............................................................................................................2-58

S.3. Zero Setting.........................................................................................................................................2-59 S.3.1. Design of Zero-Setting Mechanism. .....................................................................................2-59 S.3.2. Sensitivity at Zero Load (For Type Evaluation)....................................................................2-59

S.4. Marking Requirements........................................................................................................................2-59 S.5. Provision for Sealing. .........................................................................................................................2-59

N. Notes ..............................................................................................................................................................2-60 N.1. General. ...............................................................................................................................................2-60

N.1.1. Official Test. .........................................................................................................................2-60 N.1.2. Simulated Test. .....................................................................................................................2-60

N.2. Conditions of Tests. ............................................................................................................................2-60 N.2.1. Initial Verification. ................................................................................................................2-60 N.2.2. Subsequent Verification. .......................................................................................................2-61 N.2.3. Minimum Test Load. ............................................................................................................2-61

N.3. Test Procedures. ..................................................................................................................................2-61 N.3.1. Zero-Load Tests. ...................................................................................................................2-61 N.3.2. Material Tests. ......................................................................................................................2-62 N.3.3. Simulated Load Tests. ...........................................................................................................2-63

T. Tolerances .....................................................................................................................................................2-63 T.1. Tolerance Values. ...............................................................................................................................2-63

T.1.1. Tolerance Values – Test of Zero Stability. ...........................................................................2-63 T.2. Tolerance Values, Repeatability Tests. ...............................................................................................2-63 T.3. Influence Factors. ................................................................................................................................2-64

T.3.1. Temperature. .........................................................................................................................2-64 T.3.2. Power Supply, Voltage, and Frequency. ...............................................................................2-64

UR. User Requirements ......................................................................................................................................2-64 UR.1. Use Requirements. ..............................................................................................................................2-64

UR.1.1. Minimum Totalized Load. ....................................................................................................2-64 UR.1.2. Security Means. ....................................................................................................................2-64

2.21. Belt-Conveyor Scale Systems Handbook 44 – 2012

2-56

UR.2. Installation Requirements. ..................................................................................................................2-64 UR.2.1. Protection from Environmental Factors. ...............................................................................2-64 UR.2.2. Conveyor Installation. ...........................................................................................................2-64 UR.2.3. Material Test. ........................................................................................................................2-66 UR.2.4. Belt Travel (Speed or Velocity). ...........................................................................................2-66

UR.3. Use Requirements. ..............................................................................................................................2-66 UR.3.1. Loading. ................................................................................................................................2-66 UR.3.2. Maintenance. .........................................................................................................................2-66 UR.3.3. Retention of Maintenance, Test, and Analog or Digital Recorder Information. ...................2-68 UR.3.4. Diversion or Loss of Measured Product................................................................................2-68

UR.4. Compliance. ........................................................................................................................................2-68

2-57

Section 2.21. Belt-Conveyor Scale Systems

A. Application

A.1. General. – This code applies to belt-conveyor scale systems used for the weighing of bulk materials.

A.2. Exceptions. – The code does not apply to:

(a) devices used for discrete weighing while moving on conveyors;

(b) devices that measure quantity on a time basis;

(c) checkweighers; or

(d) controllers or other auxiliary devices except as they may affect the weighing performance of the belt-conveyor scale.

A.3. Additional Code Requirements. – In addition to the requirements of this code, Belt-Conveyor Scale Systems shall meet the requirements of Section 1.10. General Code.

S. Specifications

S.1. Design of Indicating and Recording Elements.

S.1.1. General. – A belt-conveyor scale shall be equipped with a primary indicating element in the form of a master weight totalizer and shall also be equipped with a recording element, and a rate of flow indicator and recorder (which may be analog).* An auxiliary indicator shall not be considered part of the master weight totalizer.

[*Nonretroactive as of January 1, 1986] (Amended 1986)

S.1.2. Units. – A belt-conveyor scale shall indicate and record weight units in terms of pounds, tons, long tons, metric tons, or kilograms. The value of a scale division (d) expressed in a unit of weight shall be equal to:

(a) 1, 2, or 5; or

(b) a decimal multiple or submultiples of 1, 2, or 5.

S.1.3. Value of the Scale Division.

S.1.3.1. For Scales Installed After January 1, 1986. – The value of the scale division shall not be greater than 0.125 % (1 /800) of the minimum totalized load.

[Nonretroactive as of January 1, 1986] (Added 1985)(Amended 2009)

S.1.3.2. For Scales Installed Before January 1, 1986. – The value of the scale division shall not be greater than 1/1200 of the rated capacity of the device. However, provision shall be made so that compliance with the requirements of the zero-load test as prescribed in N.3.1. Zero Load Tests may be readily and accurately determined in 20 minutes of operation.

2-58

S.1.4. Recording Elements and Recorded Representations. – The value of the scale division of the recording element shall be the same as that of the indicating element.

a) The belt-conveyor scale system shall record the unit of measurement (i.e., kilograms, tonnes, pounds, tons, etc.), the date, and the time.

b) The belt-conveyor scale system shall record the initial indication and the final indication of the master weight totalizer and the quantity.*

All of the information in (a) and (b) must be recorded for each delivery.* [Nonretroactive as of January 1, 1986] [*Nonretroactive as of January 1, 1994]

(Amended 1993)

S.1.4.1. The belt-conveyor scale system shall be capable of recording the results of automatic or semi-automatic zero load tests.** [**Nonretroactive as of January 1, 2004] (Added 2002)

S.1.5. Rate of Flow Indicators and Recorders. - A belt-conveyor scale shall be equipped with a rate of flow indicator and an analog or digital recorder. Permanent means shall be provided to produce an audio or visual signal when the rate of flow is equal to or less than 20 % and when the rate of flow is equal to or greater than 100 % of the rated capacity of the scale. The type of alarm (audio or visual) shall be determined by the individual installation.

[Nonretroactive as of January 1, 1986]

(Amended 1989 and 2004)

S.1.6. Advancement of Primary Indicating or Recording Elements. – The master weight totalizer shall advance only when the belt conveyor is in operation and under load.

(Amended 1989)

S.1.7. Master Weight Totalizer. – The master weight totalizer shall not be resettable without breaking a security means.

[Nonretroactive as of January 1, 1986]

S.1.8. Power Loss. – In the event of a power failure of up to 24 hours, the accumulated measured quantity on the master weight totalizer of an electronic digital indicator shall be retained in memory during the power loss.

[Nonretroactive as of January 1, 1986]

(Amended 1989)

S.2. Design of Weighing Elements. – A belt-conveyor scale system shall be designed to combine automatically belt travel with belt load to provide a determination of the weight of the material that has passed over the scale.

S.2.1. Speed Measurement. – A belt-conveyor scale shall be equipped with a belt speed or travel sensor that will accurately sense the belt speed or travel whether the belt is empty or loaded.

S.2.2. Adjustable Components. – An adjustable component that can affect the performance of the device (except as prescribed in S.3.1.) shall be held securely in adjustment.

(Amended 1998)

S.2.3. Overload Protection. – The load-receiving elements shall be equipped with means for overload protection of not less than 150 % of rated capacity. The accuracy of the scale in its normal loading range shall not be affected by overloading.

2-59

S.3. Zero Setting.

S.3.1. Design of Zero-Setting Mechanism. – Automatic and semiautomatic zero-setting mechanisms shall be so constructed that the resetting operation is carried out only after a whole number of belt revolutions and the completion of the setting or the whole operation is indicated. An audio or visual signal shall be given when the automatic and semiautomatic zero-setting mechanisms reach the limit of adjustment of the zero-setting mechanism.* (Amended 1999 and 2002)

Except for systems that record the zero load reference at the beginning and end of a delivery, the range of the zero-setting mechanism shall not be greater than ± 2 % of the rated capacity of the scale without breaking the security means. For systems that record the zero load reference at the beginning and end of a delivery, the range of zero-setting mechanism shall not be greater than ± 5 % without breaking the security means.** [*Nonretroactive as of January 1, 1990] [**Nonretroactive as of January 1, 2004]

(Amended 1989 and 2002)

S.3.1.1. Automatic Zero-Setting Mechanism. – The automatic zero-setting mechanism shall indicate or record any change in the zero reference.

[Nonretroactive as of January 1, 2010] (Added 2009)

S.3.2. Sensitivity at Zero Load (For Type Evaluation). – When a system is operated for a time period equal to the time required to deliver the minimum test load and with a test load calculated to indicate two scale divisions applied directly to the weighing element, the totalizer shall advance not less than one or more than three scale divisions. An alternative test of equivalent sensitivity, as specified by the manufacturer, shall also be acceptable.

[Nonretroactive as of January 1, 1986]

S.4. Marking Requirements. – A belt-conveyor scale shall be marked with the following: (See also G-S.1. Identification)

(a) the rated capacity in units of weight per hour (minimum and maximum);

(b) the value of the scale division;

(c) the belt speed in terms of feet (or meters) per minute at which the belt will deliver the rated capacity;

(d) the load in terms of pounds per foot or kilograms per meter (determined by materials tests); and

(e) the operational temperature range if other than − 10 °C to 40 °C (14 °F to 104 °F).

[Nonretroactive as of January 1, 1986]

S.5. Provision for Sealing. – A device shall be designed using the format set forth in Table S.5. with provision(s) for applying a security seal that must be broken, or for using other approved means of providing security (e.g. data change audit trail available at the time of inspection), before any change that affects the metrological integrity of the device can be made to any electronic mechanism.

[Nonretroactive as of January 1, 1999] (Added 1998)

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Table S.5.

Categories of Device and Methods of Sealing

Categories of Devices Methods of Sealing

Category 1: No remote configuration capability.

Seal by physical seal or two event counters: one for calibration parameters and one for configuration parameters.

Category 3: Remote configuration capability.

An event logger is required in the device; it must include an event counter (000 to 999), the parameter ID, the date and time of the change, and the new value of the parameter. A printed copy of the information must be available through the device or through another on-site device. The event logger shall have a capacity to retain records equal to 10 times the number of sealable parameters in the device, but not more than 1000 records are required. (Note:

Does not require 1000 changes to be stored for each parameter.)

[Nonretroactive as of January 1, 1998]

(Table Added 1998)

N. Notes

N.1. General. – Belt-conveyor scales are capable of weighing bulk material accurately. (See Tolerances) However, their performance can be detrimentally affected by the conditions of the installation. (See User Requirements) The performance of the equipment is not to be determined by averaging the results of the individual tests. The results of all tests shall be within the tolerance limits.

(Amended 2002)

N.1.1. Official Test. – An official test of a belt-conveyor scale system shall include tests specified in N.3.1. Zero Load Tests, N.3.2. Material Tests, and, if applicable, N.3.3. Simulated Load Tests.

(Amended 2006)

N.1.2. Simulated Test. – Simulated loading conditions as recommended by the manufacturer and approved by the official with statutory authority may be used to properly monitor the system operational performance between official tests, but shall not be used for official certification.

(Amended 1991)

N.2. Conditions of Tests. – A belt-conveyor scale shall be tested after it is installed on the conveyor system with which it is to be used and under such environmental conditions as may normally be expected. Each test shall be conducted with test loads no less than the minimum test load. Before each test run, the inspector shall check the zero setting and adjust as necessary.

(Amended 1986, 2004, and 2009)

N.2.1. Initial Verification. – A belt-conveyor scale system shall be verified with a minimum of two test runs at each of the following flow rates:

(a) normal use flow rate;

(b) 35 % of the maximum rated capacity; and

(c) an intermediate flow rate between these two points.

Test runs may also be conducted at any other rate of flow that may be used at the installation. A minimum of four test runs may be conducted at only one flow rate if evidence is provided that the system is used at a single

2-61 flow rate and that rate does not vary in either direction by an amount more than 10 % of the normal flow rate that can be developed at the installation for at least 80 % of the time.

(Added 2004) (Amended 2009)

N.2.2. Subsequent Verification. – Subsequent testing shall include testing at the normal use flow rate and other flow rates used at the installation. The official with statutory authority may determine that testing only at the normal use flow rate is necessary for subsequent verifications if evidence is provided that the system is used to operate:

(a) at no less than 70 % of the maximum rated capacity for at least 80 % of the time (excluding time that the belt is unloaded); or

(b) with a normal use flow rate that does not vary by more than 10 % of the maximum rated capacity.

Example: If a belt-conveyor scale system has a maximum rated capacity of 200 tons per hour (tph), and the normal use flow rate is 150 tph (75 % of the maximum rated capacity), no testing at additional flow rates is required provided the flow rates remain above 140 tph for more than 80 % of the time. If the same device were operating with a normal use flow rate of 130 tph, it is operating at 65 % of the maximum rated capacity. In this case, testing at flow rates in addition to the normal use flow rate would be required if the normal use flow rate varies by more than 20 tph (10 % of the maximum rated capacity).

(Added 2004)

N.2.3. Minimum Test Load. – Except for applications where a normal weighment is less than 10 minutes, the minimum test load shall not be less than the largest of the following values.

(a) 800 scale divisions;

(b) the load obtained at maximum flow rate in one revolution of the belt; or

(c) at least 10 minutes of operation.

For applications where a normal weighment is less than 10 minutes (e.g., belt-conveyor scale systems used exclusively to issue net weights for material conveyed by individual vehicles and railway track cars) the minimum test load shall be the normal weighment that also complies with (a) and (b).

The official with statutory authority may determine that a smaller minimum totalized load down to 2 % of the load totalized in 1 hour at the maximum flow rate may be used for subsequent tests, provided that:

(a) the smaller minimum totalized load is greater than the quantities specified in (a) and (b); and

(b) consecutive official testing with the minimum totalized loads described in N.2.3. (a), (b), or (c) and the smaller minimum test load has been conducted that demonstrates the system complies with applicable tolerances for repeatability, acceptance, and maintenance.

(Added 2004) (Amended 2008)

N.3. Test Procedures.

N.3.1. Zero-Load Tests. – A zero-load test shall be conducted to establish that the belt scale system (including the conveyor) is capable of holding a stable, in-service zero.

(Amended 1989 and 2002)

N.3.1.1. Determination of Zero. – A zero-load test is a determination of the error in zero, expressed as an internal reference, a percentage of the full-scale capacity, or a change in a totalized load over a whole number of complete belt revolutions. For belt-conveyor scales with electronic integrators, the test must be performed over a period of at least 3 minutes and with a whole number of complete belt revolutions. For

2-62 belt-conveyor scales with mechanical integrators, the test shall be performed with no less than three complete revolutions or 10 minutes of operation, whichever is greater.

(Added 2002)

N.3.1.2. Test of Zero Stability. – The conveyor system shall be operated to warm up the belt and the belt scale shall be zero adjusted as required. A series of zero-load tests shall be carried out immediately before conducting the simulated load or materials test until the three consecutive zero-load tests each indicate an error which does not exceed ± 0.06 % of the totalized load at full scale capacity for the duration of the test. No adjustments can be made during the three consecutive zero-load test readings.

(Added 2002) (Amended 2004 and 2009)

N.3.1.3. Check for Consistency of the Conveyor Belt along Its Entire Length. – During a zero-load test with any operational low-flow lock-out disabled, the absolute value of the difference between the maximum and minimum totalizer readings indicated on the totalizer during any complete revolution of the belt shall not exceed 0.12 % of the minimum test load.

Note: The end value of the zero-load test must meet the ± 0.06 % requirement referenced in the “Test for Zero Stability.”

(Added 2002) (Amended 2004 and 2011)

N.3.2. Material Tests. – Material tests should be conducted using actual belt loading conditions. These belt loading conditions shall include, but are not limited to conducting materials tests using different belt loading points, all types and sizes of products weighed on the scale, at least one other belt speed, and in both directions of weighing.

On subsequent verifications, at least two individual tests shall be conducted. The results of all these tests shall be within the tolerance limits.

Either pass a quantity of pre-weighed material over the belt-conveyor scale in a manner as similar as feasible to actual loading conditions, or weigh all material that has passed over the belt-conveyor scale. Means for weighing the material test load will depend on the capacity of the belt-conveyor scale and availability of a suitable scale for the test. To assure that the test load is accurately weighed and determined, the following precautions shall be observed:

(a) The containers, whether railroad cars, trucks, or boxes, must not leak, and shall not be overloaded to the point that material will be lost.

(b) The actual empty or tare weight of the containers shall be determined at the time of the test. Stenciled tare weight of railway cars or trucks shall not be used. Gross and tare weights shall be determined on the same scale.

(c) When a pre-weighed test load is passed over the scale, the belt-loading hopper shall be examined before and after the test to assure that the hopper is empty and that only the material of the test load has passed over the scale.

(d) Where practicable, a reference scale should be tested within 24 hours preceding the determination of the weight of the test load used for a belt-conveyor scale material test.

A reference scale which is not “as found” within maintenance tolerance should have its accuracy re-verified after the belt-conveyor test with a suitable known weight load if the “as found” error of the belt-conveyor scale material test exceeds maintenance tolerance values.*

(e) If any suitable known weight load other than a certified test weight load is used for re-verification of the reference scale accuracy, its weight shall be determined on the reference scale after the reference scale certification and before commencing the belt scale material test.*

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(f) The test shall not be conducted if the weight of the test load has been affected by environmental conditions.

*Note: Even if the reference scale is within maintenance tolerance it may require adjusting to be able to meet paragraph N.3.2.1. Accuracy of Material.

(Amended 1986, 1989, 1998, 2000, 2002, and 2009)

N.3.2.1. Accuracy of Material. – The quantity of material used to conduct a material test shall be weighed on a reference scale to an accuracy within 0.1 %. Scales typically used for this purpose include Class III and III L scales or a scale without a class designation as described in Handbook 44, Section 2.20., Table T.1.1. Tolerances for Unmarked Scales.

(Added 1989) (Amended 1991, 1993, 1998 and 2000)

N.3.3. Simulated Load Tests.

(a) As required by the official with statutory authority, simulated load tests as recommended by the manufacturer are to be conducted between material tests to monitor the system’s operational performance, but shall not be used for official certification.

(Amended 1991)

(b) A simulated load test consisting of at least three consecutive test runs shall be conducted as soon as possible, but not more than 12 hours after the completion of the material test, to establish the factor to relate the results of the simulated load test to the results of the material tests.

(Added 1990)

(c) The results of the simulated load test shall repeat within 0.1 %.

(Added 1990)

(Amended 1989 and 1990)

T. Tolerances

T.1. Tolerance Values.1 – Maintenance and acceptance tolerances on materials tests, relative to the weight of the material, shall be ± 0.25 % of the test load.

(Amended 1993)

T.1.1. Tolerance Values – Test of Zero Stability. – Immediately after material has been weighed over the belt-conveyor scale during the conduct of any material test run, the zero-load test shall be repeated. The change in the accumulated or subtracted weight during the zero-load test shall not exceed 0.12 % of the totalized load at full scale capacity for the duration of that test. If the range of zero adjustments during a complete (official) verification test exceeds 0.18 % of the totalized load at full scale capacity for the duration of the zero-load test, the official with statutory authority may establish an interval for zero-load testing during normal operation.

(Added 2004) (Amended 2009)

T.2. Tolerance Values, Repeatability Tests. – The variation in the values obtained during the conduct of materials tests shall not be greater than 0.25 % (1/400).

1 The variables and uncertainties included in the relative tolerance represent only part of the variables that affect the accuracy of the material weighed on belt-conveyor scales. If this tolerance was based on an error analysis beginning with mass standards through all of the test processes and following the principle expressed in Section 3.2.