LEV VOR TECH SPECS - VOLUME II.pdf

APPLICATION OF QUALITY ASSURANCE

SPECIFICATIONS

for

EMBANKMENT and BASE COURSE

Jointly Developed by the Technology Transfer and Training and Materials and Construction Sections of the Louisiana Department of Transportation and Development ii iii

APPLICATION OF

QUALITY ASSURANCE SPECIFICATIONS

FOR

EMBANKMENT and BASE COURSE

Developed by

TECHNOLOGY TRANSFER AND TRAINING

LOUISIANA TRANSPORTATION AND RESEARCH CENTER

For

Louisiana Department of Transportation and Development iv v

CREDITS

This manual was revised with the assistance of the technical committee listed below. It was prepared for publication by the Technology Transfer and Training section.

The Construction and Materials Sections of the Louisiana Department of Transportation and Development and the DOTD Chief Engineer have approved this manual for publication.

Technical Advisory Committee

Mr. B. Kings District 08 Laboratory Supervisor

Mr. R. McCann District 08 Project Engineering Technician 5

Mr. J. Blanton

Mr. J. Lambert Pavement Design Engineer

Mr. B. Dill

District 08 Training Coordinator (Retired)

Mr. G. Gautreau LTRC Senior Geotechnical Research Engineer

Industry Representatives

Mr. L.J. Haddox Soil Stabilizers

Mr. J. Kent

Global Laboratories vi vii

TABLE OF CONTENTS

TOPIC PAGE

Foreword

Materials

General

Excavation

Borrow

In-Place Materials

Stockpiles

Cement

Water

Lime

Blended Calcium Sulfate

Geotextile Fabric

Backfill Materials – Sections 700 & 800

Soil Usage Chart

Required Lime Treatment Chart

Equipment Plant Equipment Central Mix Plants

Central Mix Plants - Feeder System

Central Mix Plants - Mixing System

Scale and Meters

Feed Bin Calibration

Roadway Equipment Haul Equipment

Placement and Spreading Equipment

Compaction Equipment

Distributors

In-Place Mixing and Additive Spreader Equipment viii

Laboratory and Testing Equipment Automated Compaction Hammers

Nuclear Density Gauge

Other Laboratory Equipment

Personnel Training and Certification

General Certification Requirement

Certified Personnel

Department

Nondepartment

Quality Assurance/Control Quality Assurance

Quality Control

Plant Operations

Construction Practices

Construction Layout

Traffic Control

Construction Details

Weather Limitations

Pulverization

Spreading Cement

In-Place Mixing

Moisture Content

Joint Construction

Compaction

Finishing

Scarifying and Compacting

Compaction – Pipes, Manholes, & Boxes ix

Environmental Concerns

Hazardous Materials

Erosion and Pollution Control

Archaeological or Paleontological Inspections

Acceptance

Sampling and Testing

Visual Inspection

Embankments

Embankment Zones

Base Courses

Pipes, Drainage Structures and Boxes

Quality Control (QC)

Dimensional Tolerance

Composite Bases

Measurement and Payment Dedicated Stockpiles

Acceptance Without Payment Adjustment

Acceptance With Payment Adjustment

Example of Cumulative Payment Adjustment

Removal and Replacement of Base

Placing Backfill x

Special Areas of Consideration by Section:

201- Clearing and Grubbing

202 - Removing or Relocating Structures and Obstructions

203 - Excavation and Embankment

204 - Temporary Erosion Control

301 - Class I Base Course

302 - Class II Base Course

303 - In-Place Stabilized and Treated Base Course

304 - Lime Treatment

305 - Subgrade Layer

306 - Scarifying and Compacting Roadbed

307 - Permeable Bases

309 - In-Place Cement Treated Subgrade

701 - Culverts and Storm Drains

702 - Manholes, Junction Boxes and Catch Basins

802 - Structural Excavation and Backfill xi

APPENDIX PAGE

Borrow Pit Sketch - Example .................................................................................................... A-3

Borrow Pit Location Map – Example ........................................................................................ A-5

Right of Entry ........................................................................................................................... A-7

Certificate of Release ............................................................................................................... A-9

Transition from Cut to Fill - Example Sketch ............................................................................ A-11

Certificate of Material Proportions for Base Course (03-22-0751) ............................................ A-13

Density & Moisture Content Worksheet (03-22-0750) .............................................................. A-15

J-Stitch Sketch for Geotextile Fabric ........................................................................................ A-17

Inspection Report - Archaeological or Hazardous Materials

(excerpt EDSM III.1.1.22) ............................................................................................. A-19

Equipment Inspection and Certifications

Haul Equipment .................................................................................................................. A-21

Compaction Equipment ...................................................................................................... A-23

Distributors ......................................................................................................................... A-25

Plant Equipment

Plant Certification Sticker ............................................................................................ A-27

Base Course Central Mix Plant Certification Report (03-22-0753) ............................... A-29

Certification Report for Scales and Meters (03-22-3065) ............................................. A-35

Base Course Design for Central Plant Materials Mixtures (03-22-0752) ...................... A-37

Feed Bin Calibration Curves - Example ...................................................................... A-39

Daily Central Mix Plant Report (03-22-0754) ............................................................... A-41

Environmental Documentation

Standard Plans Index (online addresses) ........................................................................... A-43

Pollution Prevention Certification Statement ....................................................................... A-45

Notice of Intent (portion, pgs. 1-7 of 16) ............................................................................. A-47

Notice of Termination ......................................................................................................... A-55

Other Documents

Attachment 7 .................................................................................................................... A-57 xii

FOREWORD

This manual is designed to standardize Louisiana Department of Transportation and

Development (LADOTD) policies and procedures for embankment, base courses, and related construction or reconstruction using soils and aggregates. It references applicable sections of

201, 202, 203, 204, 301, 302, 303, 304, 305, 306, 307 and 309, and the earthwork involved in

Sections 700 & 800 of the LADOTD Standard Specifications for Road and Bridges, and any supporting Supplemental Specifications. This manual details the responsibilities of the contractor and the Department (LADOTD) in the following areas.

certification design production transportation placement quality control inspection acceptance

Other detailed manuals are available for use when references are made to asphalt concrete and

Portland cement concrete pavement and structures and should be consulted. This manual will refer to these sections when differences occur or for clarity.

While soils and the handling methods of the people who work with them are widely variable, the

LADOTD methods of acceptance and measurement are much more consistent. This manual cannot describe every condition a contractor, inspector, or engineer may encounter in the field, but it can demonstrate procedures to best handle the majority of conditions found in Louisiana.

This manual is to be used in conjunction with the 2016 Edition of the Louisiana Standard

Specifications for Roads and Bridges. Relevant specifications are referenced throughout this manual. Some specifications may be repeated in order to further detail or demonstrate how they are applied. All specifications, manuals, forms, and spreadsheets are subject to change.

Contract documents for each project should be reviewed for any specific change, update, and/or addition.

As such, in accordance with Section 105 of the Louisiana Standard Specifications for Roads and

Bridges, in case of discrepancy, the following order of precedence will apply:

1) Special Provisions

2) Plans

3) Supplemental Specifications

4) Standard Specifications (for which this manual is referenced)

5) Standard Plans

MATERIALS

GENERAL

It is the contractor's responsibility to locate and furnish materials, which meet specifications. It is also the responsibility of the contractor to ensure that those materials, after being placed and processed, will meet Department acceptance criteria. Once the contractor feels certain that the proposed material sources will meet specifications, it will be the contractor's responsibility to request acceptance testing and approval of those sources by the Department. The contractor is responsible for coordinating the arrangements for testing and approval and the planned work schedule with the project engineer and the district laboratory engineer so that sampling and testing of materials is completed prior to their planned incorporation into the project.

Failure to do so will result in a delay of the contractor's proposed schedule, since no material can be placed on a project without approval.

EXCAVATION

Soils vary both laterally and vertically within a source. Therefore, the method of excavation can contribute to the variability of material on the project. Contractors must obtain uniform materials.

If the contractor's methods of obtaining soils contribute to their non-uniformity, the engineer will direct that these methods be altered to ensure the placement of uniform material on the project.

When excavating in-place materials in locations previously tested by the Department during the design phase, a close inspection of uniformity of those materials and acceptance testing will still be required in most cases (refer to the Materials Sampling Manual for testing schedules). If materials are found to be significantly different or unsuitable, the materials will not be incorporated.

BORROW

Borrow is defined as soil or soil-aggregate not found within the limits of the project.

Refer to pages 64 and 65 for instructions concerning the submittal of borrow materials to the district lab for acceptance. The contractor will test or use a private laboratory to test all borrow materials, and be reasonably certain of their suitability before submitting to the Department for acceptance.

IN-PLACE MATERIALS

Generally, the base materials to be used for in-place stabilization or treatment will be found in the roadway embankment or base section within project limits. They may include raw or treated sand clay gravel or aggregates, asphalt concrete/soil blends, embankments, stabilized soil, etc. These materials, though previously tested by the Department, will be reexamined for the purposes of classification and additive design, normally at the time the Department was designing the roadway. Cement factors may then be placed in the contract.

If there are no cement factors in the contract, and none has been predetermined, project personnel will sample the in-place material from selected sites after it has been satisfactorily pulverized and blended by the contractor. The sample will be delivered to the district laboratory for the determination of cement factor. In order to ensure an effective, timely operation, it is critical that the contractor's operation and project engineer's sampling and delivery to the district laboratory be closely coordinated.

If unusual conditions of the soil are encountered or if the resulting blend of materials will not stabilize, the contractor shall furnish material in addition to the in-place material. When the contractor supplies material for stabilization, the materials supplied shall meet the material specifications for their applicable section. It shall be the responsibility of the contractor to locate and provide these materials, making sure they meet the specifications, and are appropriate for use.

STOCKPILES

Stockpiles at a central mix plant shall be built on a well-drained surface, far enough apart that no intermixing of materials will occur during operations. If the area is not large enough to permit adequate distance between stockpiles, a bulkhead shall be erected of sufficient height and length to prevent intermixing of materials or spillage over the top between the stockpiles. The method of removing material from the stockpiles must be approved prior to the beginning of plant operations and will be subject to continual Department inspection for satisfactory operation. No contamination or intermixing of materials between stockpiles shall occur during the removal of material from stockpiles.

When constructing Class I Base Course all soils and aggregates shall be placed in dedicated stockpiles.

Materials to be placed in a single stockpile shall be uniform in terms of classification, moisture content, moisture-density relationships, gradation, feedability (flow), stabilization, and compaction characteristics.

Additionally, soils in a single stockpile must exhibit close moisture-density relationships. If the moisture-density relationships of materials vary, the compaction required for each of those materials may vary as well. The uniformity of the material will directly help to produce better compaction results and, ultimately, less risk to the contractor by maintaining consistent compaction processes.

When stockpiles are excessively wet, production should cease until the material dries or can be processed. It is not acceptable to attempt to dry excessively wet material during blending, hauling, or placement on the project without approval from the engineer.

CEMENT

The contractor shall protect cement at a central mix plant to prevent the intrusion of dampness, water or other contaminants. Cement that has partially set or has visible signs of moisture damage shall not be used. Seals from transports shall be checked to ensure that they match the numbers on the Cement Certificates of Delivery. If the seal number does not match the Cement

Certificate of Delivery, the transport of cement is not to be accepted.

Cement to be used for In-Place Cement Stabilized Base Course shall be delivered in sealed transports. Each transport shall be accompanied by a Cement Certificate of Delivery. It shall be the responsibility of the Department to verify that the transports are sealed and that the seal number matches that indicated on the Cement Certificate of Delivery.

WATER

Water shall be from approved sources and shall not be contaminated during storage or handling.

Water pumped from natural sources should be checked for possible detrimental interactions with cement, especially those near sugar producing fields and transport roads.

LIME

All lime used in any type of treatment must be from an approved source listed in AML, either

Hydrated or Quicklime may be used. The most common form of lime used in construction is dry, hydrated (powder) lime. Quicklime (non-hydrated) comes in granular form (pelletized) in two different gradations, a 3/8-inch size, which the Department allows to be used in the same manner as powdered lime, and a 3/4 inch size, which can be used for forming lime/water slurries.

Since quicklime is non-hydrated, it has a high demand for moisture. This characteristic creates a potential health concern that requires constant vigilance on the part of personnel as this material can cause serious burns if contact with human tissue occurs.

Lime may be applied directly to the prepared surface or may be mixed with the material in a central mix plant. In dust sensitive areas, designated in the plans, either granular (pelletized), slurry application, or central plant mixing may be required. The engineer will approve the type of material and application method to be used.

A Certificate of Delivery shall accompany each transport. It shall be the responsibility of the

Department to verify that the transports are sealed and that the seal number matches that indicated on the Certificate of Delivery.

Lime must be protected from moisture prior to application or mixing in a plant or slurry. Caked or contaminated lime is not to be used. Any lime not processed within 6 hours and lime lost or damaged before incorporation due to rain, wind or other cause will be rejected, deducted from measured quantities, and shall be replaced by the contractor at no direct pay.

Lime oxidizes when exposed to the atmosphere and loses its ability to react chemically with the soil. Lime exposed to air prior to placement, stored for an excessive length of time, or for which there is a significant delay between placement and mixing is not to be used. If the lime's usability is questionable, project personnel are to sample the lime and submit it to the Materials and Testing

Section for evaluation.

BLENDED CALCIUM SULFATE

Blended calcium sulfate may be used as a non-plastic embankment, base course, or untreated subgrade layer. Blended calcium sulfate may be blended with an approved limestone or lime for pH control and placed in dedicated stockpiles. All sampling will be accomplished in accordance with the applicable specification.

GEOTEXTILE FABRIC

Geotextile fabric shall not be unwrapped prior to use and shall be spread directly in front of the operation. Geotextile fabric exposed to sunlight prior to installation will be tested for ultraviolet damage prior to placement. Geotextile fabric that has been installed shall be covered with embankment within seven calendar days. Installed fabric that is not covered within seven calendar days shall be removed and replaced or protected from further light damage until test results are obtained.

The specifications allow geotextile fabric to be joined by either overlapping or sewing depending on the location of the seam and use of the fabric. When soil is inundated with water or saturated, the fabric must be sewn. When edges are sewn, Standard Specification Section 203 requires the use of the J-Stitch with a Type 401, two-thread chain stitch. To create a J-Stitch, two parallel edges are placed together, turned in the same direction, and sewn. Refer to the diagram on page

A-17 in the Appendix for a sketch of a completed J-Stitch. Industry standards recommend two -four inches of overlap when making the J-stich. The number of lines of stitching required shall be in accordance with the plans or as directed by the Design Section. The 401 stitch is a locking stitch that protects the seam from unraveling if a thread breaks. Standard Specification Section

203 requires thread of polyester or Kevlar. These materials are resistant to moisture damage.

BACKFILL MATERIALS – SECTIONS 700 & 800

Type-A backfill material shall be stone, recycled Portland cement concrete, flowable fill, or RAP that meets the requirements of Standard Specification Section 701.

When a soil or aggregate Type-A backfill material is used, geotextile fabric shall be placed in accordance with plan details prior to placing backfill material. Care shall be taken to prevent damage to geotextile fabric during placement of backfill material. When flowable fill is specified, or allowed, the contractor shall submit a mix design for approval. The mix design and control of the mixture will follow the general guidelines of Standard Specification Section 710 and the appropriate Application of Quality Assurance manual.

Use excavatable flowable fill except where noted in the plans.

Type-B backfill material shall be selected soils. Selected soils placed as backfill for corrugated metal pipe must also meet resistivity and pH requirements. The resistivity of the material shall be greater than 1500 ohm-cm when tested in accordance with DOTD TR 429. The pH shall be greater than 5.0 when tested in accordance with DOTD TR 430.

Exposed pipe backfill shall be covered with an outside layer of plastic soil blanket in accordance with Standard Specification Section 203.

SOIL USAGE CHART

The following chart details all the different classes or categories of soils used for DOTD projects.

PI LL pH Sand (max)

Silt (max)

%Organic (max) min max min max min max

Usable Soil 11* 25 50* 5 Usable Soil-Header 11 25 65 Non-plastic Embankment See Section 1003 4 Plastic Soil Blanket 11 35 5.5 8.5 65 3 Soil for Soil Cement 301 0 12 0 35 79 60 2 Soil for Soil Cement 302 0 15 0 35 79 60 2 Soil on Cut Slope 10 5.5 8.5 Soil for Subgrade Layer 0 35 79 69

Selected Soils/ Soil for Type-B Backfill

11* 20 0 35 N/A 50* 5

Soil for Temporary Diversion 45 75

*Soils with a silt content of 50% or greater and also a PI of 10 or less will not be allowed

SPECIAL CONDITIONS OF PLASTIC INDEX USE

REQUIRED LIME TREATMENT CHART

The following chart gives the amounts of lime, when required, for treatment of soils used in the conditions separated below.

SOIL USAGE PI LIME TREATMENT

Headers (full height)

11 - 25

None Allowed

Embankments (non header)

0 - 25 26 - 34

None Required 6% by Volume*

*Treatment shall conform to Type-E (Section 304)

EQUIPMENT

Prior to construction, the project engineer will inspect the equipment to be used on the project to ensure that it is in good condition and appropriate for the activity for which it is to be used. The project engineer will supply the District Laboratory with a list of any equipment requiring certification prior to that piece of equipment being used on the project. The project engineer will require that leaking or damaged equipment be repaired or replaced before it operates on the project. The project engineer will require the replacement of equipment that is not appropriate for the project prior to its being used.

During the progress of construction, the contractor’s personnel are to inspect equipment daily to ensure that it has been maintained in good condition and that no damage that could affect its operation has occurred. Damaged equipment shall be repaired prior to its continued use. Project personnel will evaluate the effectiveness of equipment. Equipment which does not perform properly or which does not produce a quality product meeting specifications is to be replaced with acceptable equipment.

PLANT EQUIPMENT

Central Mix Plants

Central mix plants required for Soil Cement and Cement Stabilized Class I Base Courses under

Standard Specification Section 301 must be certified. Certification procedures for these plants will be in accordance with this manual. When a contractor elects to use a central mix plant to produce cement stabilized or treated base course not under Standard Specification Section 301, the plant must meet the specification requirements of Standard Specification Section 301, including certification. For base course or subgrade layers constructed of asphalt or Portland cement concrete, plants producing those materials will be certified and operated according to applicable specifications and Quality Assurance methods.

The central mix plant and location shall be maintained in a safe, clean condition. The plant shall be equipped with a laboratory conforming to Standard Specification Section 722. The plant shall be located where it will not be necessary for haul trucks to traverse any newly placed base course.

The district laboratory engineer will approve testing equipment. Scales and metering devices will be calibrated, documentation submitted to the district laboratory engineer, and their calibration approved by the district laboratory engineer prior to production. Calibration shall be by an approved, independent service or by the Weights and Measures Division of the Department of

Agriculture and Forestry. Independent calibration services must be licensed by the Department of Agriculture and Forestry.

The LADOTD laboratory in the district in which the plant is located will certify plant equipment

(except sampling and testing equipment) and plant operations, as well as evaluate and approve materials prior to the delivery of any mixture to a DOTD project. Plant certification requires an on-going, in-depth inspection by district laboratory personnel to ensure that the plant's equipment, stockpiles, storage bins, scales, metering devices, etc., are in conformance with Department specifications and standards. It is the responsibility of the contractor to keep the project engineer and the district laboratory engineer informed of the sequence of plant installation and stockpile construction. Failure to keep the Department informed of the status of the plant's installation sequence may cause delay in plant certification and production for DOTD projects.

Certification by the district laboratory signifies that the plant is capable of producing cement stabilized or treated mixtures that meet Department standards of quality. Therefore, in order to become certified, a plant must be in production and able to demonstrate its performance. Material produced during the certification process shall not be incorporated into the project without approval.

Plant certification is valid for two years, provided the plant is maintained in accordance with the conditions under which certification was issued. Relocation of the plant will invalidate certification.

A certification sticker will be placed in an obvious location on or near the control panel of a certified plant. An example of this sticker is reprinted in the Appendix on page A-27.

The district laboratory will re-inspect the plant for conformance to certification requirements at least every 90-calendar days. The LADOTD certified inspector inspects the plant and operations on a daily basis to ensure that the equipment and activities are within requirements. Inspections by the laboratory will be made more frequently if equipment, materials, or processes are modified or if deficiencies occur. It is the responsibility of both the contractor and Department personnel to notify the certifying district laboratory when modifications are made to equipment, processes, or materials.

The Base Course Central Mix Plant Certification Report (DOTD Form No. 03-22-0753) will be used to inspect the central mix plant for conformance to certification requirements and to document this inspection. Likewise, construction personnel will use this completed form for daily plant inspections. A reprint of this form begins on page A-29 in the Appendix.

Department representatives shall be allowed free access to plant facilities for inspection of plant and operations and certification. Inspections will be conducted at the option of the Department, and shall not relieve the contractor of any responsibility under the specifications. The completed form (DOTD Form No. 03-22-0753) is used for ninety-day review inspections or any intermediate inspections that may be required. Ninety-day review and intermediate inspections will be documented by date, remark, and signature at the end of the form. The completed form will be kept on file at the district laboratory and a copy sent to the project engineer(s) receiving material from the plant, the DOTD Materials Engineer Administrator, the DOTD construction section, and the contractor.

When a plant certified by the Department fails to conform to the Department standards, the certification will be revoked. The certifying district laboratory engineer can revoke plant certification. The project engineer or the LADOTD certified Embankment and Base Course

Inspector have the authority to discontinue plant operations when a plant or the mixture exhibits deficiencies. When this occurs, it is the responsibility of the project engineer or certified inspector to notify the district laboratory engineer immediately, so that the plant's certification status can be reviewed. Once certification has been revoked, the plant will be prohibited from supplying material for any Department project until all deficiencies have been corrected and certification is reinstated.

Central Mix Plants - Feeder System

The feeder system of the central mix plant is composed of bins, belts, scales, a moisture control mechanism(s), an automatic shut-off device(s), and any other plant components used to move or temporarily store soils, aggregates, and cement between the stockpiles and the pugmill. Feed rates shall be adjustable. When control is accomplished by gate openings, the gates shall be adjustable and lockable. Belt speed shall be adjustable to control plant production rate.

Bins shall be free of holes, shall not allow material to bridge or collect in corners, and shall not allow material to intermix at the top or during loading. If vibrators do not effectively result in an even flow of material through the bin, other methods shall be used to achieve satisfactory results.

Material will not flow through a bin if it is too wet; in this situation, it will be necessary to allow time for the stockpile to reach a lower, uniform moisture content.

Belts shall be free of sags, tears, or holes. Belts shall move smoothly and carry material from bins to the pugmill without spillage.

The moisture control mechanism will consist of the spray bar and metering or weighing system.

It shall be capable of adjusting the flow rate, and of being locked into position. The spray bar shall apply water uniformly across the full width of material. Blocked nozzles shall be cleaned immediately. When nozzles become blocked, operations will be stopped immediately until they are cleared. Lines shall not leak water.

An operational variation of 1% by weight in cement is allowed. The tolerance of 1% by weight is only intended to compensate for normal variations in plant operation. For aggregates and soils, the specifications allow an operational variation of 2% of the individual weight of each component;

however, the total weight of the aggregate and soils shall be within 1% of the required weight of the total material.

Central Mix Plants - Mixing System

The Central Mix Plant mixing system shall be adequate to handle the production rate on the Base

Course Design for Central Plant Materials Mixtures form (a reprint of this form, DOTD 03-22-0752, is on page A-37 in the Appendix.) It shall provide a uniformly blended material, showing no segregation. All paddles shall be in place and within the manufacturer's requirements for wear.

The mixing chamber shall be equipped with a spray bar to provide uniform water spray to the material during mixing with volume and spray pattern adjusted to ensure that the material will be uniformly at the proper moisture content during compaction. Gates shall lock and not leak during mixing.

To regulate the mixing time, the mixing system in a batch type plant shall be equipped with an automatic timing device that counts in seconds. The automatic timing device is interlocked with the mixing system of the pugmill.

For continuous type plants, to ensure a uniform blend, the feeder system shall be coordinated with the pugmill to match the feed rate to the mixing rate. The mixing rate is the speed at which the pugmill can uniformly mix and discharge the materials. The mixing system shall be arranged to discharge the material completely; no build-up shall occur in the mixing chamber. Material shall be discharged directly into haul trucks.

MATERIAL MEASURING DEVICE

ACCURACY FEED TOLERANCE

Soil/Soil-Aggregate

0.05% (wt)

2% (wt)

Cement

0.05% (wt)

1% (wt)***

Water

1% (vol) 0.5% (wt)

Liquid Additive

3% (wt)

3%

* Individual aggregates and soils within 2% of individual weight.

Total weight of aggregate within 1% of total material weight.

** Must be accurate enough to ensure 2% of optimum at time of compaction.

*** Tolerance for payment adjustment in accordance with Table 301-4 is not affected by this feed tolerance.

CALIBRATION AND FEED TOLERANCES

NOTE

Exceeding the feed tolerances will cause the inspector to require the contractor to discontinue operations. Varying within the limits of the feed tolerances can result in payment adjustments.

Scale and Meters

In order to meet certification requirements, the contractor shall arrange for all plant scales and meters to be calibrated at least every 90 days by the Weights and Measures Division of the

Louisiana Department of Agriculture and Forestry or an approved independent company.

Approved independent companies must be licensed by the Louisiana Department of Agriculture and Forestry. The district laboratory engineer will approve the independent companies for the district.

The calibration of scales and meters shall state that the equipment meets all Department requirements for accuracy. The calibration shall be documented and reported to the district laboratory engineer on the Certification Report for Scales and Meters (DOTD Form No. 03-22-

3065). A reprint of this form is on page A-35 in the Appendix. The technician representing the independent company shall sign and stamp the form with the company's identification and/or attach the company's scale certificate. The technician shall place a dated calibration sticker on each device.

Feed Bin Calibration

When a plant is controlled by feed bins, the contractor shall develop feed bin calibration curves for each type of material, denoting rate of feed expressed in terms of belt speed and gate opening.

These curves shall be submitted to the district laboratory engineer for approval prior to certification inspection. Certification will not be awarded to a plant until these curves are approved. An example of these curves is shown on page A-39 in the Appendix.

ROADWAY EQUIPMENT

Equipment used for construction under Specification Parts II, III, or IV must be approved.

Certification is not required, except for asphalt distributors when specified, and haul trucks traveling public routes. Procedures for the approval of this equipment will be in accordance with this manual. When a Class I, or Class II base course, or treated subgrade layer is asphalt concrete, placement and compaction equipment must be certified. The certification requirements shall be in accordance with Specification Part V (500) and the

Application of Quality Assurance Specifications for Asphalt Concrete Mixtures. When Portland cement concrete is used in lieu of other base course material, placement, compaction, and finishing equipment shall meet the requirements of Standard Specification Section 706.

Haul Equipment

Trucks used to transport embankment and base materials are to be inspected prior to use and daily by project personnel. Trucks that haul material over state or federal roadways shall be weight certified. A reprint of EDSM III.1.1.12 - Haul Equipment Certification is on page A-21 in the Appendix. Trucks shall be capable of hauling without loss of material, excessive drying, or segregation. If necessary, covers may be required to prevent non-uniform moisture contents or loss of fines. Beds shall be smooth metal, clean, with no holes. Extensions shall meet the requirements of EDSM III. 5.1.3. “… Any increase over the original capacity must be accomplished by use of a single increment, securely fastened to the bed by means of bolts or welded metal plates. Nailing will not be acceptable.”

Covers shall be large enough to completely cover the mixture and extend over the sides and ends of the bed, be in good condition with no tears or holes, and be equipped with adequate tie-downs.

Covers are to be large enough to prevent excessive air circulation or the intrusion of rain.

Equipment shall be in good working condition and shall not leak fluids onto the grade or roadway.

When approved equipment fails to meet these requirements, it shall be removed from the project until repairs are made and approval reinstated.

Placement and Spreading Equipment

Class I Base Course shall be placed and spread without segregation and in uniform thickness and fluff to allow for uniform compaction and finish to plan dimensions, cross slope and grade.

The equipment shall leave the material at a uniform moisture content, without excessive drying.

Class I Base Course shall be finished with an approved automatic finishing machine. The approved automatic finishing machine shall be capable of being operated from an erected stringline, and capable of automatically controlling grade and cross slope meeting the applicable requirements of Standard Specification Section V (500). The finishing machine shall leave a smooth surface at proper, uniform grade and cross slope. The finishing machine shall leave no loose material on the surface. The automatic finishing machine shall cut the material across the full width of the roadway without damaging the surface. Cold planers will not be approved.

Compaction Equipment

Rollers for Class I Base Course may be either self-propelled or tractor powered. When vibratory compactive effort is permitted, the rollers shall be capable of independently controlling amplitude and frequency.

When a Class I, or Class II base course or treated subgrade layer is asphalt concrete, placement and compaction equipment must be certified. Equipment shall be in good working condition and shall not leak fluids onto the grade or roadway. When approved equipment fails to meet these requirements, it shall be removed from the project until repairs are made and approval reinstated.

Vibratory compaction equipment shall not be used in areas of excessive moisture, perched water tables, where underlying courses have not been compacted with vibratory equipment, or where the compaction characteristics of the soil are not compatible with vibratory compaction (for example, soils with high silt content are not readily compacted with vibratory equipment.) If the use of vibratory equipment results in damage to the embankment, or underlying support layers, the use of the equipment shall be discontinued immediately. The contractor shall correct damage caused by the improper use of vibratory compaction equipment, as directed, at no direct pay.

Stone, recycled Portland cement concrete, and crushed slag shall be compacted with equipment designed for the compaction of each specific material.

The compaction equipment may be either static or vibratory. The Department reserves the right to require only static compaction equipment when the engineer determines that vibratory compaction may damage the base course or underlying or adjacent materials. (Examples of indications of damage to the base or underlying layers are loss of density, cracking, movement, free water, perched water tables, breaking down compaction in underlying layers due to silty or sandy characteristics, etc.)

The compacted aggregate material shall be finished with pneumatic tire rollers or static, smooth, steel-wheeled rollers as required by the specifications.

Stabilized base course shall be initially compacted with a conventional sheepsfoot roller or a self-propelled tamping foot compactor-type roller. The spikes shall be sufficient in size and number to provide uniform compaction for the full width and depth of the base course. Compaction equipment with smooth wheel vibratory rollers, steel wheel, or pneumatic rollers will not be permitted for compaction. Such equipment will cause lamination and non-uniform compaction, even though the average density may meet specifications. The non-uniform density caused by this equipment will lead to premature failure due to the lack of adequate density in the bottom of the base course.

The compacted stabilized material shall be finished with pneumatic tire rollers. The pneumatic roller shall have an odd number of tires, arranged so that the spaces between one row of tires are covered by the tires of the other row. All tires shall be in place, properly inflated and in good condition, and properly inflated. Tires shall be smooth tread, of the same size and ply, and inflated to within ± 5 psi of each other. A reprint of form DOTD 03-33-3050 - Compaction Equipment Certification is on page A-23 in the Appendix.

Distributors

When prime coat is being applied, the asphalt distributor shall conform to the equipment Standard

Specification Section 503, as required by Standard Specification Section 505. Asphalt distributors used to spray prime coat over the completed base shall be equipped with a spray bar that uniformly sprays the prime coat across the surface and does not apply the prime coat in streams or cause it to puddle on the surface. Clogged nozzles will not be allowed. Asphalt distributors shall be weight-certified, and shall not be loaded in excess of the permitted load limit.

Equipment used to distribute asphalt-curing membrane shall conform to Standard Specification

Section 506. Asphalt distributors spraying asphalt-curing membrane must be equipped for easy determination of the rate of application.

Water trucks are to be equipped with spray bars that uniformly spray water across the surface and do not apply water in streams or cause water to puddle on the surface. Water trucks shall be weight-certified and shall not be loaded in excess of the permitted load limit. Water trucks may be used to spray water over the surface of the completed base during finishing operations and to maintain moisture content only. They are not to be used to apply water directly to the base prior to or during the mixing process. Water trucks are also used to supply water to the in-place mixer. The tank or connections with the in-place mixer are not to leak allowing water to fall directly onto the base course. All spray nozzles must be clean and functioning properly. A reprint of form DOTD 03-33-3050 – Asphalt Distributor Certification is on page A-25 in the Appendix.

In-Place Mixing and Additive Spreader Equipment

The in-place mixer is used to blend and pulverize the base material prior to the incorporation of cement. The equipment used for preliminary blending shall be capable of achieving specification requirements for the pulverization of the untreated base material.

The in-place mixer shall be designed for soil cement construction, shall have sufficient tines, arranged in a configuration that will result in a uniform blend of base material, cement, and water, across the full width of the roadway. It will be equipped with a spray bar system adjustable across the width of the stabilizer box and on each end to prevent overlapping of water from one path to an adjacent path. The spray nozzles shall be equipped with individual cutoffs to block nozzles as necessary to prevent excessive moisture content and overlap of water. Any overlap of water spray leads to excessive moisture in narrow strips, resulting in density problems and early roadway failure. Clogged nozzles shall be immediately cleaned and restored to normal function before operations are continued.

When required by the plans or by the engineer, the cement spreader shall have a mechanically adjustable, calibrated spreader box. The box shall be calibrated to distribute cement at the required cement factor. Equipment that adjusts the rate of spread solely by means of adjusting forward speed is not to be used. The spreader shall be operated to distribute cement over the prepared surface at a uniform rate for the full length and width of the spread, without excessive dusting. The spreader shall be mechanically adjustable for variable spread widths. Excessive dusting also indicates that the minimum cement factor is not being met due to material loss. If the equipment cannot be recalibrated and adjusted properly, replacement will be required. Back-up equipment must meet the same requirements as the primary equipment. If the primary equipment is replaced with the backup equipment and the spreading problem is not corrected, operations will be discontinued until additional equipment is provided, inspected, and approved.

Scarifying Equipment shall be capable of scarifying and blending the full width of the roadway to a minimum depth of six inches or plan depth. All teeth on the Scarifier shall be in place and adequate to break up the existing roadbed into a uniform, compactable material.

LABORATORY AND TESTING EQUIPMENT

Automated Compaction Hammers

Automated compaction hammer will be as described in Standard Specification Section 722.

Verification, by the engineer, of the hammer operation will be conducted on the first day of mixing by comparing automatic compaction results with DOTD calibrated manual rammer results. A typical acceptable variance between maximum dry density results has shown to be approximately ± 2%.

Nuclear Density Gauge

Only an Authorized Density Tester (operator) is to operate a nuclear device. Authorized Density

Testers must complete training, hold a valid radiation dosimeter badge issued by the Materials and Testing Section, and must have a Nuclear Device Operator’s license authorized by the LTRC

Training Section. The radiation dosimeter badge must be worn at all times when transporting, handling, or operating a nuclear device.

Regardless of ownership, each nuclear device used for acceptance testing on a DOTD project shall be approved by the Materials and Testing Section prior to use, and every two years thereafter. This approval includes the evaluation of calibration checks and leak tests. Leak tests are to be performed every six months.

When asphalt cement or other asphalt materials are present and a nuclear device is used to determine in-place density, the moisture content used to determine the dry density shall be obtained by either stove or oven drying, in accordance with DOTD TR 403. When discrepancy occurs between a moisture content obtained with a nuclear device and a moisture content obtained in accordance with DOTD TR 403, the moisture content obtained in accordance with

DOTD TR 403 shall be utilized to determine in-place density.

Soils or soil aggregate mixtures which contain reclaimed asphalt concrete, recycled Portland cement-concrete, cement, lime, fly ash, coal, mica bearing clays, gypsum (calcium sulfates), phosphates or organic matter may cause erroneous moisture readings. Soils or soil-aggregate mixtures containing these materials will require the determination of their actual moisture content in accordance with DOTD TR 403. When a nuclear device operator encounters results that are obviously outside the normal pattern, moisture content determinations shall be performed to identify if an erroneous moisture reading is the cause of the unusual test results. When such a situation occurs, contact the District Laboratory Engineer.

Other Laboratory Equipment

Testing equipment used by the contractor or producer shall be independently certified every ninety days. Equipment that does not normally reside in the plant laboratory (equipment imported for each operation), the LADOTD certified inspector will need to approve the equipment prior to its use through inspection and calibration checking. Any testing equipment not available at the plant during the certification inspection shall be calibrated by an approved independent service prior to use.

PERSONNEL TRAINING AND

CERTIFICATION

The successful completion of all prerequisite training materials is required whenever certification of personnel is required by the specifications. It is imperative that inspectors and QC technicians be thoroughly familiar with Department specifications, policy and procedural documents, and sampling and testing procedures. The project engineer or the district laboratory engineer will approve DOTD QC technicians on the project. Likewise, the contractor will approve their own QC technicians however; both Department and contractor technicians must be certified through the

Department.

Each equipment operator shall be fully knowledgeable of the safety features, limitations, and uses of the machine. The contractor shall require that personal safety equipment be used as appropriate, including the wearing of radiation dosimeter badges by nuclear device operators.

Personnel employed by the contractor to operate equipment shall be properly trained in its operation and be capable of using the equipment to ensure compliance with specification requirements. For example, motor patrol operators shall know how to maneuver the machine and position the blade to obtain a cut that uniformly conforms to grade for the full width and length of the area being shaped. Each operator of compaction equipment shall understand the relationship between the compactive effort of the machine in terms of speed, weight, vibratory impact, number of passes and the material being compacted. It is critical to the proper compaction of soils that compaction equipment be properly operated. Failure to operate compaction equipment properly may cause earthwork not to meet specification density requirements.

GENERAL CERTIFICATION REQUIREMENTS

Basic certification requirements and procedures are published in The Administrative Manual for

Construction Technician Training and Certification. Certification is awarded by the Department upon satisfactory completion of all requirements, including six months on-the-job training in all phases of the certification area, successful completion of required training courses, and successful completion of certification testing. Arrangements for enrollment in the certification program and testing are made through the LADOTD district training office. The DOTD Materials

Engineer Administrator is the certifying authority for the Department. He has full authority to grant or to revoke certification. Any individual certified under this program who is performing substandard work will be removed from the project and is subject to having certification revoked.

Proceedings to revoke certification can be initiated by the district training specialist, district laboratory engineer, project engineer, or area engineer and will be processed in accordance with current Department procedures.

CERTIFIED PERSONNEL

Department

A certified DOTD inspector is required to be present at the jobsite during all phases of construction.

Certified inspectors are official representatives of LADOTD. They have the authority to accept or reject materials and project construction and have the responsibility to discontinue operations whenever the project does not meet Department standards or when improper construction…