TE-07 Quality Management Plans 5 June 2025.pdf

United States Army Garrison Dugway Proving Ground

Technical Exhibit 07 Paving IDIQ Contract – Quality Management Plans

Directorate of Public Works

5 June 2025 kim.v.petersen Underline

Part 8 – Materials Manual July 2003

Quality Assurance – Appendix C 1

SUMMARY

502 - Cement 503 - Reinforcing Steel Epoxy Coating 504 - Reinforcing Steel 506 - Ready Mix Concrete 507 - Fly Ash and Pozzolan 508 - Asphalt Emulsion 509 - Asphalt Binder 510 - Hydrated Lime 511 - Concrete Pumping 512 - Reinforced Steel Galvanize Coating 513 - Pavement Making Paint 514 - Hot-Mix Asphalt

Quality Management Plan Cement

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502 Cement Quality Management Plan

502.1 Introduction

502.1.1 The purpose of the Cement Quality Management Plan is to establish the procedures for becoming pre-qualified as a source of cement for the Utah Department of Transportation. The Management Plan is to assure the Utah Department of Transportation that cement manufacturers are capable of producing and furnishing quality cement.

502.2 Procedures for the Establishment of a Qualified Source of Cement.

502.2.1 Applicants shall submit to the Central Materials Testing Lab (CMTL) Engineer a letter requesting it be designated as a qualified source. The letter shall include the following:

(a) Certify the plant maintains a quality control program.

(b) Certify each type cement for which it requests be designated as a qualified source meets or exceeds the current ASTM C- 150 requirements.

(c) Name, position, address, and telephone number of an individual at each production location who may be contacted for data, shipping information , and to whom reports of tests shall be directed.

(d) Signed by a representative of the producer having legal authority to bind the company.

502.2.2 The producer requesting status as a qualified source agrees to provide the UDOT with the following:

(a) A brief outline of the procedures used to evaluate the finished product including; sampling and testing frequency and the sample preparation employed. Also include chemical analysis methods used such as X-ray, atomic absorption spectroscopy and/or wet chemistry.

(b) Submit copies of the inspection reports for each inspection by Cement and Concrete Reference Laboratory (CCRL) .

(c) As requested the results of all applicable chemical and physical tests required by ASTM C-150 on the most recent 40 samples (20 pairs) tested per type. The results shall be submitted in the format outlined in ASTM C-183 in particular the table entitled "Test Data" with the critical limits calculated as described. When the source is to be qualified for cement meeting specific optional requirements (alkali, false set, heat of hydration), test data for these properties shall be provided, critical limits calculated, and quality history charts prepared. The producer may submit data on additional pairs of samples to update the quality history and indicate new critical limits at any time.

(d) A copy of the manufactures quality control plan.

502.3 Acceptance of a Producer as Qualified Source.

502.3.1 The CMTL Engineer or his representative will evaluate the information and data submitted as outlined in section 502.2. A determination from this information will be the basis for acceptance as a qualified source.

502.3.2 The producer will be advised in writing of acceptance as a pre-qualified source by the CMTL Engineer. Designation of a plant as a qualified source will be made separately for each type of cement. An updated list of producers indicating the types of cement for which each is a qualified source will be maintained by the CMTL and made available to authorized agencies and producers as requested.

502.4 Removal of a Producer from the Qualified Source List.

502.4.1 A producing plant may be removed from the list of qualified sources for a type of cement if test results of any two consecutive samples of that type fail to conform with any specification property; or if an individual project sample fails to meet the requirements of the project specifications.

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502.4.2 A producing plant may also be removed for failure to submit data as requested as described in paragraph 502.2.2 C.

502.4.3 Prior to removing a plant from the list of qualified sources, the CMTL will take appropriate measures to confirm the validity of the sampling procedures that yielded the results. The CMTL will in addition confer with the manufacturer.

502.4.4 Failure to conform with Section 502.6.

502.4.5 The manufacturer will be advised immediately by telephone followed by written notice from the CMTL of disqualification as a source. Test data and/or field performance data will be provided to indicate the cause for such action.

502.4.6 Each manufacturer’s cement type will be removed from the qualified source list and the manufacturer will be required to re-apply as a qualified source for that type if it is not supplied to a UDOT controlled project within a 12 month period.

502.5 Procedures for Reinstatement to Qualified List.

502.5.1 Once a plant is removed from the qualified list as a source of a type of cement, a producer may gain reinstatement in the following manner:

(a) Submit a written request to the CMTL Engineer requesting such action. This request shall present reasons why it is to be anticipated that the circumstances that led to removal will not be expected to recur.

(b) If requested, provide the CMTL with samples of current production for test and evaluation.

(c) If the data provided indicate the reasons that led to removal are not expected to recur, the CMTL Engineer will reinstate the plant to the list of qualified sources for that type of cement in writing.

502.6 Procedures for Maintaining a Qualified Source of Cement

502.6.1 The plant and terminal facilities of a producer participating in this program will be visited on a random basis by a representative of the CMTL in order to achieve the following:

(a) Review of procedures employed, project requirements and guidance in the functional procedures of the program.

(b) Promote better understanding and good working relationships between the UDOT, CMTL and the manufacturer.

(c) Give the CMTL an opportunity to maintain current knowledge of production and storage facilities of the cement mills and terminals.

502.7 The Qualified Source of Cement Agrees to Provide the UDOT with the Following:

(a) Obtain a minimum of two split samples per month of each cement type. Ship one part of the split sample to the CMTL engineer and retain the other half of the split for chemical and physical testing. The manufacturer will present chemical results to the CMTL within 24 hours after the split is made. Failure of the producer to conform with ASTM C-150, ASTM C-183, or this procedure, shall disqualify the manufacturer.

502.8 Project Samples.

502.8.1 Cement from a qualified manufacturer delivered to the project site or concrete producing plant may be sampled by a representative of UDOT anytime a material is suspect. The procedures for taking project samples will be in accordance with ASTM C-183 to insure that the material sampled represents material shipped. When the test results of any two consecutive samples of that type exceed the limit for any applicable specification property, an increased in sampling intervals as determined by CMTL can and/or will occur.

Quality Management Plan 503 Reinforcing Steel Epoxy Coating

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503 Reinforcing Steel Epoxy Coating Quality Management Plan

503.1 Introduction

503.1.1 The purpose of the Reinforcing Steel Epoxy Coating Quality Management Plan is to establish the procedures for becoming pre-qualified as a source of epoxy coated reinforcing steel. The Management Plan is to assure the Utah Department of Transportation:

(a) Epoxy coating applicator plants are capable of applying quality epoxy coatings on reinforcing steel.

(b) Fabricators of epoxy coated reinforcement are capable of producing a quality product.

503.2 Pre-qualifications for Reinforcing Steel Epoxy Coating Applicators and/or Fabricators.

503.2.1 Submit a letter to the Concrete Engineer requesting designation as a qualified source. The letter will include:

(a) Proof the applicator plant producing the epoxy coated steel used in fabrication is currently certified as an Epoxy Coating Applicator Plant by the Concrete Reinforcing Steel Institute (CRSI).

(b) An Agreement to meet UDOT’s Standard Specifications, including AASHTO M-284.

(c) The name and phone number of the Quality Control Director at each production location who may be contacted for data, shipping information, and to whom reports of UDOT’s verification tests shall be directed.

(d) A signature by a representative having legal authority to bind the company.

503.2.2 The Epoxy Coating Applicator and/or Fabricator agrees to:

(a) Meet UDOT’s Standard Specifications, including AASHTOM-284.

(b) Submit CRSI inspection grade sheets and notes to the Concrete Section within seven calendar days of receiving the results.

(c). Make available to the Concrete Engineer or representative the plants quality control sampling and testing records when requested.

(d) Fax UDOT’s certificate of compliance form and mill test reports before each shipment to UDOT specification controlled projects to:

Engineer for Concrete Calvin Rampton Complex, MTF Building 4501 South 2700 West Salt Lake City, Utah 84119 Phone Number: 1-801-965-3814 Fax: 1-801-965-3843

(e) Any steel on which the epoxy coating is applied is required to be from a UDOT pre-qualified source as per UDOT’s Quality Management Plan: 504 Reinforcing Steel. A list of current UDOT Pre-Qualified Reinforcing Steel Manufactures may be found at http://www.udot.utah.gov/go/materials under Prequalified Suppliers.

503.2.3 Notification of acceptance as a Pre-Qualified Reinforcing Steel Epoxy Coating Applicator and/or Fabricator will be made in writing by the Concrete Engineer.

http://www.udot.utah.gov/go/materials

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503.3 UDOT Verification Sampling and Testing Inspections

503.3.1 The frequency of verification testing and inspections shall be determined at the discretion of the Concrete Engineer. Any materials found not meeting UDOT’s Standard Specifications will be rejected and an accelerated testing program will be put into effect.

503.3.2 Once an Applicator and/or Fabricator has been put on notice for compliance violations for not meeting UDOT’s Standard

Specifications or any rejected incident is recorded, an in-plant inspection program will be put in place by the Concrete Engineer. This inspection will be conducted a minimum of once a quarter for one year. The inspection will include an evaluation of product compliance with specifications. If an applicator and/or fabricator can not meet the standards set by UDOT, the applicator and/or fabricator may be disqualified as a source by the Concrete Engineer.

504 Reinforcing Steel Quality Management Plan

504.1 Introduction

The purpose of the Reinforcing Steel Quality Management Plan (QMP) is to establish the procedures for becoming pre-qualified as a supplier of reinforcing steel bar and mesh. The Management Plan is to assure the Utah Department of Transportation that reinforcing steel manufacturers are capable of producing quality materials. Only materials produced by a pre-qualified supplier will be accepted and certified for UDOT use. UDOT utilizes the National Transportation Product Evaluation Program (NTPEP) for qualification and verification testing of reinforcing steel.

504.2 Pre-qualifications for Reinforcing Steel Manufacturers

504.2.1 Applicants shall submit to the Concrete/Steel Engineer, a letter requesting that it be designated as a pre-qualified supplier.

The letter will include the following:

a) Name and phone number of the Quality Control Director at each production location who may be contacted for data, shipping information, and to whom reports of UDOT’s comparison tests will be directed.

504.2.2 The manufacturer shall contact the Concrete/Steel Engineer to arrange for the required sampling and testing as outlined in section 4.3 of this QMP. The manufacturer will make all necessary plant test records and manuals available to the Concrete/Steel Engineer or representative, when requested. The Concrete/Steel Engineer may choose to forgo the pre-qualification sampling and testing based upon qualification tests performed by NTPEP or transportation agencies of other states.

504.2.3 The Reinforcing Steel Manufacturer agrees to:

a) Meet or exceed UDOT’s Standard Specifications, and follow all quality control requirements outlined in the applicable ASTM and AASHTO specifications.

b) Include certified mill test reports representing each heat number with each shipment. Each bundle of reinforcing steel is to be tagged with a plastic or metal tag which lists the plant name and the heat, job or mill order number.

They must attach the tag to each bundle with a plastic or metal strip seal.

c) Certify that all reinforcing steel is domestic and meets the requirements of Title 23 U.S. Code of Federal

Regulations, Part 635.410 Buy America Requirements and UDOT Special Provision 01455M for the 2008 Standard Specification and 2012 Standard Specification 01455.

d) Submit to inspections by UDOT or its representative if requested to verify that the approved production QC procedures are being followed.

e) Have a written company quality control (QC) policy statement and a QC manual. A copy of the QC policy statement and Quality Systems manual shall be sent to UDOT’s Concrete/Steel Engineer. Have a designated Quality Inspector present on every work shift having authority to fully enforce the QC procedures. Provide adequate training to familiarize all pertinent employees with the company’s QC procedures. The quality systems manual must be approved by UDOT’s Concrete/Steel Engineer prior to acceptance as a pre-qualified manufacturer. Periodically review and update the manual as necessary. Revisions and updates of the manual will be reviewed and approved under the annual NTPEP audits. .

504.2.4 The QC manual must include the following:

a) Management responsibilities. The responsibility, authority and the interrelation of all personnel who manage, perform and verify work affecting quality shall be defined - particularly for personnel who need the organizational freedom and authority to initiate action to prevent the occurrence of product nonconformity as well as those who identify and record any product quality problems, or those who initiate, recommend or provide solutions through designated channels and control further processing of nonconforming materials.

b) Quality Control Requirements. Shall identify in-house quality control requirements, as well as provide adequate resources and assign trained personnel for quality control activities. Quality control requirements shall include inspection, testing and monitoring of the product to ensure the requirements of UDOT specifications are met.

c) Notification of acceptance as a Pre-Qualified Reinforcing Steel Fabricator will be made in writing by the Concrete/Steel Engineer.

504.3 Sampling and Testing Requirements

504.3.1 Sampling Procedure. Annual sampling and testing will be conducted by NTPEP in accordance with procedures for reinforcing steel.

504.3.2 At the request of the Concrete/Steel Engineer, UDOT may also conduct verification testing. The lot of material subject to UDOT sampling can include all sizes, grades and heats in stock, UDOT samples will be taken from three different bars from each of 10 different heats Each sample bar will be tagged on both ends with the same identification number. Each identification number will be unique. Two specimens will be made by cutting the bar into two equal lengths.

UDOT Sample Testing If UDOT testing is requested, the test methods will be in accordance with AASHTO, ASTM and UDOT Standard specifications. One specimen from each sample will be tested by the manufacturer’s laboratory utilizing test equipment which will be maintained in good working order and will have been calibrated within the preceding 12 month period by a qualified testing agency. The manufacturer’s test results will be entered on a form provided by the Concrete/Steel Engineer. The form will be signed by a representative of the manufacturer and submitted to the Utah Department of Transportation’s Concrete and Steel Section The remaining specimen from each sample will contain the markings normally used by the producer and will be sent to the UDOT’s Concrete and Steel Section to test for compliance with section 504.3.3 of this document. All shipping costs to send the test specimens will be borne by the manufacturer.

Ship Samples to:

Attn: Concrete/Steel Engineer UDOT Materials Lab 4501 South 2700 West PO Box 145950 Salt Lake City, Utah 84114-5950 Phone: 1-801-965-3814 Fax: 1-801-965-3843

504.3.3 UDOT Testing Requirements. If verification testing is conducted by UDOT, the manufacturer is required to meet the following requirements in order to obtain or maintain an approved plant status. Statistical analysis will be made to compare results obtained by the manufacturer with UDOT results. The comparisons will include both F-test and t-test methods, which will compare variances and the difference in means of the results, respectively. Both tests will be conducted at a level of significance of alpha equal to 0.01. This is to minimize the likelihood of incorrectly concluding that the test results are different when they are not. The comparisons will be for each of the following: yield strength, tensile strength and percent elongation. If, F Fcrit, then the conclusion will be that the manufactures and UDOT’s results vary significantly. If t tcrit, then the conclusion is that the means are significantly different. When test result comparisons show the variance in t tcrit the manufacturer will not qualify as a pre-qualified source. Results that show the variance in F Fcrit, will be evaluated on a case by case basis to determine a manufacturers pre-qualification status. The manufacture may investigate and if it is determined that their testing was in error, a letter shall be sent to the Concrete/Steel engineer indicating what corrective action has been made. Upon review and approval of the corrective actions, more samples may be obtained as prescribed in section 504.3.2 and re-evaluated as per this section..

504.3.4 Maintenance of Pre-Qualification Status. A pre-qualified manufacturer’s status will be in effect for a 12-month period unless the manufacturer is removed from pre-qualified status under conditions of this QMP. A disqualified manufacturer that has been removed from an approved status may regain pre-qualification status at the next annual NTPEP inspection, provided requirements for pre-qualification are met. A manufacturer that has been removed from pre-qualified status, may request a re-test for pre-qualification status prior to the annual renewal inspection provided it can demonstrate that the causes of the deficiencies have been remedied. A manufacturer will be notified in writing of any change in plant status. A list of pre-qualified manufacturers will be maintained by the UDOT Concrete/Steel Section.

504.3.5 A Manufacturer will be removed from the qualified supplier list and be required to re-apply as a qualified source, if not participating in NTPEP annual audits or due to failure of NTPEP audits or UDOT verification testing.

Quality Management Plan __________________________________ Ready-Mix Concrete

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506 Ready-Mix Concrete Quality Management Plan

506.1 Introduction

The purpose of the Ready-Mix Concrete Quality Management Plan (QMP) is to establish procedures for becoming pre-qualified as a supplier of ready-mix concrete. The QMP is to assure the Utah Department of Transportation (UDOT) that permanent and portable ready-mix concrete batch plants are capable of producing a quality ready-mix concrete product. Only pre-qualified batch plants will be allowed to supply to UDOT projects.

506.2 Pre-qualifications for Ready-Mix Suppliers

Applicants will request in writing to be designated as a pre-qualified supplier. Request will be addressed to:

UDOT Concrete Engineer 4501 South 2700 West Salt Lake City, Utah 84119 Phone Number: 801-965-3814

Request will include:

• Copy of Certification from National Ready Mixed Concrete Association (NRMCA) batch plant certification program.

• Name and phone number of the Quality Control Manager (QCM) for scheduling of inspections and general information.

• Signature of a representative having legal authority to bind the company.

Notification of pre-qualification as a Ready-Mix Concrete supplier will be made in writing by the Concrete Engineer.

506.3 Ready-Mix Supplier agrees to:

• Meet or exceed UDOT’s Standard Specifications, including all applicable AASHTO and ASTM specifications.

• Make available to the Concrete Engineer or representative all records required by this QMP when requested.

• Submit to a minimum of one batch plant inspection per year in order to maintain qualification.

506.4 Concrete Unit Plant Inspection Program

• Suppliers will pass an inspection performed by Central Materials before acceptance as a pre-qualified batch plant. Portable batch plants must be inspected each time they are moved.

• Failure to meet one or more of the requirements listed in this QMP may result in an accelerated inspection program. Any additional failures to meet these minimum requirements will result in the suspension of the plant as a pre-qualified supplier until all documented deficiencies are corrected. The supplier may be reinstated as a pre-qualified supplier after a mandatory review of the supplier’s QC program.

506.4.1 Concrete Unit Inspector Guidelines:

Initial pre-qualification inspection is scheduled at the request of the supplier. Subsequent inspections are coordinated with the Central Materials inspector and supplier. Upon completion of the inspection the Concrete Engineer will recommend one of the following:

a) Qualification as a pre-qualified Ready-Mix concrete plant.

Quality Management Plan Ready-Mix Concrete

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b) Not qualified as a pre-qualified plant. The inspector will submit a written report to the supplier outlining all deficiencies observed during the plant inspection process. The supplier is required to address all deficiencies noted in the inspector’s report, at which time the supplier may request another pre-qualification inspection.

506.4.2 Inspector Check List:

a) Verify current NRMCA batch plant certification.

b) Verify aggregate source suitability.

c) Examine and review the distribution of the plants QC Policy Statement and manual.

d) Review QC training records.

e) Review the plant records to confirm that a Quality Inspector (QI) has been assigned to each work shift and has signed the inspection checklist.

f) Interview the person(s) responsible for QC policies and procedures.

g) Verify the QI lines of authority.

h) Examine the plant’s equipment certification records.

i) Examine the plant’s agitating ready-mix truck inspection records.

j) Inspect testing equipment for damage and ensure all equipment is in good repair.

k) Verify UDOT TTQP Qualification of supplier or contract laboratory.

l) Verify production QC testing records are being maintained.

506.5 Batch Plant Quality Control Policies and Procedures

The supplier will provide adequate training for all QC personnel in the company’s QC procedures and supply each Quality Inspector (QI) with a copy of the company QC Policy Statement, and QC manual including, at a minimum, the plant certification technical criteria set forth in this document. The supplier will have a designated QI present on every work shift. The QI will have the authority to enforce the procedures.

506.6 Batch Plant QC Procedure Requirements:

The Supplier will:

• Develop, review, and update as necessary, a company QC policy statement and manual. The QC manual must be approved by the Concrete Engineer before acceptance as a pre-qualified supplier. The QC manual shall contain, at a minimum, all requirements listed in the NRMCA’s “Ready Mixed Concrete Quality Control Guide.”

• Designate a QI for every work shift. The QI must be TTQP Concrete Field Technician certified and have a minimum of six (6) months experience working in a ready-mix concrete batch plant and an ACI Self- Consolidating Concrete Technician certified if the plant produces a UDOT-approved SCC mix. The QI must be present while the batch plant is producing concrete for UDOT projects.

• Conduct meetings with the QCM and designated QI’s, a minimum of once every three months to review the company’s QC procedures, discuss possible changes and implement any procedural changes.

• The QCM or designated representative will review and evaluate the QC techniques of all QI’s once every six months to assure compliance with QA Section guidelines and certification procedures.

• Submit to a minimum of one plant inspection each year by a Central Materials Inspector.

• Address and document each deficiency noted in the inspection reports and conduct monthly follow-up meetings for a period of three (3) months to assure compliance.

506.7 Required QC Records:

Supplier will keep records of the following:

• QC testing performed at a frequency consistent with approved Quality Control Plan.

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• Approved mix designs, trial batch test results and aggregate source suitability updated yearly.

Aggregate source suitability shall be consistent with UDOT Standard Specification 03055 Portland Cement Concrete. Aggregate source suitability will include an evaluation of aggregate reactivity in accordance with AASHTO M 6 and AASHTO M 80, with the exception that ASTM C 289 is not an acceptable evaluation of aggregate reactivity. If an aggregate source has been shown through previous testing to be reactive submit test results verifying mitigation through approved AASHTO/ASTM test methods. Aggregate reactivity evaluations are not required for lightweight aggregates defined by

AASHTO M 195.

• Manufacturer’s Certificate of Compliance for all admixtures.

• QCM and QI current TTQP Qualifications, verification of experience, and QC training records.

• Submit to a minimum of one plant inspection each year.

• A written “new employee” training and/or orientation policy in the company files.

• Copies of the plant’s QC Policy Statement and QC Manual on file.

• Proof of current NRMCA certification.

• Complete inspection checklist signed by the QI for each work shift.

• Minutes of meetings of the QCM and QC personnel.

• QCM evaluation of the QI performance.

• Comprehensive reports signed by the QCM that detail the plants response and follow-up to each specified deficiency documented during inspection.

506.8 Equipment Certification Requirements:

• Maintain certification of beams, scales, water meters, moisture probes, and admixture dispensers as per UDOT Standard Specifications.

• Maintain certification of concrete testing equipment as per AASHTO Specifications.

• Remove broken or malfunctioning equipment from service immediately and replaced with new or repaired/recertified equipment.

• Use only UDOT qualified laboratories for concrete compressive strength tests.

• Conduct yearly inspections of all ready-mix trucks in accordance with NRMCA guidelines and maintain a file of current ready-mix truck inspection documents.

• Required Records:

i. Comprehensive reports signed by the QCM that detail the plants response and follow-up to each specified deficiency documented during a Concrete Unit Inspection.

506.9 Production Delivery Requirements:

Each load of ready-mix concrete delivered to a state project shall be accompanied by the following information printed on an appropriate form. Hand written forms will not be accepted:

• Target water/cement ratio (w/c)

• Quantity of cementitious material used (lb)

• Target quantity of water based on w/c (lb or gal)

• Quantity of water actually used (lb or gal)

• Aggregate source

• Weights of coarse and fine aggregates (lb)

• Moisture content (as batched) of coarse and fine aggregates (%)

• Batching time

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506.10 Volumetric Concrete Mixer Certification:

NOTE: The following section outlines the certification process for volumetric concrete mixers. It does not imply that this equipment is acceptable for all uses. Volumetric concrete mixers may not be used without the approval of the Region Materials Engineer and the Resident Engineer.

Volumetric concrete mixers supplying UDOT projects require an annual inspection and certification. A UDOT inspector or representative will verify compliance with the following (See Appendix A checklist for tolerances):

• Verify VMMB rating plate 100-1 affixed to the mixer or comparable calibration and uniformity testing records.

• Verify certification of the scale used for equipment calibrations. Certification must be conducted by an independent qualified expert.

• Verify bin condition and accuracy of cementitious delivery system. Verification of the delivery system must be by an independent calibration company.

• Verify through an independent calibration company the accuracy of the aggregate delivery system.

• Verify through an independent calibration company the accuracy of the water delivery system.

• Verify that admixture storage tanks are protected from freezing and contamination. Verify through an independent calibration company the accuracy of the admixture delivery system.

• Perform Uniformity of Batching tests according to Appendix A and provide results from an independent laboratory meeting the requirements of Appendix A, Table 1.

• Each mobile unit shall maintain and provide records of material delivered as described in Appendix A.

The UDOT inspector or representative will sign and affix a sticker with an expiration date certifying the mixer for use when approved.

Quality Management Plan 507 Fly Ash and Pozzolan

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507 Fly Ash and Pozzolan Quality Management Plan

507.1 Introduction

The purpose of the Fly Ash and Pozzolan Quality Management Plan is to establish the procedures for becoming pre-qualified as a source of these materials by establishing qualified sources and verifying the compliance of materials shipped from these sources with specification requirements.

Applicable Specifications

• Utah Department of Transportation (UDOT), Standard Specifications.

• ASTM C-618 Fly Ash and Raw or Calcined Natural Pozzolan For Use as a Mineral Admixture in Portland Cement Concrete.

• ASTM C-311 Methods of Sampling and Testing Fly Ash of Natural Pozzolan for Use as a Mineral

Admixture in Portland Cement Concrete.

507.2 Procedure for Establishment as a Qualified Source of Fly Ash and/or Pozzolan.

The manufacturer will request that a producing plant be designated a qualified source by submitting to UDOT’s Central Materials Testing Lab (CMTL) Engineer, a letter certifying the following:

• The manufacturer maintains a quality control program. The letter will give the name, position, address, and telephone number of an individual at each production location who is responsible to the manufacturer for quality control of the material being shipped to UDOT projects. It must be signed by someone having legal authority to bind the company.

• Meets current UDOT specification requirements.

• Quality control laboratory is AASHTO accredited through the Cement and Concrete Reference

Laboratory(CCRL).

507.2.1 The Manufacturer requesting status as a qualified source agrees to provide the QA Engineer the following:

• A brief outline of the procedures used to evaluate the finished product, sampling and testing frequency, test sample preparation employed, physical testing and chemical analysis methods used such as X-ray, atomic absorption spectroscopy, or wet chemistry.

• A copy of the inspection report for each CCRL inspection.

• A one year history of the chemical and physical data showing compliance with requirements of ASTM C-

311 & ASTM C-618.

• Monthly, composite sample results for all applicable chemical and physical tests required to satisfy the requirements of ASTM C-311 & C-618.

• Monthly, one set of data used to establish uniformity requirements of ASTM C-618.

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• Yearly, a list of distributing terminals and marketing points served by each Manufacturer, ie Silos, Ready Mix Plants. Include location, address, contact person & phone number.

507.3 Acceptance as a Qualified Source

507.3.1 Acceptance as a qualified source will be made in writing by the CMTL Engineer, based on the requirements of this management plan.

507.3.2 Designation of a plant as a qualified source will be made separately for each type of fly ash and/or Pozzolan.

507.4 Responsibilities of the Project Engineer.

507.4.1 Request a letter from UDOT’s CMTL Engineer that verifies the fly ash/pozzolan to be used on the project is from a pre-qualified source.

507.5 Responsibilities of UDOT’s CMTL Engineer.

• Qualify the source.

• Maintain a current file on each source including the required data that is sent.

• Conduct verification sampling and testing in accordance with UDOT’s Minimum Sampling and Testing Requirements.

507.6 Manufacturer Disqualification.

507.6.1 A producing plant may be removed from the list of qualified sources if results of tests of any two consecutive check samples do not comply with the uniformity requirements. Qualification may be discontinued for one type of fly ash and/or pozzolan without changing the status of other types.

507.6.2 A producing plant may be removed from the qualified source list if results from random sample testing do not conform with UDOT standard specifications.

507.6.3 A production plant may also be removed for failure to submit qualifying data monthly as requested.

507.6.4 A Manufacturer may be removed from the qualified source list for failure to maintain all of the requirements necessary to become an approved source.

507.6.5 A Manufacturer will be removed from the qualified source list and be required to re-apply as a qualified source, if not supplying to a UDOT controlled project within a 12 month period.

507.7 Procedures for Maintaining a Qualified Source of fly ash and/or pozzolan.

507.7.1 The power plant, batch plant, project site and terminal facilities of the suppliers participating in this program will be visited periodically by the CMTL Engineer or representative, to review procedures employed, project requirements, and provide guidance in the functional procedures of the program. They shall be afforded free access to any facility using, production or testing fly ash and/or pozzolan for UDOT projects.

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507.8 The Qualified Source of fly ash and/or pozzolan Agrees to Provide the UDOT with the Following:

• Obtain a minimum of two split samples per month of fly ash and/or pozzolan. Ship one part of the split sample to the CMTL engineer and retain the other half of the split for chemical and physical testing. The manufacturer will present chemical results to the CMTL within 24 hours after the split is made. Failure of the producer to conform with ASTM C-311, ASTM C-618, or this procedure, shall disqualify the manufacturer.

507.9 Project Samples.

507.9.1 Fly ash and/or pozzolan from a qualified manufacturer delivered to the project site or concrete batch plant may be sampled by a representative of UDOT anytime a material is suspect. The procedures for taking project samples will be in accordance with AASHTO and UDOT standard specifications to insure that the material sampled represents material shipped. When the test results of any two consecutive samples exceed the limit for any applicable specification property, an increased in sampling intervals as determined by CMTL Engineer can and/or will occur.

Quality Management Plan 508 Asphalt Emulsion

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508 Asphalt Emulsion Quality Management Plan

508.1 Introduction

The Asphalt Emulsion Quality Management System (AEQMS) is intended to provide the Utah

Department of Transportation with a quality assurance program for Cationic and Anionic Slow, Medium, Quick, and Rapid Setting Asphalt Emulsions and Asphalt Rejuvenating Agents: type B, C, and D by establishing qualified sources of these materials and verifying the compliance of materials shipped from these sources with specification requirements.

508.2 Procedures for the establishment of a qualified supplier of liquid asphalts.

508.2.1 The producer will request their producing plant be designated a qualified source by submitting a letter certifying they maintain a quality control program for the plant and that each grade of emulsion to be utilized meets the current AASHTO M-140 and M-208 and/ or applicable UDOT specification requirements. Producers of Type B modified rejuvenating agents shall also certify that the base stock used in its manufacture contains a minimum of 15 % by weight of Gilsonite ore. The letter requesting qualification as a source shall be signed by a representative of the producer having legal authority to bind the company. The letter will give the name, position, address, and telephone number of an individual at each production location who may be contacted for data, shipping information, and to whom reports of tests shall be directed.

508.2.2 The producer requesting status as a qualified source agrees to provide UDOT with the following:

508.2.2.1 A brief outline of the procedures used to evaluate the finished product, and an outline of the sampling and testing frequency.

508.2.2.2 Evidence that the laboratory that produced the quality control test data is inspected on each inspection tour of AASHTO re:source and is accredited in the applicable quality control test methods, by submission of the On-Site Assessment Reports.

508.2.2.3 The results of all tests specified by AASHTO M-140, M-208 and/or applicable UDOT specifications on the most recent 20 samples (10 pairs) tested per grade manufactured shall be submitted in a format that includes: Test data, calculated critical limits for each property, and prepared quality history charts. The quality history charts shall be updated yearly and submitted along with new critical limits.

508.2.2.4 Data on the most recent 10 pairs as described in paragraph 508.2.2.3 every six months.

508.2.2.5 A copy of the quality control plan.

508.3 Acceptance of a producer as a qualified source.

508.3.1 UDOT’s Asphalt Specialist Engineer will evaluate the information and data submitted as outlined. A determination from this evidence that an acceptable quality history and hence a quality control program exists will be the basis for acceptance as a qualified source.

June 10, 2020 Page 2 of 3

508.3.2 The producer will be advised in writing of acceptance. An updated list of emulsion producers indicating the grades of asphalt emulsion for which each is qualified will be maintained by the

UDOT Asphalt Specialist Engineer and made available to authorized agencies and producers.

508.4 Removal of a producer from the qualified source list.

508.4.1 A producing plant may be removed from the list of qualified sources for a grade of emulsion if results of UDOT tests of any two consecutive samples, from the producing plant, of that grade fails to conform with any specification property or if an individual project sample fails to meet the requirements of the project specifications.

508.4.2 A producing plant may also be removed for failure to submit data every six months as described in 508.2.2.4.

508.4.3 Before removing a plant from the list of qualified sources UDOT will take appropriate measures to confirm the validity of the sampling procedures and the representativeness of the sample or samples that yielded the results. UDOT will confer with the producer.

508.4.4 The producer will be advised immediately by telephone. The action will be documented by written notice of the removal. Test data or field performance data or both will be provided to indicate the cause of the action.

508.5 Procedures for reinstatement to a qualified list.

Once a plant is removed from the qualified list as a source of a grade of emulsion, a producer may gain reinstatement in the following manner:

508.5.1 Submit a written request to the UDOT Engineer for Materials, requesting such action.

This request shall present reasons why it is anticipated that the circumstances that led to removal will not recur.

508.5.2 If requested, provide UDOT with samples of current production for test and evaluation.

508.5.3 If the data provided in paragraphs 508.5.1 and 508.5.2 indicate that the reasons that led to removal are not expected to recur, UDOT will reinstate the plant to the list of qualified sources of that grade of emulsion.

508.6 Inspection of producer facilities.

The plant and terminal facilities of a producer participating in this program will be visited monthly during production of emulsion, by a representative of UDOT to review procedures employed, project requirements, product quality history charts, and provide guidance in the functional procedures of the program. Specifically, the quality history charts for emulsified Type B Modified Rejuvenating Agent shall include the following: weight of Gilsonite used as reflected by supplier bills of lading, base stock batch number, corresponding emulsion batch numbers made from the base stock, test results, quantities

June 10, 2020 Page 3 of 3 of base stock and emulsion made. These quantities must reflect that a minimum of 15% Gilsonite by weight of the base stock was used in the manufacture of Type B Modified Rejuvenating Agent. These visits will be conducted to promote better understanding and good working relationships between the laboratory and the producer company officials and to afford the laboratory an opportunity to maintain knowledge of production and storage facilities of the producing plant.

The visiting UDOT inspector shall take one sample of each grade of emulsion being supplied at the time of the visit. The producer will split the sample. UDOT and the producer will compare results. The producer’s test results shall be provided to the UDOT inspector within 48 hours after the split is made.

Failure of the producer to conform with AASHTO M-140 and M-208 and/or applicable UDOT specifications, or this procedure shall disqualify the producer.

508.7 Samples

Emulsions from a qualified source delivered to the project site may be sampled at any time by a representative of UDOT and forwarded to the Materials Division for testing. Samples shall be sent to the

Materials Division in sealed, one-quart plastic bottles and identified as follows:

1. Project name and number

2. Source of emulsion (manufacturer)

3. Bill of lading number

4. Grade and specification

5. Date delivered to project

6. The problem, if any, for the check/test sample shall be described.

The procedures for taking project samples will be in accordance with AASHTO T-40 to insure that the material submitted to UDOT represents material shipped from the qualified source.

Quality Management Plan Asphalt Binder

May 6, 2019 Quality Management Plan 509 Page 1 of 10

509 Asphalt Binder Quality Management Plan

509.1 Scope

This standard specifies requirements and procedures for a certification system that is applicable to all suppliers of performance graded asphalt binders (PGAB). The requirements and procedures cover materials manufactured at refineries and/or materials.

This standard may involve hazardous materials, operations, and equipment. It does not purport to address all of the safety problems associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

509.2 Referenced Documents

AASHTO Standards:

M 320 Specifications for Performance Graded Asphalt Binder

R 18 Establishing and Implementing a Quality System for Construction Materials Testing Laboratories

R 26 Certifying Suppliers of Performance-Graded Asphalt Binders

R 29 Practice for Grading or Verifying the Performance Grade of an Asphalt Binder

T 40 Sampling Bituminous Materials

T 301mod Elastic Recovery Test of Bituminous Materials by means of a Ductilometer

ASTM Standards:

D 8 Terminology Relating to Materials for Roads and Pavements

D 3665 Practice for Random Sampling of Construction Materials

509.3 Terminology

Asphalt Binder:

Asphalt based cementitious material that is produced from petroleum residue either with or without the addition of non-particulate organic modifiers to add quality and consistency for direct use in the manufacture of bituminous pavements.

ASC: Approved Supplier Certification

PGAB: Performance Graded Asphalt Binder

DSR: Dynamic Shear Rheometer

BBR: Bending Beam Rheometer

Supplier:

A supplier is defined as an individual or an entity that performs the final production, storage-for-resale, blending, or modification that alters the properties of the PGAB used in the M320 specification. A supplier could be a refinery, a terminal, or a Hot-Mix Asphalt (HMA) producer. If there is no further alteration of the PGAB after its initial production, the refinery is the supplier and must provide the certification. If there is any grade modification of the PGAB at the terminal, the terminal becomes the supplier and must provide the certification. If the PGAB is held for resale as PGAB and is re-branded by the terminal or HMA producer, the terminal or HMA producer becomes the supplier and must provide the certification.

WCTG:

Western Cooperative Test Group, a government and industry association.

May 6, 2019 Quality Management Plan 509 Page 2 of 10

NOTE 1: Various refining techniques can produce asphalt binders of equivalent grade. These asphalt binders may be incompatible with each other. Hot-mix producers should consider compatibility before combining different asphalt binders and/or asphalt binders from different sources. If different asphalt binders and/or asphalt binders from different sources are blended by the user, they become the responsibility of the Hot-mix producer.

Agency:

The Utah Department of Transportation. UDOT’s Engineer for Asphalt Materials will be responsible for the certification of PGAB suppliers and for the final acceptance of the PGAB.

Specification Compliance Testing:

Complete testing according to the specification requirements of AASHTO M 320, and Section 509.12, Table 1 of this plan. The procedure for verification of grade as described in AASHTO R 29 shall be followed.

Specification Compliance Agent:

The agent appointed by the supplier, and approved by the agency, whose authorized signature binds the supplier, i.e.: AASHTO RE:SOURCE laboratory manager.

QC Testing:

Quality Control testing could be a subset of the M320 testing that the supplier will select and describe in his Quality Control Plan. The supplier QC plan will have to be approved by the agency or its authorized representative.

Qualified Technician:

A technician with the experience, skills, and knowledge to manage the testing, and documentation necessary in a quality control laboratory. Validation of the qualified technician will come from the UDOT’s Engineer for Asphalt Materials. The agency will observe the Specification Compliance testing of at least one monthly split sample per year. The agency will test their portion of the split, correlate the data and comment on any testing deficiencies noted. Technician Qualification will be modeled after criteria from the Asphalt Institute.

Statistical Quality Control:

A product will be said to be in statistical quality control when the following occurs:

Specification Compliance Tests are accomplished on three successive binder production units (the production unit size is to be agreed upon by the agency). Use the three test values obtained immediately prior to the time a decision is being made.

The Mean and sample standard deviation of each value in the three specification compliance tests is calculated as follows:

Mean = x x

Where x is an individual test result. i.e. G*

Sample Standard Deviation = xx s

A quality limit is established for the test being analyzed. This may be an upper limit Qu or a lower limit Ql.

Qu = (Tu – Mean)/s and

Ql = (Mean – Tl)/s

Where: Tu = Upper Specification Limit and

Tl = Lower Specification Limit

May 6, 2019 Quality Management Plan 509 Page 3 of 10

The value of Qu or Ql must be greater than 1.1476 (representing 98% within limits for n = 3).

Continuous Production/Live Tank:

The method used to manufacture products without interruption. Modified asphalt continuous production may be small complete batches produced continually, then transferred to a larger sales tank, or small concentrated batches, then letdown-to-completion into the larger sales tank.

Batch, or One Time Production/Static Tank:

Batch production methods include, but not limited to small incomplete batches produced in concentrate, then transferred, letdown and completed into one large complete batch. This method will have the tank locked-out until testing is completed.

509.4 Significance and Use

This standard specifies procedures for minimizing disruption of PGAB shipments caused by testing requirements.

This is accomplished by a certification system with quality control and specification compliance tests performed by the supplier on samples obtained prior to shipment.

The number of grades available under AASHTO M 320, and Section 509.12, Table 1 of this plan may require construction of additional storage facilities to comply with the “sample and hold while testing” procedures.

This standard provides information and guidelines on the following:

General requirements that the supplier must satisfy prior to achieving approved supplier status.

Minimum requirements that must be included in a supplier’s quality control plan.

General requirements that the agency must satisfy prior to certification.

Procedural requirements for shipment of PGAB’s under an ASC system.

Procedural requirements for agency monitoring of an ASC system at the shipping facility.

509.5 Purpose

The Asphalt Binder Quality Management System (ABQMS) provides the Utah Department of Transportation with a quality management…