Pre_Bid_Presentation_Biggs_AAF_TSC_GG_FNL.pdf

BUILDING STRONG®

SOLICITATION: W9128F-18-R-0018

Repair Biggs Army Airfield

PN 85772

Ft Bliss, TX

17 May 2018

AWARENESS OF

DoD AIRFIELD REQUIREMENTS

Presented by: Gene Gutierrez

US Army Corps of Engineers

Transportation System Center (TSC) www.tsmcx.com

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TSC SERVICES - WORLDWIDE

OVERVIEW

• Introduction

• Certifications

• Materials

• Mix Design

• Construction

ADVERTISED DOCUMENTS:

Specification Highlights

• 32 13 14.13 – Concrete Pavement for

Airfields and Other Heavy Duty Pavements

• UFGS Dtd November 2017

• 32 12 15.13 – Hot Mix Asphalt Airfield

Paving

• UFGS November 2015

The information presented herein is not all inclusive of all requirements in the project documents. Please refer to applicable documents for additional and ALL requirements.

Early Age Pavement O&M Issues Experienced With

New Construction. Problems Include;

- Joint Spalling

- Cracking (shrinkage, plastic)

- Durability (Scaling, delaminations, etc.)

- Surface Problems (Voids, Drainage, etc.)

- Materials Related (“Pop-outs”, ASR, etc.)

- Quality of Construction & Workmanship

Using Agency Concerns

- O&M Costs for Early Rehab of “New Pavements”

- Impacts to Mission & Airfield Operations

- Disruptions to accommodate repairs

- Closure of T/W, R/W, Aprons, etc.

- FOD

- Construction of FOD Generating Pavements is

UNACCEPTABLE

-Safety Concerns - Personnel & Aircraft

-Frequent Inspection and Sweeping / Vacuuming of

Pavements

Using Agency Concerns

C-17

Aircraft Air Intake

Major Safety Issue

Jet engines can ingest debris & fragments on pavement surfaces leading to engine damage and/or failure

Construction of high quality, durable pavements cannot be over emphasized

F-16

No. 1 Problem

Airfield PCC

Pavements-??

FOD – Joint Spalling

Within 6 Months After BOD

Joint Intersections

Transverse Joints

FOD - Joint Spalling

FOD - Joint Spalling

Spalling within 3 weeks of Aircraft

Operations

FOD – Joint Spalling

WHY? Non- Compliant Mix Design; Means & Methods; Poor to NO CQC; Lack of QA Inspection and Enforcement w/in 5 months of use

Cracking

Sympathetic Cracking

Surface Blistering

Aggregate “Popouts”

FOD w/in 18 months

FOD – Surface Scaling

DoD Expectations

Portland Cement Concrete Pavements

(PCCP)

- Design and Construct Quality PCCP to

Provide 60+ Years of Service Life with

Minimal Maintenance.

- UFC Compliance

- Contract Enforcement

- Foreign Object Debris (FOD) Generating

Pavements UNACCEPTABLE

Foreign Object Debris (FOD)

• Safety Threat to Flight Personnel & Aircraft

• FOD is Unacceptable

• Highlight Specification Requirements that are OFTEN Overlooked During the Bidding Process

• Awareness to Project Specification / Technical Requirements

• Materials Quality

- Specialized Testing

• Mix Design

• Contractor Quality Control & Testing

• Construction

• Acceptance

OBJECTIVES

Earthwork / Subgrade / Base Course

CQC CMT Laboratory of Record

USACE Validated for ALL INDIVIDUAL

Test Methods Performed to Be Performed

Required to Submit a Copy of Certificate of Accreditation & Scope of Accreditation

(E 329, C 1077, D 3666, D 3740, A 880, E

543)

CQC CMT Lab(s)

• USACE Validation

Required [Para. 1.4.3]

• Each Test Method

Specified - Validation

• ERDC Inspection of

Field Lab Required

• Submit Request Early

• Payment Must be

Received PRIOR to

Inspection

Earthwork / Subgrade

Geotechnical Engineer

- Experienced

- Resume for Approval

- Must Visit Work Site

- Must Certify Inspections and

Test Data.

- Must Prepare Monthly

Reports and Assessments of

Work / Site Conditions

- Water flooding or jetting methods of compaction.

Subgrade for Airfield Pavements including shoulders and overruns

- Compact top 12 inches of subgrades to 100 percent of ASTM

D1557; compact fill and backfill material to 100 percent of

ASTM D1557.

Earthwork / Subgrade

• Nuclear (ASTM D 6938)

Calibration

Moisture

Sand Cone every 5000 SF (ASTM D 1556)

• Gradation Acceptance Based on “Completed Base” or After

Compaction Requirements Have Been Met

• Make Supplier Aware of This Requirement.

Base Course Materials

Recycled PCCP Option – Base

- ONLY Crushed Recycled Conrete Removed from Biggs AAF Runway as Part of This Project

Shall be Used for Crushed Recycled Concrete.

- Crushed Recycled Conrete From ALL Other

Sources Shall Not Be Used.

BUILDING STRONG®33

Base Course Placement

Base Course

Placement

Spreader

Box Method

CQC Personnel Qualifications

- CQC Systems Manager [Para 1.4.1]

- Graduate Engineer or Construction Management degree

- Minimum 5 Years Airfield Construction Experience

- Minimum 1 Year CQC Systems Manager on Airfield

Construction

- ACI Concrete Transportation Inspector [Para.1.4.1.b]

- Specialized CQC – All Aspects of Paving

- Present at Paving Site During Paving

CQC Sampling/Testing Lab

Personnel Qualifications

- Approved “On-Site” Laboratory Required [Para 1.4.3.3]

- All Production Sampling & Testing performed by an approved, onsite, independent commercial laboratory

- ACI Certifications for all field and laboratory personnel performing testing and compliance work [Para.1.4.2.c]

- NRMCA Plant Manager Certification at the Plant

Operator Level [Para.1.4.1.e]

CQC Sampling / Testing

Personnel Certifications

- Required by ASTM and Specifications

- ACI Certified Field Testing Technicians, Grade I

- ACI Certified Lab Testing Technicians, Grade I or II

- ACI Certified Concrete Strength Testing Technician

- ACI Certified Concrete Transportation Inspector

- ACI Concrete Flatwork Tech/Finisher (Lead Foreman)

Materials

Aggregates

Sieve Analysis

Field Sample Size – ASTM C 136

Military Airfield Aggregate Quality

DoD Specifications Mandate Use of High Quality Aggregates to Include

Strict Requirements for:

Applies to Each Size Group including Fine Aggregate

ASTM C33 – Min. Two Coarse Aggregates and Fine Aggregate

Intermediate Size May be Required to Meet CF/WF Combined Grading

ASTM C131 - Los Angeles Abrasion (Wear Test)

ASTM C88 - Soundness (Magnesium or Sodium Sulfate)

ASTM D4791 - Flat Particle Test & Elongated Particle Test

ASTM C1260 [C1567] - Alkali Silica Reactivity (ASR)

Deleterious Materials – Min. Sample Weights Use 6 Step Procedure

ASTM C666 – Durability Freeze Thaw Testing or Satisfactory Service

Record

Coarse Aggregates

• Meets ASTM C 33, No. 4, No. 67

• NMSA 1.5”, Meet Optimized Gradation Requirements

• Crushed , Uncrushed Gravel, Crushed Stone

SPECIFICATIONS REQUIRE All AGGREGATES BE WASHED

Aggregate Cleanliness

Fine Aggregate

• ASTM C 33 Grading

• Washed Sand Required

• Fineness Modulus

2.50 < FM < 3.40

9 of 10 production tests shall not vary more than 0.15 from average FM (Table 6)

Deleterious Materials in Pavement

- Clay and Shale

- Lightweight Particles

- Absorptive Aggregates

- Minus 200 Material

Petrographic Identification Requirements

• Submit resume of Petrographer for approval

• Resume shall indicate experience in Petrographic examination of concrete aggregate, classification, and mineralogy

• Subject to approval 20 days PRIOR to testing

• Follow Detailed 6-Step Specification Procedure on Coarse

Aggregate for Moderate Weather Conditions

Test Sample Size Requirements

• Field sample (ASTM D 75) with QA present

• 3 to 4 Times Larger Than Test Sample Size

• Material Quantity

No. 4 Coarse ( ¾” and larger): 200 Pounds

No 67 Coarse (No. 4 to ¾”): 25 Pounds

Fine: 10 Pounds

• No additional time, payment due to delays in testing, evaluation or personnel requirements

Deleterious Materials Comparison

Clay Lumps and Friable Particles 0.2 Max. 3.0 Max.

Shale 0.2 Max. No Req.

Material Finer Than 0.075 mm (No. 200) 0.5 Max. 1.0 Max.

Lightweight Particles (2.0 Sp.G) 0.2 Max. 0.5 Max.

Clay Ironstone 0.5 Max. No Req.

Chert and Cherty Stone (<2.4 Sp.G) 0.5 Max. 5.0 Max.

Claystone, Mudstone, Siltstone 0.1 Max. No Req.

Shaly and Argillaceous Limestone 0.2 Max. No Req.

Other Soft Particles 1.0 Max. No Req.

Total of All Deleterious Materials

Except Material Finer Than 0.075mm 2.0 Max No Req.

COARSE AGGREGATE UFGS ASTM

UFGS ASTM

- Clay Lumps and Friable Particles 1.0 Max. 3.0 Max.

- Material Finer Than 0.075 mm (No. 200) 3.0 Max. 3.0 Max.

- Lightweight Particles (Medium Sp. G = 2.0) 0.5 Max. No Req.

- Coal & Lignite ------ 0.5/1.0 Max

- Total of All Deleterious Materials 3.0 Max. No Req.

Deleterious Materials Comparison

FINE AGGREGATE

Durability Testing / Evaluation

All Coarse and Fine Aggregates

- Freeze Thaw Testing Required

- ASTM C 666 Procedure A

OR

Satisfactory Service Record Report

- Qualified and Experienced P.E. or Petrographer in Concrete/Materials and Related Distresses

- Submit Resume for Approval

- Three Concrete Pavement Projects

- Minimum 5 years Service Life

Alkali-Silica Reactivity (ASR) Testing

ASR Damage

ASR Testing (Alkali-Silica Reactivity Testing Requirements)

•Test Individual Aggregates (Coarse and Fine) (C-1260)

• Test Aggregate(s) with Expansions >0.08% Use ASTM C 1567, Project Cement & SCM or Lithium Nitrate

• Length Change Determined Over a 28-day Period

•If Test Fails- Reject Aggregate- Contractor to Submit New Source

ASTM C 1260 Specimens

• Approved Laboratory

• Recommend Varying Quantity of Mitigating Measure During

Testing

SCM Allowable Dosage Rates Supplementary Cementitious

Material

Minimum

Content

Maximum

Content

Fly Ash

Class F and Class N

SiO2 + Al2O3 + Fe2O3 > 70% 25% 35%

SiO2 + Al2O3 + Fe2O3 > 80% 20% 35%

SiO2 + Al2O3 + Fe2O3 > 90% 15% 35%

UFFA and UFP 7% 16%

GGBF Slag Cement 40% 50%

CQC TESTING

Aggregate Testing

- Quality Testing Including Deleterious Materials and ASR,

- Every 30 days OR

- Change on Source or Quality

- Increase Frequency to Every Three Months (90 days):

- Two consecutive Test Series Indicate Conformance

- Belt Samples After Start of Paving Operations for MA’s

- Meet Minimum Sample Sizes

Mix Design

Mix Design Requirements

- Approved Accredited and Validated Lab: Meeting

ASTM C 1077

- Representative Materials Complying with Specs

- ACI – 211 Methodology

- THREE Different W/C Ratios REQUIRED

- Basis for Mix Adjustments During Construction

- No Substitutions of Materials Permitted Without

Additional Testing and Approval

- Optimized Combined Gradation

- Method for Selecting Aggregate Grading for Use in

Concrete Mixes

- Additional Guidance: USAF ETL 97-5

- Treats the Combined Aggregate Grading as a

Single Component Instead of Individual Size

Gradings. Individual Size Groups must comply with

ASTM C 33 Size No 4 and 67

Gradation Requirements

USAF ETL 97-5

Aggregate Proportioning Guide

- Specified Flexural Strength: Based on Beams

- 650 PSI @ 90-days age

- Max. Allowable Water/Cement Ratio: 0.45

- 517 (470) lbs/CY Cementitious Minimum Required

- Correlation Option Between Compressive and Flexural

Allowed for Acceptance

- Establish During Trial Batches

- Strengths Determined @ 3, 7, 28, and 90 days Age

-TSC Recommends Consideration to test 56-days Age

Strength Specifmens. No Additional Cost

- Air Content: 6.0% + 1.5% at Paver

- Maximum Slump:

- Slip Form: Maximum Determined By Contactor.

Must Identify in Submittal.

- Same Slump for Pilot and “Fill-in” Lanes

- Fixed Form : 2” Maximum

- Proportion Batches at;

- Maximum Allowable Slump

- Maximum Allowable Air Content

- No HRWRA or Flowing Concrete Permitted

- Use Steel Beam Molds

Separate Trial Mixture Studies for

- Each Combination of Proposed Materials i.e. Cementitious, Admixtures

- Placement Methods i.e. Hand or Odd-

Shaped Slabs, Placing/Finishing Equipment

Acceptance and CQC

Production Strengths

-7-day Flexural To 90-day Flexural Strength (CQC

Production Control)

- 14-day Flexural To 90-day Flexural Strength

(Acceptance)

For Change in Materials: Conduct New

Mix Design Studies

- No Paving Until Approval of Mix Design

Deleterious, Quality & ASR Testing

DURING PRODUCTION REQUIRED

• Frequency: 1st test no later than time of uniformity test and then every 30 days of production o Coarse Aggregate

Deleterious Testing by 6-Step Procedure [Table 5]

Wear (L.A. Abrasion): ASTM C131

Soundness: ASTM C88

Flat Particle & Elongated Particle Test: ASTM D4791, Method A

Alkali Silica Reactivity (ASR): ASTM C1260 & C1567 o Fine Aggregate Deleterious Testing

Alkali Silica Reactivity (ASR): ASTM C1260 & C1567

Stationary Central Mix Plant

• NRMCA QC-3 Compliant w/

Certificate

• Documentation for ALL Weighing and Measuring Devices

• Uniformity / Mixer Efficiency

Mandatory

Type and Capacity

• “On- Site” Stationary (Semi / Fully Automatic)

• NRMCA QC-3 Compliant

• 250 CY / HR Capacity

Plant Manager & Responsible

Individual for Mix Adjustments

• NRMCA Ceritfied Plant Manager

• Responsible Individual with Authority to

Make Mix Adjustments (Alternate)

• Experienced and Qualified

•Aggregate Optimization Adjustments

• Major Adjustments MUST BE APPROVED by DOR and Government. NO EXCEPTIONS

Mixer Uniformity Testing

Three Full Production Sized Batches Required

DEMOLITION

Underbreak

Underbreak Runs Horizontally, Into

Pavement; No Fix - Remove and Replace

Panel

PCCP to Remain-Damage Underbreak

Methods

• Double Saw Cut

• PCCP Mechanical Demolition

Guillotine Breaker

Hydraulic Impact Hammer

• Saw Cut Panels Into Pieces

First Cut:

Diamond Saw Cut Full Depth @ Joint

Second Cut: Wheel Saw Min 1-1/2” Kerf

- Full Depth

Diamond Wet Saw / Wheel Saw

Construction of PCCP

Airfield Pavements

Slip Form Paver

- Paver-finisher Must Weigh at Least 2200 lb/foot of Lane Width

- Must be Self Propelled Specifically Designed for Paving and Finishing High Quality Pavements

- Must be Powered by an Engine Having at Least 6.0 Horsepower/foot of Lane Width.

- Multiple Lane Width Placement Permitted

BUILDING STRONG®81

Slip Form Paving

Multiple Lane Placements Permitted

BUILDING STRONG®83

Equipment Not Allowed for Main Line Paving

- Roller-Type Finishers - Vibratory Screeds

- Spinning Tube-Type Finishers

- Clary Screeds - Bridge Deck Finishers

BUILDING STRONG®84

Underlying Material

Transfer Spreader/Placers

- After the underlying material has been prepared for concrete placement, equipment is not permitted thereon with exception of the paver.

- Transfer spreader / placer Required:

Deposits concrete evenly in front of the paver. Equipment operates outside of the lane(s) being placed.

BUILDING STRONG®85

Acceptable Transfer Placer

BUILDING STRONG®86

Dumping Concrete in Front of Paving

Equipment NOT PERMITTED

Saw Cutting

Water Flushing and Vacuuming of Initial Saw Cuts Required

Curing

• Spraying machine shall be self-propelled and span paving lane

• Two coat application: 400 sq ft/gal

• One coat application: 200 sq ft/gal

• Hand operated, mechanical powered pressure sprayers used only for odd shaped slabs and concrete surfaces exposed after removal of forms

• Hand sprayer requires two coats 90 degrees to each coat

Placement of Temporary Cord (Backer Rod) and Spraying with Curing Compound Immediately after Flushing Initial Saw Cut Required.

• Concrete Surfaces Subjected to Rainfall Within 3 hours Shall Be Resprayed

Epoxy Coated Dowels Required

Epoxy Grout Retention Disks Required

Transverse Dowel

Inserters NOT Allowed

Longitudinal Dowel Inserters

NOT Allowed

Acceptance of PCCP

Pavement Lots

• One Shift NTE 1,000 CY

• 1 Lot = 4 equal Sublots

• Grade & Surface Smoothness Test Results are Evaluated on the Entire Lot

Acceptance of Lot

• Must Meet Specification Requirements – No Payment Adjustments:

- Strength

- Edge Slump

- Joint Face Deformation

• Pavement Characteristics – Pay Adjustment (Based on Scale) o Surface Smoothness o Plan Grade o Thickness

• No Excess Mortar / Paste on surface

• Surface free of voids, bug holes, discontinuities

• Must Comply with Combined Gradation Requirement (WF / CF)

Lot Payment Adjustment Computation

(Example) Pavement Characteristic Payment Percentage

Surface Smoothness

Straight Edge (18%) 75%

Profilograph (1.5 in / Mi) 95%

Grade (8%) 95%

Thickness - (0.55 in) 50%

Actual Percent Payment For Lot 50%

Contract $300.00 CY $ 150.00/CY

Other Requirements

PCCP Pavement Grinding

Unacceptable

Acceptable

Grinding PCCP

- Only Diamond Grinding

Allowed

- Maximum area corrected by grinding of PCCP 10 percent of the total area of any sublot.

- Maximum Depth of Diamond

Grinding : ¼” inch.

- New Hot Mix Asphalt Concrete Pavements Must Cure for a

Minimum of 30 days Before Grooving Permitted.

- New Portland Cement Concrete Pavements Must Cure for a Minimum of 28 Days Before Grooving Permitted.

- Submit Grooving Sequence and Method of Placing Guide

Lines to Control Grooving Operation

Pavement Grooving

Hot Mix Asphalt (HMA)

HMA Placments Require Use of

Material Transfer Vehicle (MTV)

Cutting Wheel Required for Longitudinal Construction Joints

Joints

- Density Determined by Cores

- Core Across / Bisecting the Joint

Smooth Drum Roller Damage

PCCP / HMA Joint Interface

Appearance Before and After Grinding

Appearance after Grinding

Please Refer to Specific

Detailed Requirements for

Your Project in the

Applicable Contract

Documents.

THANK YOU

FOR COMING!