Construction_control_manual.pdf

CESPK PAM 415-1-2

15 Jun 89

TABLE OF CONTENTS

PARAGRAPH PAGE

CHAPTER 1 CONSTRUCTION CONTROL MANUAL

General Definitions Purpose Responsibility, Compilation, Submittal of Test Results

Contractor's Quality Control Government Quality Assurance Laboratory Facilities Quality Control Plan Special Test Requirements

CHAPTER 2 SOILS AND PROCESSED AGGREGATES

S c o p e T e s t s Sampling and Testing of Fill, Backfill, Embankment, Drainage, Subgrade, Subbase, Base Course Materials . . .

Compilation of Test Data for Submittal of Test Results

1 - 1 l - 2 l - 3

1 - 4 l - 5 l - 6

1 - 8 1 - 9

2 - l 2 - 2

2 - 3

2 - 4

CHAPTER 3 AIRFIELD AND HELIPORT PAVEMENT, CONSTRUCTION

AND PROCESSED AGGREGATES

S c o p e Tests Sampling and Testing of Fill, Embankment, Subgrade, Subbase, Base Course Materials

Production Control Testing of Subbase Base Course Materials

Compilation of Test Data for Submittal of Test Results

CHAPTER 4 BITUMINOUS MATERIAL AND

BITUMINOUS-AGGREGATE MIXTURES

S c o p e T e s t s Mix Design Submittals Minimum Test Requirements Sample Transmittal Compilation of Test Data for Submittal of Test Results

3 - 1

3 - 1 3 - l

3 - 3

3 - 4

3 - 5

3 - 3

3 - 4

3 - 4

4 - l 4 - l 4 - 2 4 - l 4 - 3 4 - l 4 - 4 4 - l 4 - 5 4 - 6

4 - 6 4 - 6 l - l l - l l - l l - l l - 3 l - 4 1 - 4 l - 4 l - 5

2 - 1 2 1

2 - 3

2 - 7

TABLE OF CONTENTS Cont.

CHAPTER 5 CONCRETE

s c o p e Mix Designs Excepted Features Minimum Test Requirements Admixtures Methods of Curing Procedures for Sampling Testing . . .

Compilation of Test Data for Submittal of Test Results

PARAGRAPH PAGE

5 - l 5 - 1 2 5 - 1

5 - 3 5 - l 5 - 4 5 - 1 5 - 5 5 - 5 5 - 6 5 - 5 5 - 7 5 - 5

5 - 8 5 - a

CHAPTER 6 MASONRY CONSTRUCTION

S c o p e . . . . . . . . . . . . . . . : . . 6 - 1 Test Requirements for Masonry Units . . . 6 - 2 Test Requirements for Mortar and Grout . 6 3

APPENDIX A Master Test Forms

6 - 1 6 - l 6 - 2

A-l A-23 ii

FIGURE

2-l

FORM TITLE PAGE

SPD 56

1 72

2-2

2-3

SPD FORM 312-R

UNNUMBERED

2-4 ENG FORM 3841

Jun 65

2-5 ENG FORM 2087

May 63

2-6

2-7

DD FORM 1209

ENG FORM 3840

Jun 65

4-l SPD FORM 59 1 Mar 80

4-2 SPD FORM 55 EXTRACTION TEST HOT MIX ASPHALTIC

1 72 CONCRETE

4-3

4-4

4-5

WES FORM 886

Aug 55

Sep 65

DD FORM 1218

4-6 UNNUMBERED

4-7 DD FORM 1217

CESPK PAM 415-1-2

15 Jun 89

INDEX OF COMPLETED TEST FORMS

COMPACTION-MOISTURE DENSITY

DETERMINATIONS

FIELD DENSITY

NUCLEAR FIELD DENSITY TEST

WORKSHEET

SIEVE ANALYSIS

GRADATION CURVES

ATTERBERG LIMITS DETERMINATION

SPECIFIC GRAVITY TESTS

DAILY PLANT AND LABORATORY

REPORT OF BITUMINOUS PAVEMENT

AGGREGATE GRADING CHART

SIEVE ANALYSIS

MARSHALL METHOD COMPUTATION OF

PROPERTIES OF ASPHALT MIXTURES

THEORETICAL SPECIFIC

GRAVITY OF ASPHALT CONCRETE

BITUMINOUS MIX DESIGN

AGGREGATE BLENDING

iii

2-8

2-9

2-10

2-11

2-12

2-13

2-14

4-8

4-9

4-10

4-11

4-12

4-13

4-14

INDEX OF COMPLETED TEST FORMS

FIGURE

5-l

FORM

SPD FORM 58

1 72

TITLE PAGE 5-2

CONCRETE FIELD CONTROL 5-9

5-2 SPD FORM 221

10 74

CONCRETE CONTROL DATA 5-10

5-3 SPK FORM 217

1 82

SAND TEST 5-11

5-4

6-1

6-2

SPD FORM 54 AGGREGATE GRADING 5-12

1 72

SPK FORM 421 COMPRESSIVE STRENGTH CONCRETE

1 Aug 88 CYLINDERS 6-3

SPK FORM 181 TEST DATA ON ABSORPTION 6-4

1 Aug 88 AND MOISTURE CONDITION OF

MASONRY BLOCKS

iv

CESPX PAM 415-l-2

CHAPTER 1

CONSTRUCTION CONTROL MANUAL

l-l. General. This manual is applicable to contracts awarded on or after the date which appears on the cover of this manual. The 10 June 1983 manual applies to projects awarded before the above-referenced date.

l-2. Definitions.

a. Control (CC) Construction Control is a system involving the concurrent but separate efforts of the Contractor and the Government personnel to achieve the level of quality established by the project's contract documents.

b. Contractor Control Contractor's Quality Control is that part of the system by which the Contractor regulates, tests, and inspects his procedures, equipment, materials, and personnel so that the completed product will comply with the requirements of the project's contract documents.

C. Government Oualitv Assurance Government Quality Assurance is that part of the system by which the Government (owner) verifies (1) that the Contractor's Quality Control system is performing properly and (2) that the final product complies with the project's contract documents.

d. Processed Processed aggregates are any materials the Contractor must process by washing, sorting, screening, crushing, etc. to produce an aggregate meeting the contract requirements.

l-3. This manual prescribes procedures to be followed by Contractor and Government personnel assigned the responsibility of performing the Construction Control compliance. Procedures outlined in this manual are for testing materials including, but not limited to, materials used in fills, embankments, subgrades, base courses, flexible and rigid pavements, structural concrete, and masonry.

Unless otherwise noted, this manual shall be used for all projects.

l-4. Resnonsibilitv. Comnilation. and Submittal of Test Results.

a . The Contractor shall be responsible for full compliance with these instructions in the performance of tests and the preparation, submittal, and maintenance of tests included herein and l-l

CESPK PAR 415-1-2

15 89 listed in the contract specifications. The test results from QC and QA testing shall be compiled separately as outlined in this manual.

The Resident Contracting Officer shall have overall responsibility to assure compliance by the Contractor, however, the Contractor shall be responsible for controlling quality and for compliance with contract requirements. The test results from both control and assurance tests shall be compiled as outlined in this manual. Copies of each test result shall be prepared with all necessary data recorded, documentation and computations completed. Distribution to the Corps of Engineers shall be as follows:

4 conies total:

2 copies to Resident Contracting Officer, Corps of Engineers

1 copy to District Engineer (through Resident Contracting Officer), Corps of Engineers

1 copy to Area Contracting Officer, Corps of Engineers

b. Distribution of the copies to the Resident Contracting Officer shall be made within 48 hours after sampling or initiating each test, except when the test duration requirements exceed 4% hours In the latter case, distribution shall be within 24 hours after completion of the test. Each test shall be started and completed without delay. Payment for materials placed, as well as for any subsequent construction dependent upon contract compliance of these materials, will not be authorized until test reports have been properly distributed. The Government will furnish sufficient copies of the test report forms, if blank master forms (to be reproduced as necessary by the Contractor) are not found in this manual. Request for resupply of forms will be the responsibility of the Contractor.

C . All test forms shall be accurately completed, and a test location plan shall be submitted when directed by the Resident Contracting officer. All test forms not accurately completed will be immediately returned to the Contractor for correction or completion, and no Quality Control tests will be accepted unless signed by the Laboratory Manager and Supervising Technician. The Materials Test Log (summarizing QC testing) shall be maintained at the Contractor's project office and will be divided into four parts for recording sample numbers of tests on (S) soils and processed aggregates, bituminous materials and mixes, (C) Portland Cement concrete, and (0) l-2 other types of material such as masonry, roofing material, etc. Each sample and test will be assigned a laboratory number at the time of arrival of the sample at the laboratory or beginning of the test.

This number shall contain the last four digits of the contract number, followed by a letter designating the construction use of the material using the letter for soils and processed aggregate, for bituminous material, for Portland Cement concrete, and for other types of material and then followed sample number.

For soil, processed aggregates, as well as bituminous materials and mixes, a second letter will be included to differentiate a test on a material from a bulk sample from a material obtained from a field density hole use a letter from bulk samples and a from densities. Retests will be made for failed tests and assigned the same number as the original tests with a final letter to identify them as a retest. For example In addition, a copy of the Materials Test Log shall be submitted with each monthly progress report for determining the Contractor's progress payment for materials placement represented by these tests.

1-5. Contractor's Oualitv Control The QC program is based, in part, on specific tests required for several items of work involved.

The location and frequency of tests required depend on the manner in which the work is being performed and the uniformity and quality of the tests obtained. A minimum testing program for quality control testing is outlined in this manual. Additional testing may be required by the specifications for contracts when the minimum testing program is not considered to be adequate or applicable. Tests indicating noncompliance with the contract documents shall be reported immediately to the Resident Contracting Officer or the Resident Contracting Officer's representative, however, the Contractor's Quality Control representative will recommend steps to be taken to alleviate areas of noncompliant conditions. The Resident Contracting Officer or his representative reserves the right to designate the location and type of additional sampling and testing (to be performed at the Contractor's expense) to verify compliance if quality is inconsistent or questionable. References to standard test methods and testing procedures for sampling and testing of the material are given in each chapter of this manual, unless otherwise specified, and additional types of tests may be required by other areas of the contract documents. Periodic Quality Assurance tests shall be made by the Contracting Officer's representative to assure the Contractor's compliance with contract requirements and specifications.

l-3

1-6. Government Assurance Unless otherwise specified, the frequency of QA testing will be determined by the Contracting Officer's representative. For all projects, the recommended minimum testing frequency will be at least two tests done concurrently with the first two QC tests and thereafter at a rate of one test for every 10 tests made by the Contractor.

Laboratorv Facilities. The Contractor shall use only an established commercial laboratory approved by the Resident Contracting Officer. Laboratory facilities and personnel are to be in accordance with ASTM D 3740 (soils), ASTM C 1077 (concrete), and ASTM D 3666 (asphalt) as applicable. The Government reserves the right to make inspections of the Contractor's designated laboratory facilities, including test equipment and procedures. This is to ensure that all equipment is in proper working order, as well as correctly calibrated, and that specified test procedures are being performed by qualified personnel. The Government also reserves the right to conduct additional QA testing, using either its own equipment and facilities or the Contractor's. This additional QA testing shall be performed for all projects, as the Resident Contracting Officer deems necessary, to assure the Contractor's compliance with the contract documents.

l-8. Qualitv Control Plan. As soon as possible after the contract has been awarded and prior to commencement of any work, a Construction Quality Control Meeting shall be held. The purposes of this meeting will be to discuss quality control inspection requirements as well as the Contractor's Quality Control Plan designed to fulfill these requirements. To address testing portion of the Quality Control Plan, the following shall be included with the Quality Control Plan using this manual for guidance:

a . The QC organization and its structure.

b. Proposed methods of performing inspections.

C . Established areas of responsibility.

d. Name and qualifications of each individual assigned a QC function. (Quality Control Representative, Laboratory Manager, Supervising Technician, and Technicians) l-4

15 Jun

e. Description of how testing will be performed.

(1) Name of commercial laboratory (to be approved by the Resident Contracting Officer).

(2) Technicians employed by the laboratory to perform the test(s).

(3) Test methods to be used.

(4) Location and availability of test equipment.

f. Schedule of tests that will be performed (Materials Test Summary).

A date when the laboratory facility can be inspected laboratory approval).

No construction work shall commence until the Quality Control Plan has been approved by the Resident Contracting Officer, and any changes in the Quality Control Plan shall be submitted in writing for approval.

1-9. Test Reuuirements.

a. Soils and Processed Aaareaates. When more than 30% of the material is retained on a sieve, laboratory maximum density shall be determined in accordance with EM 1906, Appendix VI A (Utilizes a 12-inch mold). Field tests shall be determined in accordance with ASTM D 1556 using a diameter ring and sand cone.

b. Lime. or Cement Stabilization. Shall be sampled and tested as stated in the contract documents.

C . Geotextiles. Shall be sampled and tested as stated in the contract documents.

l-5

CHAPTER 2

SOILS PROCESSED AGGREGATES

2-l.

a . This chapter prescribes methods and procedures for the Contractor Quality Control (QC) testing of materials used in all fills (except large dam embankments and cofferdams), backfills, embankments, subgrades, subbases, and base courses, unless otherwise noted hereinafter. Drainage materials are included in this scope and shall include poorly-graded and well-graded processed aggregates used to remove moisture (or prevent the entrance of moisture) detrimental to final construction.

b. The types and frequencies of QC tests for large dam embankments and cofferdams are excluded from this manual and will be provided in the contract specifications for the respective projects.

c. The types and frequencies of QC tests for airfield and heliport construction are covered separately in this manual under Chapter 3: Airfield and Heliport Pavement Soils and Processed Aggregates, or in the contract specifications for such projects.

2-2. Tests Testing and reporting shall be performed in accordance with Society of Testing and Materials (ASTM) Standards as indicated below or as shown in Chapter 1 of this manual (latest editions at time of contract award, unless otherwise indicated).

a. Samolinq. Sampling Aggregates.

b. ASTM D 2217 Wet preparation of Soil Prenaration. Samples for Particle Size

Analysis and Determination of Soil Constants (Method

C . Gradation. ASTM C 117 Materials Finer than No.

200 Sieve in Mineral Aggregates by Washing.

ASTM C 136 Sieve or Screen Analysis of Fine and Coarse Aggregates.

2-1

CESPK PAW 415-l-2

d. Unit Weiaht. ASTM C 29

e. Svecific Gravity.

f . Svecific Gravity.

Atterberq Limits.

h. Moisture Content.

1 . Moisture Density

Densitv.

ASTM D 422

Apparatus B

ASTM c 127

ASTM D 854

ASTM D 4318

(Procedure B)

ASTM 2216

ASTM 1557

EM 1110-2-1906

Appendix VI A (Utilizes a 12-inch mold)

ASTM

ASTM

Particle-Size Analysis of Soils. (Only used when hydrometer analysis is specified)

Wire-Cloth Sieves for Testing Purposes.

Unit Weight and Voids in Aggregates.

Specific Gravity and Absorption of Coarse Aggregate.

Specific Gravity of Soils.

Liquid Limit, Plastic Limit and Plasticity Index of Soils.

Laboratory Determination of Moisture Content of Soil.

Moisture-Density Relations of Soil and Soils Aggregate Mixture using Rammer and Drop (Methods B or D).

Moisture-Density Relations of Soil (using a diameter mold).

Maximum Index Density of Soils Using a Vibratory Table.

Density of Soil in Place by the Sand-Cone Method.

2-2

ASTM D

ASTM D

k. Wear Test. ASTM C 131

1. Materials ASTM D 2487 Classification.

CESPK PAM 415-1-2

15 Jun 89

Density of Soil and Aggregate in Place by Nuclear Methods (Shallow Depth).

Moisture Content of Soil Soil-Aggregate in place by

Resistance to Abrasion of Small-Size Coarse Aggregate by Use of the Los Angeles Machine.

Classification of Soils for Engineering Purposes.

*Vibratory table shall be used for cohesionless materials for which a well-defined moisture-density relationship cannot be obtained using

ASTM D 1557.

**The field density test shall be performed in accordance with the Standard Method of Test for Density of Soil in Place by the Sand-Cone Method, ASTM D 1556, except that in each test the weight of the disturbed sample representing the full depth of layer shall be not less than 10 pounds for fine-grained or sandy materials and 12 pounds for gravelly materials using a scale for weighing of sufficient capacity sensitive to pounds. All field density samples shall be oven-dried in accordance with ASTM D 1556 and D 2216.

***The use of Nuclear Methods for determining field densities and moisture contents shall be limited to drainage materials and base course materials as outlined by Table 2-1, paragraph C-l.

2-3. and Testina of Fill. Backfill. Embankment, Drainaae.

Subarade. Subbase, and Base Course Materials. This sampling and testing shall be in accordance with the standard procedures referred to in this manual. The minimum number of QC tests to be performed shall be as indicated in Table 2-l.

2-3

PAM 415-I-2

Table 2-l. Type of Tests and Frequency

A. BACKFILL AND EMBANKMENT

TEST FREQUENCY

1. Field Density w/Moisture Content.

1 . Two per lift for each increment or fraction of 2000 placed during each shift.

2. Gradation Limits 2. One per 5 field (from Compacted Material)* densities.

3. Moisture-Density Relation-ships w/Gradation, Atterberg Limits, Specific Gravity, and Classification (from Bulk Sample).

3 . One per 5 field densities (with not less than one per type of material) for the first 25 field density tests.

Thereafter, one additional test for each change in material.

B. AND SUBBASE

TEST FREQUENCY

1. Field Density Content

1 . Two per lift for each increment or fraction of 1000 placed during each shift.

2. Gradation Limits (from Compacted Material)*

2. Two per five field densities.

3. Moisture-Density Relation-ship w/Gradation, Atterberg Limits, Specific Gravity and Classification (from Bulk Sample)

3. One per 5 field densities (with not less than one per type of material) for the first 25 field density tests.

Thereafter, one additional test for each change in material.

2-4

PAM 415-1-2

C. BASE COURSE AND DRAINAGE MATERIAL

TEST FREQUENCY

1. Field Density w/Moisture.

2. Gradation and Atterberg Limits (From Compacted Material)*

1. Two per lift for each increment or fraction of 1000 placed during each 8-hour shift. First 5 testsduring initial construction of each base course or drainage material shall be determi-ned by ASTM D 1556 and by ASTM D 2992 for correlation of sand cone and nuclear methods.

Thereafter, every 5th nuclear test method shall be verified by sand cone method. If verification testing does not show adequate correlation as determined by the Contracting Officer, all tests shall be performed in accordance with ASTM D 1556. However, the Contractor may, at his option, perform all field density tests in accordance with ASTM D 1556.

2. Two per five field density tests.

3. Moisture-Density Relationship w/Gradation, Atterberg Limits, Specific Gravity, and Classifica-tion (from Bulk Sample).

3. One per 5 field density tests (with not less than one per type of material) for the first 25 field density tests.

Thereafter, one additional test for each change in mater ia l .

2-5

CESPK 415-l-2

4 . Crushed Faces, Abrasion, and Smoothness

Frequency to be in accordance with contract specifications.

D. BACKFILL FOR CULVERT TRENCHES, WALLS, CULVERTS, BUILDING

PERIMETERS

TEST FREQUENCY

1. Field Density w/Moisture la. Culverts and Utility Trenches: One per lift for each increment or fraction of 500 lineal feet of backfill.

lb. Walls and Building Perimeters: One per lift for each increment or fraction of 200 lineal feet of backfill.

2. Lab Moisture Density Relations 2. One per 5 field w/Atterberg Limits, Gradation, density tests (with not Specific Gravity, and Classification less than one per type of (from bulk sample). material) for the first

25 field density tests.

Thereafter, one additional test each time there is a change in material.

*Compacted material sample taken adjacent to field density test site.

For subbase and base courses, measure thickness of lift concurrently with field density test and record on test form.

In addition to the minimum testing program listed above, representative samples of subgrade, subbase, base, and all other construction materials (including on-site materials) shall be collected (prior to compaction) by the Contractor and submitted to the Government for testing. Samples shall be taken under the direction of the Contractor's Quality Control representative.

samples for this purpose shall be shipped within 24 hours by the Contractor at the Contractor's expense to the Sacramento District Laboratory, Corps of Engineers, 2021 Jefferson Boulevard, West Sacramento, California 95691. Weight of these samples shall be a

2-6 minimum of 100 pounds for material containing less than 10% plus No. 4 material, 150 pounds for material containing more than 10% plus NO. 4 material, or 750 pounds for material containing more than 30% plus material.

2-4. Comoilation of Test Data for Submittal of Test Results.

The following six test results shall be submitted concurrently:

a. Moisture-Density Determinations, 2-l). This form is for use in determinins the moisture and maximum unit weight (density of soils-and processed aggregates). The moisture-density curve shall be plotted based on a minimum of four compaction test specimens. The zero-air-voids curve shall also be plotted using the specific gravity test data from ASTM D 854 and ASTM C 127. Classification of sample shall be in accordance with ASTM D 2487, with the classification group name and group symbol clearly and accurately stated. The Resident Contracting Officer may require, at no additional cost to the Government, single-point checks of moisture-density relations (ASTM D 1557 dry of optimum moisture), if it is evident through Quality Assurance testing that the Quality Control testing is not being adequately controlled with respect to the precision requirements of ASTM D 1557, paragraph 9.

This This fill test

b. Field Test (Sand Cone Method).

test form is used to determine the degree of compaction.

sheet can also be used for recording moisture content of in borrow material or as placed.

C. Field Density Test (Nuclear Method). 2-3). This form is used to determine the degree of compaction when using the Nuclear Method.

d. Gradation Sheets, 2-4 and 2-5). These forms are used to record the results of gradation tests for all materials.

Figure 2-4 shows a typical example in which gradation tests were performed in accordance with ASTM Standards C 136 and C 117.

Results from these tests shall be tabulated as shown in Figure 2-4 and plotted as shown in Figure 2-5.

e. Limits Determination, This form is used to compute liquid limit, plastic limit, and plasticity index.

f. Specific Gravitv Tests, 2-7). This form is used to compute specific gravity of soils, aggregate, and stone.

2-7

CESPK PAW 415-1-2

CHAPTER 3

AIRFIELD HELIPORT PAVEMENT CONSTRUCTION,

SUBGRADE, AND PROCESSED AGGREGATES

3-l. This chapter prescribes methods and procedures for the Contractor Quality Control testing of materialsused in the backfill, embankment, subgrade, subbase, and base courses, etc. for rigid and flexible airfield and heliport pavement construction. Refer to Chapter 2 for testing of other earthwork features such as building fills and trench backfill.

3-2. Tests. Testing and reporting shall be performed in accordance with the American Society for Testing and Materials (ASTM) Standards as listed below as specified in Chapters 1 and 2 of this manual.

a. Samnlinq. ASTM D 75

b. Samole ASTM D 2217

C . Gradation. ASTM c 117

ASTM C 136

ASTM D 422

Apparatus B

ASTM E 11

d. Unit Weisht. ASTM c 29

Sampling Aggregates.

Wet Preparation of Soil Samples for Particle-Size Analysis and Determination of Soil Constants (Method B).

Materials Finer than No.

200 Sieve in Mineral Aggregates by Washing.

Sieve or Screen Analysis of Fine and Coarse Aggregates.

Particle-Size Analysis of Soils.

used when hydrometer

Wire Cloth Sieves for Testing Purposes.

Unit Weight and Voids in Aggregate.

3-1

CESPK PAW 415-1-2

CHAPTER 3

AIRFIELD HELIPORT PAVEMENT CONSTRUCTION,

SUBGRADE, AND PROCESSED AGGREGATES

3-l. This chapter prescribes methods and procedures for the Contractor Quality Control testing of materialsused in the backfill, embankment, subgrade, subbase, and base courses, etc. for rigid and flexible airfield and heliport pavement construction. Refer to Chapter 2 for testing of other earthwork features such as building fills and trench backfill.

3-2. Tests. Testing and reporting shall be performed in accordance with the American Society for Testing and Materials (ASTM) Standards as listed below as specified in Chapters 1 and 2 of this manual.

a. Samnlinq. ASTM D 75

b. Samole ASTM D 2217

C . Gradation. ASTM c 117

ASTM C 136

ASTM D 422

Apparatus B

ASTM E 11

d. Unit Weisht. ASTM c 29

Sampling Aggregates.

Wet Preparation of Soil Samples for Particle-Size Analysis and Determination of Soil Constants (Method B).

Materials Finer than No.

200 Sieve in Mineral Aggregates by Washing.

Sieve or Screen Analysis of Fine and Coarse Aggregates.

Particle-Size Analysis of Soils.

used when hydrometer

Wire Cloth Sieves for Testing Purposes.

Unit Weight and Voids in Aggregate.

3-1

e. ASTM C 127 Gravity.

ASTM D 854

f. Atterberq ASTM D 4318 Limits.

(Procedure

Moisture ASTM D 2216 Content.

h. ASTM D 1557 Density

EM 1110-2-1906

Appendix VI A

ASTM D

1. Field ASTM D

Wear Test. C 131

k. Materials ASTM D 2487 Classification.

Specific Gravity and Absorption of Coarse Aggregate.

Specific Gravity of Soils.

Liquid Plastic Limit, and Plasticity Index of Soils.

Laboratory Determination of Moisture Content of Soil.

Moisture-Density Relations of Soils and Soil-Aggregate Mixture Using Rammer and Drop (Methods B, or D).

Moisture-Density Relations of Soil Using a 12-inch Diameter Mold.

Maximum Index Density of Soils using a Vibratory Table.

Density of Place by the Sand-Cone Method.

Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and impact in the Los Angeles Machine.

Classification of Soils for Engineering Purposes.

*Vibratory table shall be used for cohesionless materials for which a well-defined moisture-density relationship cannot be obtained using

ASTM D 1557.

3-2

e. ASTM C 127 Gravity.

ASTM D 854

f. Atterberq ASTM D 4318 Limits.

(Procedure

Moisture ASTM D 2216 Content.

h. ASTM D 1557 Density

EM 1110-2-1906

Appendix VI A

ASTM D

1. Field ASTM D

Wear Test. C 131

k. Materials ASTM D 2487 Classification.

Specific Gravity and Absorption of Coarse Aggregate.

Specific Gravity of Soils.

Liquid Plastic Limit, and Plasticity Index of Soils.

Laboratory Determination of Moisture Content of Soil.

Moisture-Density Relations of Soils and Soil-Aggregate Mixture Using Rammer and Drop (Methods B, or D).

Moisture-Density Relations of Soil Using a 12-inch Diameter Mold.

Maximum Index Density of Soils using a Vibratory Table.

Density of Place by the Sand-Cone Method.

Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and impact in the Los Angeles Machine.

Classification of Soils for Engineering Purposes.

*Vibratory table shall be used for cohesionless materials for which a well-defined moisture-density relationship cannot be obtained using

ASTM D 1557.

3-2

**The field density test shall be performed in accordance with the Standard Method of Test for Density of Soil in Place, by the Cone Method, ASTM D 1556, except that in each test the weight of the disturbed sample representing the full depth of layer shall be not less than 10 pounds for fine-grained or sandy materials and 12 pounds for gravelly materials using a scale for weighing of sufficient capacity sensitive to 0.01 pounds. All field density samples shall be oven-dried in accordance with ASTM D 1556.

3-3 and Testina of Fill, Embankment. Subarade. Subbase, and Base Course Materials, etc. The sampling and testing shall be in accordance with the standard procedures referred to in this manual.

The minimum number of tests required is shown in Table 3-l.

Table 3-1. Type of Tests and Frequency.

A. SURFACE PREPARATION AND FILL

TEST FREQUENCY

1. Field Density w/Moisture 1. Two per lift for each Content. increment or fraction of

2,500 placed during each 8-hour shift.

2. Gradation Limits 2. One per 5 field density (from Compacted Material)* tests.

3. Lab Moisture-Density Relationship w/Gradation, At'cerberg Limits, Specific Gravity, and Classification (from Bulk Sample)

3. One per 5 field density tests (with not less than one per type of material) for the first 25 field density tests.

Thereafter, one additional test for each change in materials.

B . SUBGRADE, SUBBASE, AND BASE COURSES**

TEST FREQUENCY

1. Field Densitv w/Moisture 1. Two lift for each increment or fraction of 1,500 placed during each shift.

2. Gradation w/Atterberg Limits (From Compacted Material)*

2. Two per five field density tests.

3-3

3. Lab Moisture-Density Relationship w/Gradation, Atterberg Limits, Specific Gravity, and Classification (from Bulk Sample)

3 . One per 5 field density tests (with not less than one per type of material) for the first 25 field density tests.

Thereafter, one additional test for each change in material.

*Compacted Sample taken adjacent to field density test site.

**Includes other imported aggregates, such as select granular material, filter, or drainage materials.

Note: Unless otherwise specified, refer to Chapter 2 regarding requirements for backfill of culverts and utility trenches.

In addition to the minimum testing program above, representative samples of subgrade, subbase, base, and all other earthwork materials shall be sampled by the Contractor (prior to compaction) for the first two and every tenth field density tests and submitted to the Government for testing. Samples shall be taken under direction of the Contractor's Quality Control representative. Bag samples for this purpose shall be shipped within 24 hours by the Contractor at the Contractor's expense to the Sacramento District Laboratory, Corps of Engineers, 2021 Jefferson Boulevard, West Sacramento, California 95691. Weight of these samples shall be minimum 100 pounds for material containing less than 10% plus No. 4 material, 150 pounds for material containing more than 10% plus No. 4 material, or 750 pounds for material containing more than 30% plus inch material.

3-4. Production Control of Subbase and Base Course Materials. Samples of the material shall be tested as specified, and test reports submitted at least 30 days prior to starting placement operations. These samples shall be representative and obtained at the source, from trucks, stockpiles, belts, hoppers, or other designated locations. The minimum number of tests required during production shall be two gradation tests daily. Other specified tests shall be made whenever a change of materials occurs.

3-5. Comoilation of Test Data for Submittal of Test Results. The following test results shall be submitted concurrently:

3-4 a . Moisture-Density Determinations, 2-l). This form is for use in determining the optimum moisture and maximum unit weight (density of soils and processed aggregate). The curve shall be plotted based on a minimum of four compaction test specimens. In additions, the zero-air-voids curve shall be plotted using specific gravity data obtained. Classification of sample shall be in accordance with ASTM D 2487. The Resident Contracting Officer may require, at no additional cost to the single-point checks of moisture-density relations (ASTM D 1557, dry of optimum moisture), if it is evident through Quality Assurance testing that the Quality Control testing is not being adequately controlled with respect to the precision requirements of ASTM D 1557, paragraph 9.

b. Field Test (Sand Cone), This test form is used to determine the degree of compaction. This sheet can also be used for recording moisture content of fill in borrow material or as placed.

Field Densitv Test (Nuclear Method), 2-3). This test form is used to determine the degree of compaction when using the Nuclear Method.

d. Gradation Sheets, (Figures 2-4 and 2-51. These forms are used to record the results of gradation tests of all materials.

Figure 2-4 shows a typical example in which gradation tests were performed in accordance with ASTM Standards C 136 and C 117. Results from these tests shall be tabulated as shown in Figure 2-4.

e. Atterbers Limits Determination, 2-6). This form is used to compute liquid limit, plastic limit, and plasticity index.

f compute

Gravitv Tests. Z-7). This form specific gravity of soils, aggregate, and stone.

is used

3-5

BITUMINOUS MATERIAL AND BITUMINOUS-AGGREGATE

4-l. This chapter prescribes methods and procedures for the Contractor Quality Control testing of bituminous mixtures used for the construction of streets, roads, parking area pavements, and unless otherwise specified, for the construction of airfield and heliport pavements.

4-2. Tests Testing and reporting shall be performed in American Society for Testing Materials (ASTM)

Standards as listed herein.

4-3. Mix Desian Submittals. Certain features on projects which involve comparatively small quantities of bituminous mixture (less #an 6 tons) may be excluded from testing requirements listed hereinafter, provided the material is delivered from a plant with a history of consistently producing bituminous mixtures which conform to contract requirements. The Contracting Officer's representative reserves the right to request certified test data to ensure that materials produced from the plant will conform to the contract requirements. On projects requiring more than 6 tons the Contractor shall submit the minimum items in Table 4-1, A.l. at least 30 days prior to bituminous material placement.

4-4. Minimum Test Recruirements. For placement, the minimum number of each type of production test and each type of control test are listed below. These frequencies of testing may be increased by the Contracting Officer to maintain adequate control of the bituminous mix, plant production, and placement operations.

Table 4-1. Contractor's Materials Submittal Quality Control Testing.

A. SUBMITTALS AND TEST SAMPLE SUBMITTALS

ITEM REQUIREMENT

1. Mix Design* (prior to placement)

1 . Test results and material sources 30 days (minimum) in advance of paving. These data shall be presented with respect

4-l

A. SUBMITTALS AND TEST SAMPLE SUBMITTALS

ITEM REQUIREMENT

1. Cont.

2 . Hot Mix Sample (during placement) to asphalt cement content in tabulated form, as well as in graphical form, and shall include curves for unit weight, percent voids of total mix, percent voids filled, and stability; the optimum oil content shall be indicated, unless otherwise specified.

2 . Two (minimum) samples shall be obtained from the belt or transport truck. One shall be obtained at the beginning of each 8-hour shift and one at mid-shift. Each sample shall be split in half. The two half-samples (from beginning and mid-shift) shall be labeled packed separately and then submitted for QA testing to the Sacramento District Laboratory within 24 hours of sampling. Retain remaining two half-samples for QC testing.

3. Aggregate Sample** (during placement)

3 . Two 50-pound (minimum) samples shall be obtained from the hot bins. One shall be collected at the beginning of each 8-hour shift and one at shift. Each 50-pound sample shall be split in

4-2

A. SUBMITTALS AND TEST SAMPLE SUBMITTALS

ITEM REQUIREMENT

3. Cont. half. The two half-samples (from the beginning and mid-shift) shall be packed separately and submitted to the Sacramento District Laboratory within 24 hours of obtaining. Retain remaining two half-samples for QC testing.

4 . Bituminous Material Sample (during placement)

5. Core Specimens diameter min.)

(after each day's placement)

4. Obtain one quart of bituminous material and refinery certification of compliance and submit to Sacramento District Laboratory with first hot mix sample. Repeat anytime bituminous material source changes.

5. Obtain set of 5 cores per each hot mix sample obtained (if possible, 2 cores from centerline of joints).

Number cores and note locations obtained on built drawings. From each set, 2 cores shall be sub-mitted Sacramento District to the Laboratory, (Preferably 1 core from joint). Retain remaining cores for QC testing.

4-3

CESPK 415-l-2

B. QUALITY CONTROL TESTING

ITEM REQUIREMENTS

1. Bituminous Material. 1. None.

2 . Aggregate. 2 . On each of the split samples of aggregates retained by the Contrac-tor, a sieve analysis and specific gravity test shall be performed.

3. Hot Mix Sample*

4. Core Specimens

5. Smoothness Testing.

3. On each of the split samples retained by the Contractor, the Contractor shall determine the bitumen content and per-form a complete Marshall Method test, (including stability, flow, weight, percent voids of total mix and percent voids filled with bitumen).

On every 10th sample the Contractor shall perform a retained-stability test.

4. For each core specimen retained by the Contractor the relative compaction and bitumen content shall be determined. The thick-ness of the cores shall be measured and recorded.

5. Shall be performed by the Contractor as required by the contract documents.

4-4

Table 4-2. Reference Test Procedures

REFERENCE TEST PROCEDURE

ASTM D 1559 Test for Resistance to Plastic flow of Bituminous Mixtures using Marshall Apparatus (mechanical agitators in the hot water baths, in addition to the other equipment, shall be required).

reouired by contract specifications,

3.5 of ASTM D 1559 shall be changed to

75 blows (high density Mechanical hammer may be used when properly calibrated against standard manual hammer.

ASTM D 2726

ASTM D 2172

ASTM C 131

ASTM C 136

ASTM C 2041

ASTM C 183

ASTM C 188

ASTMC88

ASTMD75

ASTM D 140

ASTM D 946

Standard Test Method for Bulk Specific Gravity of Compacted Bituminous Mixtures.

Standard Test Method for Quantitative Extraction of Bitumen from Bituminous Paving Mixtures, Method A or B.

Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine.

Standard Test Method for Sieve or Screen Analysis of Fine and

Theoretical Maximum Specific Gravity of Bituminous Paving Mixtures.

Density of Hydraulic Cement.

Sampling and Acceptance of Hydraulic Cement.

Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate.

Sampling Aggregates, Practice.

Sampling Bituminous Materials.

Penetration-Graded Asphalt Cement for Use in Pavement Construction.

4-5

CESPX PAM 415-1-2

4-5. Transmittal. Samples of asphalt, aggregates, cores, and hot mixes (noted in Table 4-l) shall be delivered to the Sacramento District Laboratory, Corps of Engineers, 2021 Jefferson Boulevard, West Sacramento, California 95691. These samples shall be taken under the direction of the Contractor's Quality Control representa-tive and shall be shipped prepaid in suitable containers by the Contractor at the Contractor's expense. Testing of these samples in the Sacramento District Laboratory will be performed by the Government at no cost to the Contractor.

4-6. Comnilation of Test Data for Submittal of Test Results.

a. Plant and Laboratorv Bituminous Pavement 4-1). This form is used to record the data from the tests performed on asphaltic concrete mix samples taken prior to placement on grade and from cored samples taken from the compacted pavement.

All data shall be recorded in appropriate spaces and columns according to the examples given.

b. Extraction Test Hot Mix Concrete, 4-2).

The test data for asphalt extraction shall be recorded on this form.

Ausreaate Chart, 4-3) The aggregate of hot bin samples and the extraction tests and specific limits shall be recorded on this form.

d. Sieve Analvsis, (Ficrure 4-4). The grading data from the hot bin samples shall be recorded on this form.

e. Marshall Method Comvutation of of Mixture, 4-5). This work sheet form is used in recording Marshall test data and for recording field density data.

f. Theoretical Maximum Gravitv. (Ficrure 4-6). This form shall be used to record test data for theoretical maximum specific gravity.

Bituminous Mix This form is to be used for computations for combined gradings of aggregate for bituminous mix design.

4-6

*The theoretical maximum specific gravity of paving mixtures shall be determined in accordance with ASTM D 2041 (standard procedure). When determining Marshall properties on hot mix samples, measure the maximum specific gravity in triplicate and average. When determining Marshall properties for mix design purposes, measure the maximum specific gravity in triplicate for each design curve point and average determine the maximum specific gravity in triplicate on the projected optimum and calculate the specific gravity of the remaining points in accordance with the Asphalt Institute Manual 2, Chapter VI paragraph 6.07 (May 1984, or most recent edition).

**For batch plants not utilizing hot bins, individual bin samples shall be obtained from the cold feed bins. If it is determined by the Contracting Officer's representative that representative samples cannot be readily obtained from the individual cold feed bins, representative samples shall be obtained from the combined cold feed conveyor.

4-7

CHAPTER 5

CONCRETE

5-l. This chapter prescribes methods and procedures for the Contractor Quality Control testing of concrete materials used in the construction of buildings and other facilities and will be prescribed in the contract documents for the respective projects.

5-2. Mix Desians. For projects involving 1,200 cubic yards or more of concrete, a job mix design shall be made for each class of concrete, unless otherwise specified. For projects involving less than 1,200 cubic yards, an established plant mix design may be used, for each class of concrete, provided it meets all specified requirements.

5-3. Features. Certain features which involve small quantities of concrete (10 cubic yards or less) may be excluded from the testing requirements shown in Table 5-1, provided the material delivered is from a plant consistently producing concrete which conforms to the requirements of the contract documents. The Contracting Officer's representative reserves the right to request supporting test data reports in evidence of plant and materials conformance with the aforementioned documents. Some typical excepted project features are nonstructural concrete curbs and gutters, sidewalks, duct backfill, thrust and anchor blocks, pole anchorage, lean concrete backfills, and manhole works. Project features such as isolated, continuous, and strip footings for the wall and columns, piles and pile caps, exterior vehicular slabs, interior on-grade floor slabs, and similar structurally related building features to be considered excluded items regardless of the quantities of concrete required.

5-4. Minimum Test Reouirements. A minimum number of production and control tests are listed below. The frequency of testing may be increased or decreased as directed by the Contracting Officer to maintain adequate control of the concrete mix, plant productions, and placement operations.

5-l

PAM

Table 5-1. Test Requirements.

ITEM REQUIREMENT

1. Concrete Mix Design 1. Mix design for each class of concrete shall include all of the following data:

(a) Weights and volumes of all materials.

(b) Water-cement ratio by weight.

(c) 7 and 28-day compressive strengths.

(d) Air Content.

(e) Slump.

(f) Unit weight (also 28-day air-dry unit weight for lightweight concrete).

(g) For class P concrete, beam strength for 7, 28, and 90 days, as specified.

Certified test reports of aggregate compliance with ASTM C 33 (ASTM C 330 for lightweight aggregate) or other specified standards.

(i) Certification of admixture compliance with the requirements as stated in the contract documents.

5-2

1. Cont.

REQUIREMENT

(j) Certified test reports for cement and pozzolan, accompanied by Mill Test Reports from a plant with a record of high quality production for the past 3 years.

2. Entrained Air, Unit Weight (Lightweight Concrete Only), Temperature of Mix

3. Test Cylinders

2. Three per day per shift as minimum and whenever there is a change in consistency of concrete. Samples shall be taken at the point of discharge as stated by ASTM C 172, unless other-wise specified. Samples shall be taken at the beginning, midpoint, and end of each daily place-ment of each concrete used.

3. One set of three cylinders shall be made for each increment or fraction 150 placed during each shift. For lightweight concrete, a minimum of one set of four cylinders shall be taken. One cylinder shall be used to determine 28-day air-dry unit weight. If the consistency of the concrete (as measured by the slump test) exceeds the maximum slump obtained in the design mix or by the contract requirements, then one additional set of

5-3

ITEM REQUIREMENT

3. Cont. represent any deficient concrete already delivered to the forms. Any remaining concrete at the site exceeding the slump stated be removed from the site at no additional cost to the Government. All subsequent batches shall be tested for slump until the necessary adjustments have been made to ensure that concrete delivered to the forms does not exceed the maximum slump.

4. Test Beams

5. Plant and Mixing Equipment Compliance Tests and Materials Tests at Plant

4. For concrete, one set of four beams shall be made for each increment or fraction of 300 placed during each 8-hour shift. Additional sets may be required when concrete slump or mix proportions are adjusted. Additional sets will be required when the concrete slump is excessive as stated in Item 3 above, or when mix proportions are adjusted.

5. Contractor compliance with ASTM C 94 "Standard Specifications for Ready Mix Concrete", with documentation, reports, or certification of compliance upon request by the Contracting Officer.

*Where pumping is approved samples for slump test shall be obtained prior to entering the pump.

5-4

5-5. Admixtures. Except where authorized by the specifications, admixture other than an air-entraining agent is not to be used in any concrete without prior approval of the Contracting Officer. The admixture type proposed for use will be thoroughly investigated in laboratory tests of concrete made with the cement and aggregate proposed for use on the project. Minimum test requirements will include the effect of the admixture on strength of concrete at an age of 28 days and may include strength test of up to 90 days, as well as on such other properties as may be necessary to demonstrate that there will be no adverse effect on the concrete. Continued use of any approved admixture other than entrained air will be based on satisfactory control of the concrete under all conditions in the field.

5-6. Methods of Curinq.

are suitable, Several different methods of curing and the Contractor is given the option of selecting a preferred method in accordance with requirements, unless otherwise specified. However, any curing method that has proved unsatisfactory in a particular geographic area will not be permitted for projects in that area. All materials and equipment necessary for curing and protecting the concrete must be available on the job before concrete placement is started, curing will be tolerated.

and no delays in starting the Curing procedures will include provisions for attaining proper moisture and temperature conditions in the concrete. Experience has indicated that evaporation shrinkage cracking can be controlled by moist curing of the concrete under wet covers for a minimum of 24 hours after placement.

excessive heat loss and promote hydration, To prevent it is important that the covers extend over the forms as well as the concrete surface.

spraying equipment should direct a very fine mist of water onto the concrete surface until curing under wet covers can be started.

During cold weather, other approved methods of curing providing adequate protection against rapid heat loss from the concrete shall be used during the early hardening period. Precautions shall also be taken at the end of the curing period to avoid rapid cooling of the concrete and the resulting development of undesired stresses.

5-7. Procedures for and Testinq.

a. Testing and reporting shall be performed in accordance with the American Society for Testing and Materials (ASTM) Standards as follows: Sampling Fresh Concrete', ASTM C 172; Slump of Portland Cement Concrete, ASTM C 143; Air Content of Freshly- Mixed Concrete by Pressure Method, ASTM C 231 (for lightweight concrete use

5-5

PAM 415-l-2 volumetric method, ASTM C 173); and Unit Weight, Yield, and Air Content (Gravimetric) of Concrete, ASTM C 138, with the exception that a 0.25 cubic-foot container, such as the lower part of an air meter, may be used in place of the 0.50 cubic-foot capacity specified for concrete with coarse aggregates up to inch maximum size.

b. The minimum number of cylinder specimens shall be three per set (one for 7-day and two for compressive strength tests).

For lightweight concrete, one additional cylinder specimen shall be taken to test for air-dry unit weight. Additional specimen shall be made if required to establish strengths for form stripping or other purposes. Concrete samples shall be secured in conformance with Standard Method of Sampling Fresh Concrete, ASTM C 172, and test specimens fabricated and cured in accordance with Standard Method of Making and Curing Concrete Compression Test Specimens in the Field, ASTM c 31. Cylinders shall be tested in accordance with Standard Test Method for Compressive Strength of Molded Concrete Cylinders, ASTM C 39. Unit weight shall be tested in accordance with Standard Test Method for unit weight for Structural Lightweight Concrete, ASTM C 567.

C . Use of plastic molds, in lieu of other approved molds, will be based upon the following:

(1) Prior approval as to type, dimensions, and other properties shall be required.

(2) Plastic molds will not be reused.

d. Field adjustment of approved water-cement ratios.

(1) Addition of water to the plastic…