Attachment_01_Performance_Work_Statement_Polymeric_Pavement_Repair_Material_Testing.pdf

Polymeric Pavement Repair Material Testing Performance Work Statement

Purpose The Airfields and Pavement Branch (APB) at the Engineer Research and Development Center (ERDC) conducts independent testing on pavement repair materials used by the USAF and other branches of the DOD. APB tests and maintains a listing of commercial proprietary cementitious and polymeric-based products recommended for field use. To be included on the recommended product list, candidate materials are tested under controlled laboratory conditions to ensure adequate mechanical and durability performance within the operational constraints required for airfield repairs. Materials are also tested to check user-friendliness with typical personnel and equipment used to conduct repairs. The laboratory testing protocol by which all products are evaluated is detailed in Air Force Engineering Technical Letters (ETLs). Various laboratory testing standards are completed, and the results of each test are compared against their corresponding failure criteria. Further development and refinement of in-place specifications or testing methods utilized in the testing and evaluation process may be required as issues arise.

Work The contractor shall conduct controlled material testing of three (3) polymeric-based pavement repair materials using the standard testing methods described in Table 1. All testing listed in Table 1 will be repeated for each of the repair materials supplied. The ERDC will obtain and deliver the candidate repair materials to the material testing laboratory for testing. This includes the polymer binder, required surface priming materials, and all aggregates required to extend the product to follow the manufacturer’s batching information. Material delivery will occur within the first week after the contract is awarded. The test results submitted by the laboratory will be reviewed by an APB engineer at the conclusion of testing to verify testing procedures used and data usability for material classification.

Engineering Testing Service Requirements An USACE validated material testing laboratory is required to conduct the testing on the polymeric-based pavement repair materials. Additional information on the USACE Laboratory Validation Program can be found at the website provided below. The material testing laboratory must be proficient in the standard aggregate and concrete tests listed in Table 2. USACE credentials must remain valid until at least June 30, 2016.

Any laboratory that is proficient in ASTM C78 may be considered proficient in ASTM C293 for this work; however, the laboratory must supply a memorandum to the ERDC detailing its capability to perform the work following ASTM C580 and understanding the differences in the testing method compared to the more industry standard ASTM C78 test procedure.

Additional requirements of the material testing laboratory include:

Physically located within 1,200 miles of the ERDC-Vicksburg, MS location to enable prompt delivery of the materials to the selected laboratory. Materials supplied by the ERDC will be in the manufacturer’s original packaging and transported on shrink-wrapped wooden pallets. The laboratory will be responsible for offloading the delivery vehicle upon its arrival.

The laboratory shall have lead/supervisory personnel that are American Concrete Institute (ACI) certified in the following grades to direct and/or perform the work. Copies of the certification certificates shall be submitted to the ERDC before work begins and shall not expire before June 30, 2016.

o Aggregate testing: Aggregate Testing Technician Grade 1 o Specimen production: Concrete Field Testing Technician Grade 1 o Specimen testing: Concrete Strength Testing Technician

Individual products delivered to the testing lab must be stored according to manufacturer specifications and tested within the manufacturer’s printed shelf life on the units provided. The ERDC will provide materials with at least 3 months of usable shelf life to the laboratory for testing. If the manufacturer does not provide this information, an indoor location away from direct sunlight with temperature controls set to 65 ± 15°F will be used at a minimum.

Conform to any modifications to the standardized test procedures as described in Table 1.

The laboratory must report test results to APB via Microsoft Word file and provide

Microsoft Excel files with all test results within 2 weeks of completion of all tests.

The test results must be reviewed by a professional engineer before submitting to the

ERDC.

Aggregate Extender Usage All products will be tested extended with aggregate according to manufacturer specifications/recommendations. Products sold as extended products (with aggregate) will be extended using the aggregate provided with the product for testing. Products with specific fixed aggregate batching quantities will follow the information given by the manufacturer. The maximum extension used will be the maximum of either 50% by volume or the maximum allowed by the manufacturer for a repair depth of 2 in. for products that allow for variable aggregate quantity usage. The volume of aggregate used for extending the materials will be standardized to the yield difference reported by the manufacturer for products with variable aggregate volume usage [Reported/Calculated Extended Yield – Reported Neat Yield = Aggregate Volume]. Some manufacturers report the aggregate extension by weight, but aggregate properties will vary and the use of weights may provide inaccurate results where formulation changes cannot be monitored. Aggregate extenders used when producing repair material will be air dry (moisture content on production day less than its saturated surface dry value) at the time of batching.

Aggregate testing of prepackaged manufacturer’s aggregate extension materials is not required.

Testing of bulk aggregates provided by the ERDC is required to verify conformance to manufacturer requirements and to correctly batch extenders. Bulk aggregate materials will be provided by the ERDC in 5-gal plastic buckets as needed. Aggregate will consist of an ASTM C33 #8 pea gravel or natural concrete sand local to Vicksburg, MS, unless otherwise specified by the manufacturer. The material testing laboratory will be responsible for washing the aggregates before product batching.

Material Production Manufacturer’s guidelines for producing individual products at specified test temperatures will be applied; however, this will not interfere with the requirements stated in ASTM C881 or as described in the individual testing standard used to control the production of all materials made for comparisons. Any deviations made to procedures described in the individual test standards or manufacturer’s recommended uses must be fully described to and approved by APB.

Strength Testing Tolerances Timing of the testing conducted is critical. Strength or fresh property specimens will be tested within the allowed time tolerances provided in each standard or as directed based on the time two-part systems are first mixed or one-part systems are first dispensed. If an individual standard does not specify time tolerances, values from ASTM C39 must be applied to allow for consistent data reporting. The early strength measurements (1, 2, and 4 hr) do not have specified testing time tolerances in ASTM C39. Therefore, a tolerance of ± 10 min will be applied to this testing to ensure true measures of strength at the specified times are collected while balancing the laboratory’s ability to collect the information in a timely manner. All specimens made for an individual test are not required to come from the same batch of material made to assist in meeting short testing tolerance times, but, records of the individual batches (production notes and quantities) made are to be kept to help explain any potential irregularities in the results.

Chemical Resistance Solution Requirements Standard immersion solutions used for ASTM C267 testing are to be used as indicated in Table

1. ASTM reference solutions shall follow the requirements given in ASTM D471. Standard JP- 8 solution shall follow the requirements given by US Military Specification MIL-DTL-83133H.

The ERDC can provide commercial source information for solutions to the contractor as needed.

Copies of the manufacturer’s certificates of analysis for each reference solution shall be provided to the ERDC for review before chemical resistance testing is to begin. No certificate is necessary for distilled or deionized water; however, the laboratory shall report which type of water will be used before testing.

Work Constraints

Security (only required if contractor visits the ERDC)

All contractor and all associated sub‐contractors employees shall comply with applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative).

The contractor shall also provide all information required for background checks to meet installation access requirements to be accomplished by installation Provost Marshal Office, Director of Emergency Services or Security Office.

Contractor workforce must comply with all personal identity verification requirements as directed by DOD, HQDA and/or local policy.

In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any individual facility or installation change, the Government may require changes in contractor security matters or processes

Data ownership and use The contactor (or utilized subcontractors) shall not release any verbal or written information to the public or media without approval from the ERDC contracting office.

All data collected must be furnished and provided access to the ERDC contracting office as requested.

Equipment operations The contractor shall be responsible for the operation, maintenance, and repair of the equipment used for the evaluation.

Testing or data collection delays greater than 2 days shall be discussed with the ERDC representative immediately to determine the best course of action for resolution.

Performance Requirements Summary Statement Standard AQL Monitoring Method

Incentive/ Remedy

The contractor shall have the technical capability and personnel with adequate knowledge of the required testing. Disposable supplies and equipment required to complete work tasks are in good and working order.

- A USACE validated laboratory is used to conduct the standardized tests as listed in the performance work statement (PWS).

- Contractor personnel have training/certification credentials as listed in the PWS.

- Contractor procures adequate test media for ASTM C267 testing.

100% - ERDC verifies that candidate laboratory is a USACE Validated Laboratory for the standardized tests listed in the performance work statement (PWS) before final selection of the contractor used.

- Candidate laboratory submits American Concrete Institute (ACI) Level 1 training/certification credentials as listed in the PWS for ERDC review before work is to begin.

- Contracted laboratory submits certificates of analysis concerning the standard media solutions used for ASTM C267 testing for ERDC review before work is to begin.

Satisfactory or Unsatisfactory Rating in CPARS

The contractor shall complete each test required as described by its appropriate standard. An organized listing of each standardized test method’s reporting requirements is submitted. The testing results submitted produce acceptable results for the ERDC classification analysis completed.

- Specified forms of data storage device used to transfer data to ERDC representative.

- The documented test results should be easy to read and follow. The results cover the minimum required to report as described by each test standard.

- ERDC will validate the submitted dataset to ensure the data reported is correct, accurate, and usable for the evaluation efforts.

- Incorrect, inaccurate, or unusable data will require resubmission and/or retesting.

100% - 100% inspection reported by ERDC representatives after contractor submits testing results.

Exceptional, Satisfactory or Unsatisfactory Rating in

CPARS

Customer satisfaction 95% satisfaction rate of contract specifications

100% 100% inspection as reported by ERDC representatives.

Exceptional, Satisfactory or Unsatisfactory Rating in

CPARS

Timeliness 100% timely response to requirements and project requests

100% 100% inspection and/or random basis reported by ERDC representatives.

Satisfactory or Unsatisfactory Rating in CPARS

Timely submission of proper invoices

- 100% submission of invoice(s).

- Final invoice shall have the word “final” written on it.

100% - At the end of project.

- Final invoice submitted shall have the word “final” written on it.

Satisfactory or Unsatisfactory Rating in CPARS

Invoices will not be processed for payment if desired outcome is not met. KO will be advised of the situation by COR and KO will discuss what other actions are warranted.

USACE Validated Laboratories Website http://www.erdc.usace.army.mil/Media/FactSheets/FactSheetArticleView/tabid/9254/Article/476 661/materials-testing-center.aspx

Required Start Date: Three (3) weeks after contract award.

Required Completion Date: 30 Mar 2016 http://www.erdc.usace.army.mil/Media/FactSheets/FactSheetArticleView/tabid/9254/Article/476661/materials-testing-center.aspx

Table 1. Testing Requirements per Material Tested.

Item Standard Specimens per Test Condition

Additional Testing Specifics

Aggregate Testing Only required for repair materials that utilize local aggregates as extenders.

Sampling technique ASTM D75 -

- #200 material ASTM C117 1 - Reject if greater than 1% passes the #200 sieve Gradation ASTM C136 1 - Reject material if maximum size is greater than 0.75”

- ASTM C33 #8 aggregate max size is 0.5” LA Abrasion ASTM C131 1 - Expect to use Gradation C for testing for a #8 aggregate

- Reject material if mass loss is greater than 50% Specific Gravity and Absorption

ASTM C127

or C128

1 - Testing efforts are only expected to require coarse aggregate.

Material Testing Laboratory Specimen Construction

Varies All - Condition components, supplies, and equipment to a temperature of 73 ± 4 °F for 2 days before batching products.

- Demold specimens 30 - 40 minutes after batching materials

- Cure all specimens at 73 ± 4°F and 50 ± 10% relative humidity

Compressive Strength

ASTM C579 6

(2 groups of 3 specimens preferred)

- Using test method B (assumes #8 aggregate or smaller is used)

- Test time at 1 hr, 2 hr, 4 hr, 1 day, 7 day and 28 day.

- If aggregates larger than #8 sized are provided by manufacturer, test method C may be used using 2” x 4” cylinders. Historically, cube vs. cylinder results are not equal. Discuss with APB before starting if this occurs.

Flexural Strength and Elastic Modulus

ASTM C580 3 - Use method C with 3” x 3” square cross-section beams.

- Test time at 1 hr, 2 hr, 4 hr, 1 day, 7 day and 28 day.

- Report tangent and secant elastic modulus values

Bond Strength ASTM C882-modified

3 - Test material using a pre-made dummy (PCC or repair material) bonded to the repair material. The total specimen will consist of two halves; A: pre-cast and hardened dummy and B: wet cast repair material against half A.

- 3” x 6” specimens. Slant face of pre-cast dummy sand blasted with 80 grit media before placing repair material.

- Two testing conditions: repair material-to-repair material (of same material) and repair material-to-ordinary plain concrete with a primed surface (using manufacturer’s recommended primer material if required).

- Test time at 4 hr and 1 day.

Thermal Compatibility

ASTM C884 3 - The concrete base for constructed specimen is to be made by ASTM C672. The ERDC can provide an initial mixture design and material source information that meets the requirements given for use if requested. The testing laboratory will be responsible for obtaining materials needed for casting the base slabs used for testing and verification of

Item Standard Specimens per Test Condition

Additional Testing Specifics the required mixture properties.

- New bases must be used for each specimen made.

- Sand blast bonding surface with 80 grit media

- Ensure a mortar material is used. If aggregates larger than 3/8” are present in any aggregate component used, screen component through a 3/8” sieve before use.

- Demold polymeric specimen after 1 day and cure for an additional 6 days.

- Grinding and/or sawcutting may be needed on vertical faces. Complete all corrective efforts 2 days before individual specimens are placed in the freezer.

- Freezer temperature set to -6 ± 3°F. Make 5 total freeze-thaw cycles after curing. Each freeze and thaw duration is 24 ± 1 hr.

Chemical Resistance

ASTM C267 3 - Using test method B

- Cure for 7 days including casting day

- Change test medium weekly

- Solvents used: JP-8 standard grade (MIL-DTL-83133), ASTM Reference Fuel B, ASTM Reference Fuel F, ASTM Reference Oil #3/IRM #3, and distilled/deionized water.

- Test temperatures: 73°F, 150°F

- Compression strength measurements taken after cure time: 1 hr, 2 hr, 4 hr, 1 day, 7 day, and 28 day.

Dynamic Mechanical Analysis

ASTM

D5023

4 - Test from -60 to 400°F where the temperature increases linearly 3°C per minute.

- Load in sinusoidal 3-point bending applied every 0.1 sec and a maximum strain of 0.01%.

- Discuss specimen size options with APB and try to use the maximum specimen size allowed with available equipment.

- Specimen without aggregates

- Test specimens after 7 days of curing.

Time of Set ASTM C308 3 - Setting time measurement only. Measurement interval scheme needs development, but is expected to be quicker than that listed.

- Use of ASTM C279, Type III compliant bricks is not required. Use of a standard specimen ring and glass plate as used in ASTM C191 is allowed if similar measurement location requirements are used.

- Setting time of the materials will vary. Rapid setting products will require testing a much shorter intervals than listed in the standard and ASTM C191. Make at least 10 measurements as evenly as possible over the test duration. Make an additional measurement 60 seconds after the first test where less than 1 mm of indention is recorded for verification of test completion. Continue testing if verification is not achieved.

Table 2. Minimum Testing Procedure Validation Required Aggregate Cement/Concrete

ASTM C117 ASTM C39

ASTM C127 ASTM C109

ASTM C128 ASTM C191

ASTM C131 ASTM C192

ASTM C136 ASTM C293

ASTM D75