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Construction Materials

William G. LaSage NYSDOT Region 7 Materials Engineer. Construction Materials. Materials Forms and Manuals. Where do I find these documents? https://www.nysdot.gov/divisions/engineering/technical-services/materials-bureau/forms-manuals What’s available?

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Construction Materials

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  1. William G. LaSage NYSDOT Region 7 Materials Engineer Construction Materials

  2. Materials Forms and Manuals Where do I find these documents? • https://www.nysdot.gov/divisions/engineering/technical-services/materials-bureau/forms-manuals What’s available? • MURK Part 2A - Materials Inspection Manual (Materials Acceptance Requirements) • Materials Method 9.1 - Plant Inspection of Portland Cement Concrete • Materials Method 9.2 - Field Inspection of Portland Cement Concrete • Materials Procedure NY05-04 – Preparing and Processing Fabrication Drawings for Precast Products • Materials Procedure 401 - Plant Inspection of Hot Mix Asphalt (Superpave)

  3. Miscellaneous NYSDOT Publications MURK Part 1B - Construction Inspection Manual (CIM) • https://www.nysdot.gov/main/business-center/contractors/construction-division/construction-repository/murk1b_cim_20030225.pdf Steel Construction Manual 3rd Edition (March 2008) • https://www.nysdot.gov/divisions/engineering/structures/manuals/scm Prestressed Concrete Construction Manual (September 2000) • https://www.nysdot.gov/divisions/engineering/structures/manuals/pccm Standard Sheets • https://www.nysdot.gov/main/business-center/engineering/cadd-info/drawings/standard-sheets Standard Specifications • https://www.nysdot.gov/main/business-center/engineering/specifications

  4. Materials Certifications Where do I find out what is required? • Contract Plans/Proposal • NYSDOT Standard Sheets • NYSDOT Standard Specifications • Each Section has a “Materials” narrative (XXX-2) detailing the Materials Acceptance requirements for a given item. • MURK Part 2A - Materials Inspection Manual Approved List • Aggregates • https://www.nysdot.gov/divisions/engineering/technical-services/materials-bureau/fine-coarse-aggregates • Materials and Equipment • https://www.nysdot.gov/divisions/engineering/technical-services/materials-bureau/materials-and-equipment

  5. Hot Mix Asphalt Plant Inspection Hot Mix Asphalt Plant • NYSDOT Approved Plant • Annual Inspection • 90 Day Scale Checks Up-to-Date Mix Designs • NYSDOT Regional Materials assigns production status to all Superpave mix designs that have been successfully plant verified. • The owner is encouraged to review all Superpave mix designs and make their own determination on acceptability. • For all Marshall Mixes, a mix design must be submitted for approval by the owner. Plant Inspection • Required for daily Superpave production >500 TON. • Plant may certify quantities of less than 500 TON. • NYSDOT Standard Specifications §401-3.03 requires 3:00 PM notification the day before production to arrange for inspection. • Contractor must give notification to plant prior to 3:00 PM to ensure scheduling can be accommodated.

  6. Hot Mix Asphalt Plant Inspection Plant Inspection • Quality Assurance/Quality Control Certification Program (Alfred Certification) • Inspector must possess current certification. • Recertification is required every 5 years. • Superpave (NYSDOT Standard Specifications §402) • Inspection progressed as per NYSDOT Materials Procedure 401. • Daily production for each mix is broken into 1000 TON Sublots. • Independent QC and QA aggregate and hot mix asphalt samples are taken within each Sublot. • Samples are tested for Gradation, Bulk Specific Gravity, Maximum Specific Gravity, and % Air Voids. • A Plant Production Quality Adjustment Factor (QAF) is calculated based upon the results of these tests. • The inspector also completes all required paperwork, records in the Hot Mix Asphalt Daily Diary pertinent/required information pertaining to the day’s production, and prepares the BR 343 – Daily Hot Mix Asphalt Authorized Shipments.

  7. Hot Mix Asphalt Plant Inspection Plant Inspection • Marshall Mix (NYSDOT Standard Specifications §403) • Section 403-3 Construction Details assigns responsibility to the Contractor for production Quality Control. • Unless otherwise specified, a Quality Control Technician is not required to be present during production. • Typically the Quality Control Technician will monitor and verify mix production via automation. • Owners are encouraged to perform Quality Assurance Testing to ensure the quality of the hot mix asphalt being produced. • Asphalt content verified via automation. • AASHTO T27 – Sieve Analysis of Fine and Coarse Aggregates • AASHTO T245 - Standard Method of Test for Resistance to Plastic Flow of Bituminous Mixtures Using Marshall Apparatus • AASHTO T166 – Bulk Specific Gravity of Compacted Mixtures • AASHTO T209 – Theoretical Maximum Specific Gravity of Bituminous Paving Mixtures • AASHTO T269 – Percent Air Voids in Compacted Dense and Open Bituminous Paving Mixtures

  8. Hot Mix Asphalt Field Inspection Compaction Methods • Marshall Mix • NYSDOT Standard Specification Tables 403-2 (Similar to 80 Series) • Superpave 80 Series • Number of Passes • NYSDOT Standard Specification Table 402-5 • Superpave 70 Series - Nuclear/Non-Nuclear Density Gauge Monitoring • “Peak the Gauge” • NYSDOT Standard Specification §402-3.07.C • EIC’s must obtain a copy of the Nuclear Gauge Operators Associated General Contractors, New York State, Density Gauge Inspector Certification for the project records. • Superpave 60 Series – Coring of Test Strip with Nuclear/Non-Nuclear Density Gauge Monitoring • NYSDOT Standard Specification §402-3.07.B • EIC’s must obtain a copy of the Nuclear Gauge Operators Associated General Contractors, New York State, Density Gauge Inspector Certification for the project records.

  9. Hot Mix Asphalt Field Inspection Temperature Readings, Yields and Depth Checks • Must be done on a regular basis and recorded. Tack Coat • Tack Trucks • NYSDOT Standard Specifications §407-3.01 Equipment • Self-Certification and Annual Calibration (ASTM D 2995) must be provided prior to use on the project. • Application Rates as per NYSDOT Standard Specifications Table 407-1. • Sampling & Testing • Sampling as per NYSDOT Materials Method 8.2 - Asphalt Emulsion Quality Assurance. • Emulsion must meet requirements of NYSDOT Standard Specifications Table 702-10.

  10. Hot Mix Asphalt Paperwork/Certifications Plant Certifications • BR 307 – Region 7 Quality Control Hot Mix Asphalt Certification • Generated by the Plant for all Marshall Mix or non-testable quantities of Hot Mix Asphalt. • BR 343a – Daily Hot Mix Asphalt Authorized Shipments • Generated by the Plant Inspector. • Certifies Type of Material, Quantity, and Quality Adjustment Factor. Delivery Tickets • Must conform to NYSDOT Standard Specifications §401-4 Method of Measurement. • Verify Mix Codes (09F32YB) using NYSDOT Standard Specification Table 401-7. Density Monitoring • Nuclear Gauge = BR 340 & BR 341 – Hot Mix Asphalt In-Place Pavement Density Data • Non-Nuclear Gauge = BR 66, BR 68 & BR 69 – Hot Mix Asphalt In-Place Pavement Density Data • Coring = BR 109 - Test Section Nuclear Gauge Test Data

  11. Concrete Plant Inspection Concrete Plant • NYSDOT Approved Plant • Annual Inspection • 90 Day Scale Checks Up-to-Date • NYSDOT Inspected Transit Mixers (Inspection Sticker) • Annual Inspection • Barrel/Fin Condition • Counter Function • Water Tank Calibration Mix Designs • Annually or when updates are necessary, Regional Materials provides the producer with mix designs for all NYSDOT concrete classes (A, D, J, H, etc.). • For all non-NYSDOT mixes, a mix design must be submitted for approval by the owner. Plant Inspection • Required for all concrete production of 25+ CY. • Plant may certify quantities of less than 25 CY. • NYSDOT Standard Specifications §501-3.03 requires 3:00 PM notification the day before production to arrange for inspection. • Contractor must give notification to plant prior to 3:00 PM to ensure scheduling can be accommodated.

  12. Concrete Plant Inspection Plant Inspection • NYSDOT Concrete Batch Plant Inspector Certification Program • Inspector must possess current certification. • Recertification is required every 5 years. • Inspection progressed as per Materials Method 9.1 - Plant Inspection of Portland Cement Concrete. • Each production day, aggregates are sampled and tested for gradation and moisture content. • For HP concrete, moisture corrections are calculated to determine the required hold back water. • Cement, flyash, and microsilica samples are obtained and sent for testing, as appropriate. • Frequent sampling is encouraged to ensure the quality of the materials incorporated in the batch. • Verify the correct mix design is being batched under automation, in spec, using approved materials, and being transported in an approved truck. • The inspector records in the Concrete Daily Diary all pertinent/required information pertaining to the day’s production and prepares the BR 316 – Daily Concrete Batch Plant Report.

  13. Concrete Field Inspection Field Inspection • Certifications. • ACI Concrete Field Testing Technician Grade I • NYSDOT Field Testing Technician Program • NICET Level II Construction Materials Testing Technician • Inspection as per Materials Method 9.2 - Field Inspection of Portland Cement Concrete. • Slump/Air Tests at a minimum of every 50 CY. • Slump/Air/Temperature/6” x 12” Concrete Cylinders at a minimum of every 200 CY. • A minimum of 2-28 Day Cylinders must be cast for each structural element. • No more than 8 Cylinders should be cast for any structural element. • All samples must not be obtained from the first or last 10% of the load. • Cylinder samples must come from the middle third of the load. • Additional slump/air testing and fabrication of cylinders may be necessary, if mix quality problems are encountered. • To limit the potential risk of out of spec material being incorporated into the work, placement should be halted while the concrete is being tested.

  14. Concrete Field Inspection Field Inspection • If the material begins to test marginally, • Inform your Contractor. • The contractor should then contact the plant to request corrective action. • Increase testing frequency until you have confidence the material has improved. • Communication, communication, communication! • If you encounter out of spec test results, • Inform your Contractor. • Resample and Retest. • If the retest fails, reject the load. • Increase testing frequency until you have confidence the material quality has improved. • Out of Spec Material CANNOT be accepted! Cylinder Curing • NYSDOT Standard Specification Table 555-4 • Notes 1 & 3 require “Early Open” cylinders to be cured in the same manner as the structural element they represent. • Cylinders should also be protected from freezing or excessive heat (baking in the sun).

  15. Concrete Paperwork/Certifications Plant Certifications • BR 316 – Daily Concrete Batch Plant Report • Generated by the Plant Inspector • BR 342 – Portland Cement Concrete Materials Certification • Producer Certification of Concrete (<25 CY) Other Paperwork • Batch Tickets • Must conform to NYSDOT Standard Specifications §501-3.02.D - Delivery Tickets. • Record the water added onsite on the delivery ticket. • Record the Begin/End Discharge times. • BR 300 – Concrete Cylinder Report • One form per cylinder set (2 cylinders) is required.

  16. Questions?

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