New Jersey

Department of Transportation

Standard Specifications

for Road and Bridge Construction

2007

Division 900 – Materials

Section 901 – Aggregates

901.01 Source  

Use aggregates from a single source and geological classification in any 1 construction item unless otherwise authorized. Use only sources of aggregate that are listed on the QPL.

The ME may allow aggregates from different sources if they are of the same geological classification and have similar specific gravities and aggregate properties.

Use test methods for gradation according to the appropriate provisions of AASHTO T 11 or T 27, unless otherwise noted. Gradations of aggregates in the various tables of this and other Sections are the percentages passing by weight.

The aggregate producer shall submit annually, to the ME for approval, a quality control plan for the aggregate products. The aggregate producer may obtain guidelines for developing the quality control plan from the ME upon request.

901.02 Stockpiles   

Provide an area for each stockpile of adequate size, reasonably uniform in cross-section, well drained, and cleared of foreign materials.

At concrete and HMA mixing plants, stockpile a sufficient quantity of aggregate to provide for a minimum of 1 day’s operations. Place the aggregate stockpiles on a firm, hard surface, such as a compacted aggregate, HMA, or concrete surface. Construct the stockpile by placing the aggregates in layers of not more than 3 feet thick.

Locate the piles so that there is no contamination by foreign material and no intermingling of aggregates from adjacent piles. Do not use steel-tracked equipment on the stockpiles.

Do not store aggregates from different sources, geological classifications, or of different gradings in stockpiles near each other unless a bulkhead is placed between the different materials. If blending aggregates of different gradings and from different sources, proportion through weigh hoppers. The ME may allow loader blending of aggregate stockpiles if included in the approved aggregate producer’s quality control plan. The Department will reject aggregates found segregated or contaminated. If a stockpile is rejected for segregation, the Contractor may reconstruct it for further evaluation. Use methods that prevent segregation when charging aggregates from stockpiles.

Do not use washed aggregates sooner than 24 hours after washing or until the surplus water has drained out and the material has a uniform moisture content.

Do not stockpile RAP higher than 15 feet. Cover or otherwise protect stockpiles of RAP for use in HMA to prevent buildup of moisture.

901.03 Coarse Aggregate  

Obtain coarse aggregate as specified in 901.01. Use coarse aggregate that is broken stone or washed gravel graded as specified Table 901.03-1. Stockpile coarse aggregate as specified in 901.02. The ME will sample coarse aggregate as specified in Table 901.03-2.

901.03.01 Broken Stone

Use broken stone that is uniform in texture and quality and that conforms to the requirements specified in Table 901.03.01-1.

The geologic classifications are as follows:

1. Argillite. A thoroughly indurated and cohesive rock composed predominantly of silt size or smaller particles of clay, quartz, and feldspar or the fine-grained thermal recrystallization products of this assemblage (hornfels). Ensure rock is bedded thickly enough so as not to break into thin pieces at planes of stratification.
   
   
2. Carbonate Rock. A thoroughly indurated and cohesive rock composed predominantly of calcite and dolomite, bedded thickly enough so as not to break into thin pieces at planes of stratification. Minerals insoluble in hot hydrochloric acid are discrete grains of quartz, clay, and mica.
   
   
3. Gneiss. A metamorphic rock consisting principally of quartz and feldspar. Ensure rock has a dense structure, with a uniform distribution of minerals that will not break into thin pieces at lines of stratification.
   
   
4. Granite. An equigranular or porphyritic igneous rock consisting principally of quartz and feldspar.
   
   
5. Quartzite. A metamorphic rock composed principally of quartz. Quarry rock so that only the nonarkosic, uniformly compacted quartzites are included in the graded products. Ensure quartzite is not schistose in structure.
   
   
6. Trap Rock. An igneous rock, locally, either basalt or diabase, with a uniform distribution of constituent minerals. Amygdaloidal or vesicular basalt is not considered trap rock and is considered a deleterious material for testing purposes.

901.03.02 Washed Gravel

Use washed gravel that is either crushed or uncrushed as specified and that conforms to the requirements specified in Table 901.03.02-1.

Quartz gravel is composed of natural pebbles, of which the majority is coarsely crystalline quartz. Ensure that the individual crystals within each pebble are intergrown into a tenacious, nonporous, interlocking texture that fractures as a single unit. Ensure that the percent of wear determined according to the Los Angeles Abrasion Test is as specified for the various uses, except that the percent maximum loss for quartz gravel is 50 percent.

When the sodium sulfate soundness and scratch hardness tests total 10 percent or more, the ME will perform a petrographic analysis to determine the amount of unsound and weathered material.

901.04 Blast Furnace Slag

Obtain blast furnace slag as specified in 901.01. Use as blast furnace slag the air-cooled residue resulting from the production of pig iron. Ensure that the blast furnace slag consists of tough, durable, angular fragments that are uniform in density, absorption, and quality, and are free from flux stone, dirt, or other objectionable material. Stockpile blast furnace slag as specified in 901.02. Ensure that blast furnace slag conforms to the requirements specified in Table 901.04-1.

901.05 Aggregates for HMA  

901.05.01 Coarse Aggregate

Use coarse aggregate for HMA that is broken stone conforming to 901.03.01, except that the Contractor may use carbonate rock for the surface course only in shoulder areas, parking areas, or driveways.

901.05.02 Fine Aggregate

For HMA surface course, use fine aggregate that is manufactured stone sand or natural sand.

Manufacture stone sand from aggregates conforming to 901.03, with not more than 15 percent passing the No. 200 sieve. When the percent passing the No. 200 sieve exceeds 15 percent, blend the stone sand with another approved sand so that the combination contains no more than 15 percent passing the No. 200 sieve, based on stockpile samples theoretically combined. Feed each sand source into the plant through a separate cold feed hopper.

Use natural sand consisting of material composed of predominantly angular particles of quartz or other hard durable minerals conforming to the quality and gradation requirements specified in Table 901.05.02-1 and Table 901.05.02-2, respectively.

For HMA surface course, wash and grade the natural sand. Natural sand does not need to be washed if it conforms to the requirements of 901.06.02, except that the allowable percent passing the No. 200 sieve is 0 to 5 percent.

The ME will sample fine aggregate at a frequency of 10 pounds for each 500 tons.

901.05.03 Mineral Filler

Use mineral filler for HMA that is free from lumps and foreign materials. Produce mineral filler from broken stone conforming to 901.03.01, fly ash conforming to 903.02.03.A, kiln dust from cement manufacture, or baghouse fines from an HMA plant. Produce baghouse fines from a consistent geological source of coarse and fine aggregate.

Ensure that a HMA mixture containing the filler retains 70 percent of its initial strength after an immersion cycle of 14 days when prepared according to AASHTO T 167 and tested according to AASHTO T 165.

Use mineral filler that, when tested according to AASHTO T 37, conforms to the gradation requirements specified in Table 901.05.03-1.

901.05.04 Reclaimed Asphalt Pavement (RAP)

Process RAP for HMA through screening and crushing operations to ensure that it is 100 percent passing the maximum aggregate size for the mixture.

Use RAP containing asphalt binder that is free from solvents or other contaminating substances. Ensure that the coarse aggregate contained in the RAP conforms to the requirements of 901.03.01 for broken stone and to the requirements of 901.03.02 for gravel. Ensure that the fine aggregate contained in the RAP conforms to the quality requirements in 901.05.02.

901.05.05 Crushed Recycled Container Glass (CRCG)

Use container glass that is derived from items such as bottles. Use glass that when crushed does not produce thin sliver and flake-like fragments. Ensure that no more than 5 percent of the material is glass derived from thin walled items, such as test tubes and other laboratory glassware, which are not considered to be container glass. Use CRCG that is 100 percent passing a 3/8-inch sieve.

Ensure that the CRCG contains no more than the maximum allowable percent of foreign materials specified in Table 901.05.05-1.

901.05.06 Ground Bituminous Shingle Material (GBSM)

Use GBSM that is derived from pre-consumer roofing shingles and is 100 percent passing a 3/4-inch sieve and that conforms to the composition requirements specified in Table 901.05.06-1.

Submit a certificate of compliance, as specified in 106.07, for the GBSM. Submit test methods and results along with the certification.

Add the GBSM to the mixture through a feed system that individually proportions the GBSM and is approved by the ME.

901.05.07 Remediated Petroleum Contaminated Soil Aggregate (RPCSA)

For use as a coarse aggregate, fine aggregate, or both in HMA base course, the Contractor may use a maximum of 20 percent remediated ID-27 petroleum contaminated soil, produced by a NJDEP approved “Class B” recycling center operating pursuant to N.J.A.C 7:26A, provided it conforms to all quality requirements specified in 901.05.01 and 901.05.02.

901.06 Aggregates for Concrete, Mortar, and Grout  

The ME will test aggregates used in concrete according to AASHTO T 303 for potential expansion due to alkali-silica reactivity. The ME will classify aggregates that produce expansion of 0.1 percent or more after 14 days in solution as potentially reactive. Use potentially reactive aggregate in concrete only in conjunction with remedial agents such as fly ash, slag, or low alkali cement at the minimum addition rates specified in 903.03.01.

901.06.01 Coarse Aggregate

Use coarse aggregate that is broken stone or washed gravel conforming to 901.03.01 or 901.03.02, respectively, except do not use carbonate rock for concrete surface courses, bridge approach, or bridge decks. Use coarse aggregate that is the size or sizes shown in Table 903.03.06-1 and Table 903.03.06-2. Wash the coarse aggregate at least 24 hours before use.

901.06.02 Fine Aggregate

For all classes of concrete and mortar, use fine aggregate that is washed and sized through a sand classifier plant and composed of quartz or other hard, durable particles. Ensure that the fine aggregate is subangular to angular in shape and free of soft particles. Derive fine aggregate from either a natural sand deposit resulting from glacial or water action, or produce a manufactured stone sand from the mechanical crushing of quarried rock or gravel that conforms to 901.03. Ensure that the fine aggregate also conforms to 901.01 and 901.02 and the gradation specified in Table 901.06.02-1.

Ensure that the fine aggregate does not have more than 45 percent passing any sieve and retained on the next sieve and that the fineness modulus according to AASHTO M 6 is from 2.3 to 3.1 for concrete. Ensure that the fine aggregate conforms to the quality requirements specified in Table 901.06.02-2.

The ME will test the fine aggregate for organic impurities and will reject it if it produces a color darker than the standard. Ensure that the mortar-making properties of the fine aggregate for concrete and mortar are not less than 100 percent of those of standard Ottawa sand.

The ME will sample fine aggregate at a frequency of 10 pounds for each 500 tons.

901.06.03 Lightweight Aggregate

Manufacture lightweight aggregate by expanding or sintering material such as slate or shale by the rotary kiln process. Grade the lightweight aggregate to the size designation requirements for 3/4-inch to No. 4 sieves of Table 1 of ASTM C 330. Ensure that the lightweight aggregate producer has at least 5 years experience and a record of successful production and use of such product. Submit to the ME a certification of compliance as specified in 106.07. Ensure that the lightweight aggregate conforms to ASTM C 330 and the following requirements:

1. Sodium Sulfate Soundness. Use a lightweight aggregate that has a sodium sulfate soundness loss of weight that does not exceed 10 percent after 5 immersion and drying cycles when tested according to AASHTO T 104. Use a sample of sufficient size to provide the amounts specified in Table 901.06.03-1 of the various sieve sizes:
   



Table 901.06.03-1 Sampling for Sodium Sulfate Soundness Testing
Sieve Size	Weight
1" to 3/4"	2.20 pounds
3/4" to 1/2"	1.65 pounds
1/2" to 3/8"	1.10 pounds
3/8" to No. 4	0.66 pounds



2. Percentage of Wear. Use a lightweight aggregate with a loss that does not exceed 40 percent when tested according to AASHTO T 96.

901.07 Grit  

Use grit for spreading over the epoxy waterproofing that is a subangular, natural, 98 percent silica sand. Ensure that 90 percent of the total sample by weight falls between the No. 4 and No. 30 sieves, with 0 percent passing the No. 30 sieve.

901.08 Riprap Stones  

Use riprap stones that consist of a uniformly graded mixture of rock conforming to 901.03.01, such that 50 percent of the mixture by weight is equal to or larger than the designated median stone size (d₅₀). Ensure that the stones are a well-graded mixture composed primarily of the larger stone sizes, but with a sufficient quantity of other sizes to fill the progressively smaller voids between the stones. Ensure that the diameter of the largest stone size is less than 1.5 times d₅₀.

901.09 Gabion Basket Stone  

To fill gabion baskets, use crushed stone consisting of trap rock, granite, or gneiss and conforming to the requirements of 901.03.01. To prevent breakdown after placement, use aggregate that is free of cracks due to jointing, faulting, or other causes. Ensure that the aggregate conforms to the size requirements specified in Table 901.09-1.

901.10 Dense-Graded Aggregate (DGA)  

Use a DGA that is listed on the QPL. For gradation acceptance, the ME will sample DGA according to AASHTO T 2 for each 500 cubic yards. The ME will apply the gradation requirements to the material after it has been placed and compacted on the Project.

901.10.01 Virgin

Produce virgin DGA from broken stone conforming to 901.03.01, crushed gravel conforming to 901.03.02, or blast furnace slag conforming to 901.04, except that at least 90 percent of all fragments shall contain at least 1 fractured face. Ensure that the DGA conforms to the following requirements and gradation:

1. Moisture Content. Ensure that the moisture content of DGA immediately before placement is 6 ± 2 percent based on dry weight. If dense-graded aggregate is to be paid for on a weight basis, do not deliver DGA to the Project with the moisture content exceeding 8 percent.
   
   
2. Plasticity and Gradation. When tested according to AASHTO T 90, ensure that the portion passing the No. 40 sieve is non-plastic. Ensure that the gradation conforms to the requirements specified in Table 901.10.01-1.
   



Table 901.10.01-1 Gradation Requirements for DGA
Sieve Size	Percent Passing
1-1/2"	100
3/4"	55 - 90
No. 4	25 - 50
No. 50	5 - 20
No. 200	3 - 10

901.10.02 Recycled Concrete Aggregate (RCA)

The Contractor may produce DGA from recycled concrete aggregate that conforms to the gradation and plasticity requirements specified in 901.10.01 and to the following:

1. Composition. Ensure that the composition, as determined according to NJDOT A-3, conforms to the requirements specified in Table 901.10.02-1.
   



Table 901.10.02-1 Composition Requirements for RCA
Aggregate Property	Minimum Percent	Maximum Percent
Concrete1	90
HMA		10
Brick, cinder block, schist, concrete washout, and other friable material		4
Reactive material		0
Wood		0.1

1	To meet the minimum requirement for concrete, the Contractor may add broken stone, vitreous china, or crushed gravel. Use broken stone conforming to 901.03.01 or crushed gravel conforming to 901.03.02, except that it need not be washed



2. Percentage of Wear. Ensure that the loss does not exceed 50 percent when tested according to AASHTO T 96.
   
   
3. Reporting of Recycled Materials Usage. Report the tonnage of concrete aggregate being recycled to the Solid Waste Management District of origin, according to N.J.A.C 7:26A.

901.10.03 Virgin and RAP Mixture

The Contractor may also produce DGA by mixing a maximum of 50 percent RAP conforming to 901.05.04 with previously approved virgin DGA.

Use a method of mixing that will ensure that the blended mixture is homogeneous with regard to particle size and composition. Ensure that the blended mixture meets the following requirements:

1. Composition. Ensure that the composition, as determined according to NJDOT A-3, conforms to the requirements specified in Table 901.10.03-1.
   



Table 901.10.03-1 Composition Requirements for Virgin DGA and RAP Mixture
Aggregate Property	Percent by Weight Maximum
RAP	50
Concrete	5
Brick, schist, and other friable material	4
Reactive material	0
Wood	0.1



2. Plasticity and Gradation. Use a blended material that is non-plastic when the portion passing the No. 40 sieve is tested according to AASHTO T 90. Ensure that the DGA containing RAP conforms to the gradation for DGA as specified in 901.10.01, except that the percent passing the No. 200 sieve is 0 to 10 percent when tested according to NJDOT A-6.
   
   
3. Density Control. Perform density control as specified in 302.03.01, except for the method for determining the dry density. After determining the wet density according to AASHTO T 310 (Direct Transmission Mode), the ME will take a 1000-gram sample of the DGA for subsequent weighing, drying, and reweighing in the laboratory to determine the moisture content. The ME will calculate the dry density using the wet density measured according to AASHTO T 310 and the moisture content measured from the lab tested sample. The ME will use the dry densities to determine the Q statistic for acceptance of the density.

901.11 Soil Aggregate  

Use soil aggregates that are natural or prepared mixtures consisting predominately of hard, durable particles of stone, gravel, or sand. Mixtures may contain some silt, clay, or stone dust. Ensure that stone conforms to 901.03.01, and that gravel is crushed or uncrushed and conforms to 901.03.02. Use sand that is either natural sand resulting from the weathering process or stone sand produced by grinding or crushing of rock. Ensure that stone sand is manufactured from an aggregate source as specified in 901.03. Provide natural sand consisting of material composed of predominantly angular particles of quartz or other hard, durable minerals.

The Contractor may use soil aggregate produced from RPCSA produced by a NJDEP approved “Class B” recycling center operating pursuant to N.J.A.C 7:26A.

Do not place soil aggregate obtained from subaqueous sources until the ME has determined that its moisture content is not excessive.

Ensure that soil aggregate conforms to the following:

1. Composition of Soil Aggregate. Ensure that the soil aggregate is free from elements or chemicals which, in the presence of water, would produce detrimental effects to pavements, structures, or utility lines, and is free of organic matter, garbage, metal, debris, lumps of clay, or other deleterious matter.
   
   Produce Designations I-1, I-2, I-3, I-4, I-9, I-10, I-11, I-12, I-13, and I-15 from sand, gravel, or stone.
   
   Produce Designation I-5 from hard, durable gravel or stone mixed with sand or stone dust so that it can be compacted into a hard, dense mass. Ensure that the coarse aggregate fraction of the I-5 is composed of at least 85 percent by weight of hard, durable aggregate of a geologic type conforming to 901.03, as determined by lithologic analysis performed according to NJDOT A-3.
   
   Ensure that Designations I-6, I-7, and I-8 consist of clean, free-draining sand, gravel, or stone.
   
   For Designation I-14, use material that is composed of soil aggregate and rock. The material may also contain recycled concrete or HMA. Ensure that the proportion of soil aggregate is sufficient to fill all voids in the rock and larger pieces of recycled material. For Designation I-14, the Contractor may use up to 30 percent steel slag by weight of the coarse aggregate portion of the soil aggregate.  Obtain steel slag from a source listed on the QPL as specified in 901.01.  Use steel slag that was produced as a co-product of the steel making process.  Ensure that the steel slag consists of tough, durable pieces that are uniform in density and quality.  Stockpile steel slag as specified in 901.02.  Ensure steel slag for blending with I-14 Soil Aggregate does not exceed 0.50 percent expansion from hydration when tested according to ASTM D 4792.
   
   
2. Gradation. Use soil aggregate that conforms to the gradation specified in Table 901.11-1 for the various designations. The gradation requirements shall apply to the material after it has been placed and compacted on the Project. Where compaction is not prescribed, the requirements for any given type shall apply to the material at the time of placement. Should the source contain oversize material, the RE may require the Contractor to eliminate such oversize material.
   
   For Designation I-14, ensure that the portion of material passing the 4-inch sieve contains no more than 35 percent by weight of material passing the No. 200 sieve. Ensure that the proportion of soil aggregate is sufficient to fill all voids in the rock and larger pieces of recycled material. When embankments are constructed outside the ROW in areas where the State has purchased slope rights to construct embankments, use material that is 100 percent passing the 2-inch sieve to construct the top 2-1/2 feet. When driving piles through the embankment, use material that is 100 percent passing the 2-inch sieve.
   



Table 901.11-1 Standard Soil Aggregate Gradations
Gradation Designations, percentage by weight passing square mesh sieves
	6"	4"	2"	1-1/2"	1"	3/4"	1/2"	No. 4	No. 8	No. 16	No. 50	No. 100	No. 200
I-1		100	70-100			50-95		30-60			5-25		0-7
I-2			100			65-100		40-75			5-30		0-7
I-3				100		60-90		40-80			10-35		0-8
I-4			100		60-100		40-100	25-100	20-100	15-85	8-45		5-10
I-5			100			70-100		30-80			10-35		5-12
I-6					100		80-100		45-100	30-90	0-20	0-3
I-7					100		80-100		35-100	25-90	5-50	0-8	0-2
I-8							100	95-100		45-70	5-25		0-5
I-9		100	80-100			60-100		40-100		20-70	5-35	0-20	0-8
I-10		100	80-100			60-100		40-100		20-70	5-40	0-30	0-20
I-11		100	80-100			60-100		40-100			0-75		0-9
I-12		100				70-100					0-75		0-5
I-13		100						30-100					0-12
I-14	See Text.
I-15	100	80-100						30-80			0-25		0-10



3. Combining and Mixing. If bank-run or other materials conforming to the requirements are not available, the Contractor may produce materials that conform to requirements by combining and mixing, or by washing. The Contractor may combine materials and mix on the grade only with RE approval. Do not blend Designation I-9 to meet gradation requirements. Perform blending on the grade using a traveling high-speed rotor mixer capable of cutting and thoroughly mixing to a minimum depth of 6 inches.
   
   
4. Electrochemical Requirements for Designation I-15. Ensure that Designation I-15 conforms to the electrochemical requirements specified in Table 901.11-2.




Table 901.11-2 Electrochemical Requirements for Designation I-15
Property	Test Method	Requirement
Resistivity, ohm-cm	AASHTO T 288	Greater than 3000
pH	AASHTO T 289	Acceptable Range of 5 - 10
Organic Content	AASHTO T 267	1.00% Maximum
Chloride	AASHTO T 291	Less than 100 ppm
Sulfates	AASHTO T 290	Less than 200 ppm


If the resistivity is greater than or equal to 5000 ohm-cm, the Department will waive the chloride and sulfates requirements.

Test Designation I-15 at a rate of once for every 1000 cubic yards of material placed to ensure conformance to the electrochemical limits specified in Table 901.11-2. Whenever the appearance or behavior of the material changes, the ME may require additional samples.

Ensure that the material has a sodium sulfate loss of less than 15 percent after 5 cycles as determined according to AASHTO T 104.

Provide the RE with a certification of compliance, as specified in 106.07, certifying that the Designation I-15 conforms to the requirements of this Section. Attach a copy of the test results representative of material used on the Project.

The ME will sample soil aggregate as specified in Table 901.11-3.

The ME may sample stockpiles before placement, but the Department will make the final and governing determination of conformance or nonconformance based on sampling and testing of the materials after they have been placed as specified in the Contract. Remove materials that do not conform and replace with conforming materials, or correct the deficiencies of the non-conforming materials. If corrective action has been taken, the ME will take an additional sample, and if necessary, one check sample. If the materials still do not conform after corrective action, the ME will not perform further testing until the Contractor tests and certifies that the rejected material has been corrected. After this certification, the ME will analyze an additional sample, and if this sample does not meet the requirements, the Contractor shall remove and replace the material.

Section 902 – Asphalt

902.01 Bituminous Materials  

Use the following temperature-volume correction (TVC) factors to convert the volume of bituminous materials, measured at the temperature at the point of use, to the volume at 60 °F:

1. For PG Binder and MC 800, use the following equation:




TVC = 1.0211326242 − 3.548988118 x 10−4 [T (°F)] + 4.49881 x 10−8 [T (°F)]2



2. For all other cutbacks, use the following equation:




TVC = 1.02413769 − 4.0641418 x 10−4 [T (°F)] + 6.79176 x 10−8 [T (°F)]2



3. For emulsified asphalts, use Table 902.01-1.

902.01.01 Asphalt Binder

Use asphalt binder that conforms to AASHTO M 320, Table 1. Use Grade 64-22, except the ME may direct that an asphalt of softer grade be used when the mixture contains a high percentage of RAP and except where otherwise specified.

When specified, use PG 76-22 asphalt binder that is a storage-stable, pre-blended, homogeneous, polymer modified asphalt binder using styrene-butadiene or styrene-butadiene-styrene formulations. Ensure that the binder’s rolling thin film oven test (AASHTO T 240) residue has a minimum elastic recovery (ASTM D 6084, Procedure A) of 60 percent when tested for at 25 °C.

The asphalt binder producer shall provide the asphalt binder quality control plan annually to the ME for approval. Ensure that the quality control plan conforms to AASHTO R 26.

Submit to the ME a certification of compliance, as specified in 106.07, for the asphalt binder. The ME will perform quality assurance sampling and testing of each asphalt binder lot as defined in the approved quality control plan.

902.01.02 Cutback Asphalts

Use cutback asphalt of the rapid-curing types conforming to AASHTO M 81 and cutback asphalt of the medium-curing types conforming to AASHTO M 82.

For cutback asphalt that will not be used as a penetrating prime coat, use and store according to N.J.A.C 7:27-16 et seq., which includes a limitation for use only between October 15 and April 15.

The cutback asphalt producer shall provide the cutback asphalt quality control plan annually to the ME for approval.

Submit to the ME a certification of compliance, as specified in 106.07, for the asphalt binder. The ME will perform quality assurance sampling and testing of each cutback asphalt lot as defined in the approved quality control plan.

902.01.03 Emulsified Asphalts

Use emulsified asphalts of the rapid-setting (RS), medium-setting (MS), and slow-setting (SS) types conforming to AASHTO M 140. Use cationic emulsified asphalts of the rapid-setting (CRS), medium-setting (CMS), and slow-setting (CSS) types conforming to AASHTO M 208.

The emulsified asphalt producer shall provide the emulsified asphalt quality control plan annually to the ME for approval.

Submit to the ME a certification of compliance, as specified in 106.07, for the asphalt binder. The ME will perform quality assurance sampling and testing of each emulsified asphalt lot as defined in the approved quality control plan.

902.01.04 Polymer Modified Tack Coat

Use a tack coat consisting of homogeneous cationic emulsified asphalt modified using styrene-butadiene, styrene-butadiene-styrene, natural latex, or synthetic latex and conforming to the requirements specified in Table 902.01.04-1.

902.02 Hot Mix Asphalt (HMA)  

902.02.01 Mix Designations

The requirements for specific HMA mixtures are identified by the abbreviated fields in the Item description as defined as follows:

HOT MIX ASPHALT 12.5H64 SURFACE COURSE

1. “HOT MIX ASPHALT” “Hot Mix Asphalt” is located in the first field in the Item description for the purpose of identifying the mixture requirements.
   
   
2. “12.5” The second field in the Item description designates the nominal maximum size aggregate (in millimeters) for the job mix formula (sizes are 4.75, 9.5, 12.5, 19, 25, and 37.5 mm).
   
   
3. “H” The third field in the Item description designates the design compaction level for the job mix formula based on traffic forecasts as listed in Table 902.02.03-2 (levels are L=low, M=medium, and H=high).
   
   
4. “64” The fourth field in the Item description designates the high temperature (in °C) of the performance-graded binder (options are 64, 70, and 76 °C). All binders shall have a low temperature of –22 °C, unless otherwise specified.
   
   
5. “SURFACE COURSE” The last field in the Item description designates the intended use and location within the pavement structure (options are surface, intermediate, or base course).

902.02.02 Composition of Mixtures

Mix HMA in a plant that is listed on the QPL and conforms to the requirements for HMA Plants as specified in 1009.01.

Composition of the mixture for HMA surface course is coarse aggregate, fine aggregate, and asphalt binder, and may also include mineral filler and up to 15 percent Reclaimed Asphalt Pavement (RAP). Ensure that the finished mix does not contain more than a total of 1 percent by weight contamination from Crushed Recycled Container Glass (CRCG).

The composition of the mixture for HMA base or intermediate course is coarse aggregate, fine aggregate, and asphalt binder, and may also include mineral filler and up to 35 percent of recycled materials. The 35 percent of recycled materials may consist of a combination of RAP, CRCG, Ground Bituminous Shingle Material (GBSM), and RPCSA, with the following individual limits:

Combine the aggregates to ensure that the resulting mixture meets the grading requirements specified in Table 902.02.03-1. In determining the percentage of aggregates of the various sizes necessary to meet gradation requirements, exclude the asphalt binder.

Ensure that the combined coarse aggregate, when tested according to ASTM D 4791, has less than 10 percent flat and elongated pieces retained on the No. 4 sieve and larger. Measure aggregate using the ratio of 5:1, comparing the length (longest dimension) to the thickness (smallest dimension) of the aggregate particles.

Ensure that the combined fine aggregate in the mixture conforms to the requirements specified in Table 902.02.02-2. Ensure that the material passing the No. 40 sieve is non-plastic when tested according to AASHTO T 90.

902.02.03 Mix Design

Submit a mix design including a job mix formula (JMF) for each mixture on forms supplied by the ME. Include a statement naming the source of each component and a report showing that the results conform to the criteria specified in Table 902.02.03-1, Table 902.02.03-2, and Table 902.02.03-3. If a change in sources or properties of materials occur, the ME may require the HMA producer to establish a new mix design and to obtain approval before production can continue.

To establish the JMF for each mix design, determine the percentage of dry weight of aggregate passing each required sieve size and an optimum percentage of asphalt binder based upon the weight of the total mix. Determine the optimum percentage of asphalt binder according to AASHTO M 323 and R 35. Combine the aggregates to ensure that the resulting mixture conforms to the grading requirements specified in Table 902.02.03-1. In determining the percentage of aggregates of the various sizes necessary to conform to gradation requirements, exclude the asphalt binder.

1. Percentage of RAP or GBSM.
2. Percentage of asphalt binder in the RAP or GBSM.
3. Percentage of new asphalt binder.
4. Total percentage of asphalt binder.
5. Percentage of each type of virgin aggregate.

At the ME’s request, test the mix design to ensure that it meets a minimum tensile strength ratio of 80 percent, when tested according to AASHTO T 283. The ME will require tensile strength ratio testing for new aggregate sources and for aggregates suspected of stripping susceptibility.

For each mix design, submit with the mix design forms 2 gyratory specimens and 1 loose sample corresponding to the composition of the JMF. The ME will use these to verify the properties of the JMF. Compact the specimens to the design number of gyrations (N_des). For the mix design to be acceptable, all gyratory specimens must comply with the requirements specified in Table 902.02.03-1 and Table 902.02.03-3. The ME reserves the right to be present at the time the gyratory specimens are molded.

The ME’s may verify a mix on an annual basis rather than on a project-to-project basis if the properties and proportions of the materials do not change. If written verification is submitted by the HMA supplier that the same source and character of materials are to be used, the ME may waive the requirement for the design and verification of previously approved mixes.

902.02.04 Sampling and Testing

1. General Acceptance Requirements. The RE or ME may reject and require disposal of any batch or shipment that is rendered unfit for its intended use due to contamination, segregation, improper temperature, lumps of cold material, or incomplete coating of the aggregate. For other than improper temperature, visual inspection of the material by the RE or ME is considered sufficient grounds for such rejection.
   
   For PG 64-22 or PG 70-22, ensure that the temperature of the mixture at discharge from the plant or surge and storage bins is at least 290 °F when the ambient temperature is less than 50 °F or is at least 275 °F when the ambient temperature is greater than or equal to 50 °F. For PG 76-22, ensure that the temperature of the mixture at discharge from the plant or surge and storage bins is at least 10 °F above the manufacturer’s recommended laydown temperature. Do not allow the mixture temperature to exceed 330 °F at discharge from the plant.
   
   Combine and mix the aggregates and asphalt binder to ensure that at least 95 percent of the coarse aggregate particles are entirely coated with asphalt binder as determined according to AASHTO T 195. If the ME determines that there is an on-going problem with coating, the ME may obtain random samples from 5 trucks and will determine the adequacy of the mixing on the average of particle counts made on these 5 test portions. If the requirement for 95 percent coating is not met on each sample, modify plant operations, as necessary, to obtain the required degree of coating.
   
   
2. Sampling. The ME will take a random sample from each 700 tons of production for volumetric acceptance testing and to verify composition.. The ME will perform sampling according to AASHTO T 168, NJDOT B-2, or ASTM D 3665.
   
   
3. Quality Control Testing. The HMA producer shall provide a quality control (QC) technician who is certified by the Society of Asphalt Technologists of New Jersey as an Asphalt Technologist, Level 2. The QC technician may substitute equivalent technician certification by the Mid-Atlantic Region Technician Certification Program (MARTCP). Ensure that the QC technician is present during periods of mix production for the sole purpose of quality control testing and to assist the ME. The ME will not perform the quality control testing or other routine test functions in the absence of, or instead of, the QC technician.
   
   The QC technician shall perform sampling and testing according to the approved quality control plan, to keep the mix within the limits specified for the mix being produced. The QC technician may use acceptance test results or perform additional testing as necessary to control the mix.
   
   To determine the composition, perform ignition oven testing according to AASHTO T 308. For fully automated plants, the QC technician may determine composition using hot bin analysis according to NJDOT B-5. Use only one method for determining composition within a lot.
   
   For each acceptance test, perform maximum specific gravity testing according to AASHTO T 209 on a test portion of the sample taken by the ME. Sample and test coarse aggregate, fine aggregate, mineral filler, and RAP according to the approved quality control plan for the plant.
   
   When using RAP, ensure that the supplier has in operation an ongoing daily quality control program to evaluate the RAP. As a minimum, this program shall consist of the following:
   
   
   1. An evaluation performed to ensure that the material conforms to 901.05.04 and compares favorably with the design submittal.
   2. An evaluation of the RAP material performed using a solvent or an ignition oven to qualitatively evaluate the aggregate components to determine conformance to 901.05.
   3. Quality control reports as directed by the ME.
   
   
4. Acceptance Testing and Requirements. The ME will determine volumetric properties at N_des for acceptance from samples taken, compacted, and tested at the HMA plant. The ME will compact HMA to the number of design gyrations (N_des) specified in Table 902.02.03-2, using equipment according to AASHTO T 312. The ME will determine bulk specific gravity of the compacted sample according to AASHTO T 166. The ME will use the most current QC maximum specific gravity test result in calculating the volumetric properties of the HMA.
   
   The ME will determine the dust-to-binder ratio from the composition results as tested by the QC technician.
   
   Ensure that the HMA mixture conforms to the requirements specified in Table 902.02.04-1, and to the gradation requirements in Table 902.02.03-1. If 2 samples in a lot fail to conform to the gradation or volumetric requirements, immediately initiate corrective action.
   
   The ME will test a minimum of 1 sample per lot for moisture, basing moisture determinations on the weight loss of an approximately 1600-gram sample of mixture heated for 1 hour in an oven at 280 ± 5°F. Ensure that the moisture content of the mixture at discharge from the plant does not exceed 1.0 percent.




Table 902.02.04-1 Hot Mix Asphalt Requirements for Control
Compaction Levels	Required Density (% of Theoretical Max. Specific Gravity)	Voids in Mineral Aggregate (VMA), % (minimum)						Dust-to-Binder Ratio
		Nominal Max. Aggregate Size, mm
	@Ndes1	37.5	25.0	19.0	12.5	9.5	4.75
L, M, H	95.0 – 97.0	11.0	12.0	13.0	14.0	15.0	16.0	0.6 - 1.3

1	As determined from the values for the maximum specific gravity of the mix and the bulk specific gravity of the compacted mixture. Maximum specific gravity of the mix is determined according to AASHTO T 209. Bulk specific gravity of the compacted mixture is determined according to AASHTO T 166.

5. Plants Producing for Multiple Projects. When a plant is producing HMA for 2 or more Department projects at the same time, the ME will establish 1 common lot for each mix and will use the sample results for the lot to represent the HMA for each Contract on which a part of that lot was used.

902.03 Open-Graded Friction Course (OGFC) and Modified Open-Graded Friction Course (MOGFC)  

902.03.01 Composition of Mixtures

Mix OGFC and MOGFC in a plant that is listed on the QPL and conforms to the requirements for HMA plants as specified in 1009.01.

Composition of mixture for OGFC and MOGFC is coarse aggregate, fine aggregate and asphalt binder. Ensure that the mixture conforms to the following requirements:

1. Use aggregate for OGFC and MOGFC that conforms to 901.10, except, for coarse aggregate, use broken stone of gneiss, granite, quartzite, or trap rock. Do not use RAP, CRCG, GBSM, or RPCSA.
2. Use asphalt binder for OGFC and MOGFC that is PG 76-22 as specified in 902.01.01.
3. For MOGFC, add a stabilizing additive consisting of mineral fiber or cellulose fiber to the mix. Use a stabilizing additive that conforms to the requirements for stabilizing additives in AASHTO MP 8. Use only 1 type per mix design. If using mineral fibers, use a dosage rate of 0.4 percent by weight of total mix. If using cellulose fibers, use a dosage rate of 0.3 percent by weight of total mix. The dosage rate may be increased, as necessary, to prevent draindown as measured by the visual draindown determination of asphalt content in NJDOT B-8. Accurately control proportioning the fibers into the mixture within ±10 percent of the required weight, and use equipment that ensures uniform dispersion of the fibers. Store fibers in a dry location with a storage temperature not to exceed 120 °F. The supplier of the cellulose or mineral fibers shall provide a certification of compliance, as specified in 106.07, that the material supplied conforms to AASHTO MP 8. Ensure that a technical representative from the additive supplier is at the work site for the first full day of construction for technical assistance.

902.03.02 Mix Design

Submit a mix design including JMF for each mixture on forms supplied by the Department. Include a statement naming the source of each component and a report with the results for the criteria specified in Table 902.03.03-1. Design the mix to meet the criteria in Table 902.03.03-1.

In the JMF for each mixture, establish the percentage of dry weight of aggregate passing each required sieve size and an optimum percentage of asphalt binder based upon the weight of the total mix. Determine the optimum asphalt binder content for OGFC as specified in NJDOT B-7. Determine the optimum asphalt binder content for MOGFC as specified in NJDOT B-8. Ensure that the JMF is within the master range specified in Table 902.03.03-1.

Prepare compacted test specimens for submittal to the ME at least 30 days before the initial production date. Prepare these specimens from material mixed according to the final JMF, using 50 gyrations of the Superpave gyratory compactor according to AASHTO T 312.

The ME will test 2 specimens to verify that the final JMF produces a mixture that has a minimum void content as specified in Table 902.03.03-1. The ME will determine percent air voids according to AASHTO T 209, and either NJDOT B-6 or AASHTO T 331.

The ME will test 6 specimens according to AASHTO T 283, except for the following:

1. No specific air void level is required.
2. Compact specimens with 50 gyrations using the Superpave gyratory compactor.
3. Apply a vacuum of 26 inches of mercury for 10 minutes to saturate the compacted specimen. No specific saturation level is required.
4. Submerge the specimen in water during 1 freeze/thaw cycle.

If the tensile strength ratio falls below 80 percent, adjust the mixture to satisfy the minimum requirement. Adjustments may include the use of anti-stripping agents.

For MOGFC only, the ME will test 2 test specimens for abrasion and impact resistance using a modified L. A. Abrasion Test according to NJDOT B-8. The maximum allowable loss as calculated by this method is 30 percent.

Do not modify the JMF unless the ME approves the modification.

902.03.03 Sampling and Testing

Perform and meet requirements for quality control testing as specified in 902.02.04.C. Ensure that the mix meets the requirements as specified in 902.02.04.A, otherwise the RE or ME will reject the material.

During production, the ME will take one random acceptance sample from each 700 tons of production to verify composition. Conduct air voids and draindown tests as directed by the ME.

If the composition testing results are outside of the production control tolerances specified in Table 902.03.03-2 for an acceptance sample, determine if a plant adjustment is needed and immediately run a quality control sample. If the quality control sample is also outside of the control tolerances in Table 902.03.03-2, immediately take corrective action to bring the mix into compliance. Take additional quality control samples after the corrective action to ensure that the mix is within the production control tolerances. If 2 consecutive acceptance samples are outside the tolerances specified in Table 902.03.03-2, immediately stop production. Obtain ME approval of a plant correction plan before resuming production. Upon restarting production, do not transport mixture to the Project Limits before the results of a QC sample from the mixture indicate that the mixture meets JMF tolerances. The ME will reject mixture produced at initial restarting that does not meet tolerances.

The ME will perform sampling according to NJDOT B-2 or ASTM D 3665, and will perform testing for composition according to AASHTO T 308 or NJDOT B-5. Perform testing for air voids according to AASHTO T 209 and either NJDOT B-6 or AASHTO T 331. Perform testing for draindown according to NJDOT B-7 or NJDOT B-8.

902.04 Ultra-Thin HMA  

902.04.01 Composition of Mixture

Mix ultra-thin HMA in a plant listed on the QPL conforming to the requirements for HMA plants specified in 1009.01.

Use ultra-thin HMA that consists of coarse aggregate, fine aggregate, and polymer modified asphalt binder and that may contain mineral filler. Do not add RAP, CRCG, GBSM, or RPCSA. Combine the material in such proportions that the total aggregate and asphalt binder conform to the composition percentages specified in Table 902.04.02-1.

To produce the ultra-thin HMA, use aggregates and asphalt binder that conforms to the following:

1. For asphalt binder, use PG 76-22 conforming to the requirements of 902.01.01.
2. For fine aggregate, use stone sand conforming to 901.05.02. Ensure that the combined gradation with coarse aggregate conforms to Table 902.04.02-1.
3. Use coarse aggregate that conforms to 901.05.01 and Table 902.04.01-1. Permissible geologic classifications for coarse aggregate are argillite, gneiss, granite, quartzite, or trap rock. Ensure that the combined gradation with fine aggregate conforms to Table 902.04.02-1.




Table 902.04.01-1 Coarse Aggregate Properties
Tests	Test Method	Maximum Percent
Percentage of wear, Los Angeles Abrasion Test	AASHTO T  96	25
Micro Deval	AASHTO T 327	18



4. Use mineral filler, if necessary, that conforms to 901.05.03.

902.04.02 Mix Design

At least 30 days before the initial production date, submit a JMF, within the limits of Table 902.04.02-1, to the ME for approval on forms supplied by the Department. Include in the submission a statement naming the source of each component and the results of all applicable tests.

If the source of any component material changes, submit a new JMF and obtain ME approval before using the new material. When unsatisfactory results or other conditions make it necessary, the ME may require a new JMF.

Design the ultra-thin HMA so that it has a draindown of less than 0.1 percent when tested according to AASHTO T 305.

When tested for moisture sensitivity according to AASHTO T 283, ensure that the ultra-thin HMA has a tensile strength ratio of at least 80 percent. Prepare specimens according to AASHTO T 312, and test according to T 283 except for the following:

1. Before compaction, condition the mixture for 2 hours according to AASHTO R 30, Section 7.1.
2. Compact specimens with 100 gyrations.
3. Extrude specimens as soon as possible without damaging.
4. Use AASHTO T 269 to determine void content.
5. Record the void content of the specimens.
6. If less than 55 percent saturation is achieved, repeat the procedure, unless the difference in tensile strength between duplicate specimens is greater than 25 pounds per square inch.
7. If visual stripping is detected, modify or readjust the mix.

Size, uniformly grade, and combine aggregate fractions in proportions so that the grading of total aggregate and asphalt binder in the JMF conform to the composition by mass percentages specified in Table 902.04.02-1.

902.04.03 Sampling and Testing

Ensure that the mix meets the requirements as specified in 902.02.04.A, otherwise the RE or ME will reject the material.  Maintain the temperature of the mix between 300 °F and 330 °F.  Perform and meet requirements for quality control testing as specified in 902.02.04.C.

During production, the ME will take one random acceptance sample from each 700 tons of production to verify composition. Conduct draindown tests as directed by the ME.

If the composition testing results are outside of the production control tolerances specified in Table 902.04.02-1 for an acceptance sample, determine if a plant adjustment is needed and immediately run a quality control sample. If the quality control sample is also outside of the control tolerances in Table 902.04.02-1, immediately take corrective action to bring the mix into compliance. Take additional quality control samples after the corrective action to ensure that the mix is within the production control tolerances. If 2 consecutive acceptance samples are outside the tolerances specified in Table 902.04.02-1, immediately stop production. Obtain ME approval of a plant correction plan before resuming production. Upon restarting production, do not transport mixture to the Project Limits before the results of a QC sample from the mixture indicate that the mixture meets JMF tolerances. The ME will reject mixture produced at initial restarting that does not meet tolerances.

The ME will perform sampling according to NJDOT B-2 or ASTM D 3665, and will perform testing for composition according to AASHTO T 308, or NJDOT B-5. Perform testing for draindown according to NJDOT B-7 or NJDOT B-8.

902.05 Stone Matrix Asphalt (SMA)  

902.05.01 Composition of Mixture

Mix SMA in a plant that is listed on the QPL and conforms to the requirements for HMA plants as specified in 1009.01.

The composition of the SMA mixture is coarse aggregate, fine aggregate, mineral filler, mineral fibers or cellulose fibers, and polymer modified asphalt binder.

Use asphalt binder for SMA that is PG 76-22 as specified in 902.01.01.

For coarse aggregate in SMA, use crushed stone conforming to 901.05.01 and Table 902.05.01-1.

For fine aggregate, use stone sand conforming to 901.05.02. Ensure that the combined fine aggregate in the mixture conforms to the requirements in Table 902.02.02-2.

For mineral filler, use rock dust or crushed limestone conforming to AASHTO M 17. Ensure that the mineral filler has a plasticity index of less than 4 percent when tested according to AASHTO T 90.

Do not add RAP, CRCG, GBSM, or RPCSA to the mixture.

Add stabilizing fibers consisting of mineral fiber or cellulose fiber conforming to AASHTO MP 8. Use only one type per mix design. If using mineral fibers, use between 0.4 and 0.6 percent by weight of total mix. If using cellulose fibers, use between 0.3 and 0.4 percent by weight of total mix. Provide control to accurately proportion the fibers into the mixture within ±10 percent of the required weight, and use equipment that ensures uniform dispersion of the fibers. If using pre-packaged bags of fibers added to the pugmill during the dry mix cycle, follow the manufacturer’s recommendations for the dry and wet mixing time. Store fibers in a dry location with a storage temperature not to exceed 120 °F. The supplier of the cellulose or mineral fibers shall provide a certification of compliance, as specified in 106.07, for the fibers. Ensure that a technical representative from the fiber supplier is at the HMA plant for the first full day of production for technical assistance.

902.05.02 Mix Design

Design the SMA to meet the requirements in Table 902.05.02-1 and Table 902.05.02-2. Prepare the JMF according to AASHTO R 46. Determine the JMF at 4 percent air voids and 75 gyrations of the Superpave gyratory compactor.

902.05.03 Sampling and Testing

Perform quality control testing as specified in 902.02.04.C. Ensure that the mix meets the requirements as specified in 902.02.04.A, otherwise the RE or ME will reject the material.

During production at the plant, the ME will take a sample from each 700 tons of production to verify composition and air voids.  Conduct draindown, VCA_mix, VCA_dry, and VMA testing as directed by the ME. Perform tests according to AASHTO PP 41.

If the testing results are outside of the production control tolerances specified in Table 902.05.02-1 and Table 902.05.02-2 for an acceptance sample, determine if a plant adjustment is needed and immediately run a quality control sample. If the quality control sample is also outside of the control tolerances in Table 902.05.02-1, immediately take corrective action to bring the mix into compliance. Take additional quality control samples after completing the corrective action to ensure that the mix is within tolerances. If 2 consecutive acceptance samples are outside the tolerances specified in Table 902.05.02-1 and Table 902.05.02-2, immediately stop production. Obtain ME approval of a plant correction plan before resuming production. Upon restarting production, do not transport mixture to the Project Limits before the results of a QC sample from the mixture indicate that the mixture meets JMF tolerances. The ME will reject mixture produced at initial restarting that does not meet tolerances.

The ME will perform sampling according to NJDOT B-2 or ASTM D 3665, and will perform testing for composition according to AASHTO T 308, or NJDOT B-5. The ME will determine bulk specific gravity of the compacted sample according to AASHTO T 166 or AASHTO T 331. The ME will use the most current QC maximum specific gravity test result, obtained according to AASHTO T 209, in calculating the volumetric properties of the SMA. Perform testing for draindown according to AASHTO T 305.

902.06 Asphalt-Stabilized Drainage Course (ASDC)  

902.06.01 Composition

Mix ASDC in a plant that is listed on the QPL and conforms to the requirements specified in 1009.01.

The mixture shall consist of asphalt binder and aggregate. Use asphalt binder that is PG 64-22 as specified in 902.01.01. Use aggregate that conforms to 901.05 and the gradation requirements specified in Table 902.06.01-1.

Design the mixture to have an asphalt binder content of 3 ± 1/2 percent by weight of dry aggregate.

902.06.02 Mix Design

Submit to the ME for approval, a JMF for the material that includes the source of each component.

Establish with the JMF the percentage of dry weight of aggregate passing each required sieve size and the optimum percentage of asphalt binder based upon the weight of the total mix. Ensure that the design values of percent passing each sieve size are within the gradation band specified in Table 902.06.01-1. Design the mix to have a permeability of 2000 ± 500 feet per day.

At least 45 days before the production of the asphalt-stabilized drainage course, submit a mix design for approval. In addition, submit samples of the component materials to the ME for verification. Submit the following quantities:

The ME will perform gradation testing according to AASHTO T 27 on the submitted aggregate sample. The ME will prepare the specimens for permeability testing according to AASHTO T 167. The ME will compact specimens at 260 °F. The ME will determine permeability according to NJDOT B-1.

At the ME’s option, verification may be done on an annual basis for a mix rather than on a project-to-project basis, provided the properties and proportions of the materials do not change. If written verification is submitted by the HMA supplier that the same source and character of materials are to be used, the ME may waive the requirement for the design and verification of previously approved mixes.

902.06.03 Sampling and Testing

Perform quality control testing as specified in 902.02.04.C. Ensure that the mix meets the requirements as specified in 902.02.04.A, except that the temperature of the mix at discharge is required to be between 230 °F and 275 °F, otherwise the RE or ME will reject the material.

During production, the ME will take one random acceptance sample from each 700 tons of production to verify composition. Conduct draindown tests as directed by the ME.

If the composition testing results are outside of the production control tolerances specified in Table 902.06.01-1 for an acceptance sample, determine if a plant adjustment is needed and immediately run a quality control sample. If the quality control sample is also outside of the control tolerances specified in Table 902.06.01-1, immediately take corrective action to bring the mix into compliance. Take additional quality control samples after the corrective action to ensure that the mix is within tolerances. If 2 consecutive acceptance samples are outside the tolerances specified in Table 902.06.01-1, immediately stop production. Obtain ME approval of a plant correction plan before resuming production. Upon restarting production, do not transport mixture to the Project before the results of a QC sample from the mixture indicate that the mixture meets JMF tolerances. The ME will reject mixture produced at initial restarting that does not meet tolerances.

The ME will perform sampling according to NJDOT B-2 or ASTM D-3665 and will perform testing for composition according to AASHTO T 308 or NJDOT B-5. If directed by the ME, perform testing for draindown according to AASHTO T 305.

902.07  Asphalt-Rubber Open-Graded Friction Course (AR-OGFC)

902.07.01  Composition of Mixture

Mix AR-OGFC in a plant listed on the QPL and conforming to the requirements for HMA plants specified in 1009.01. Ensure the HMA plant is equipped with asphalt-rubber binder blending equipment as specified in 1009.03.

Composition of mixture for AR-OGFC is coarse aggregate, fine aggregate and asphalt-rubber binder.  Ensure that the mixture conforms to the following requirements:

1. Use aggregates that conform to 901.05.  Use fine aggregate that is manufactured stone sand and conforms to Table 902.02.02-2.
2. Do not use RAP, CRCG, GBSM, or RPCSA.
3. Use asphalt-rubber binder that conforms to 902.07.02.

902.07.02  Asphalt-Rubber Binder

1. Materials.  Use the following materials:

1. Ground Crumb Rubber.  Ensure that the ground crumb rubber has a specific gravity of 1.15 ± 0.05, is free of wire or other contaminating materials, and contains not more than 0.5 percent fabric.  Use crumb rubber that is ambient ground and conforms to the gradation requirements specified in Table 902.07.02-1.  Ensure that the moisture content is less than 0.75 percent.  The Contractor may add up to four percent calcium carbonate by weight of the granulated rubber, to prevent the particles from sticking together.

Table 902.07.02-1  Ground Crumb Rubber Gradation
Sieve Size	Percent Passing1, 2
No. 8	100
No. 16	65 – 100
No. 30	20 – 100
No. 50	0 – 45
No. 200	0 – 5
1.  Perform gradation according to AASHTO T27 using a minimum 50 gram sample
2.  Ensure that the gradation is performed as specified in NJDOT B-11.

Submit to the ME a certification of compliance, as specified in 106.07, for the ground crumb rubber.  In addition, ensure that the certificates confirm that the rubber is a crumb rubber, derived from processing whole scrap tires or shredded tire materials; and the tires from which the crumb rubber is produced are taken from automobiles, trucks, or other equipment owned and operated in the United States.  Include with the certifications verifications that the processing did not produce, as a waste product, casings, or other round tire material that can hold water when stored or disposed of above ground.

2. Asphalt Binder.

1. Use asphalt binder that conforms to AASHTO M 320, Table 1; PG 64-22, PG 58-28 or an approved blend of both grades. The asphalt binder producer is required to provide the asphalt binder quality control plan annually to the ME for approval. Ensure that the quality control plan conforms to AASHTO R 26. Submit to the ME a certification of compliance, as specified in 106.07, for the asphalt binder. The ME will perform quality assurance sampling and testing of each asphalt binder lot as defined in the approved quality control plan.
   
   
   
2. Use one or more of the following types of warm mix asphalt (WMA) additives or processes:

1. Organic additives such as a paraffin wax or a low molecular weight esterified wax.
2. Chemical additive that acts as a surfactant or dispersing agent.

Do not use controlled asphalt foaming systems or any other steam injection processes or steam introducing additives. WMA is a method of producing asphalt pavement at a mixing and compaction temperatures at least 30 ºF lower than Hot Mix Asphalt (HMA) by using one or more of the types of WMA additives listed above. Submit information on the WMA additive or process with the Paving Plan required in 402.03.02.A. Include in the submission, the name and description of the additive or process, the manufacturer’s recommendations for usage of the additive or process, recommendations for mixing and compaction temperatures, and details on at least one project on which the additive was successfully used in the United States on a crumb rubber modified asphalt mixture. In the details of a project, include tonnage, type of mix, dosage, mixing and compaction temperatures, available test results, and contact information for project. If a WMA additive is pre-blended in the asphalt binder, ensure that the asphalt binder meets the requirements of the specified grade after the addition of the WMA additive. If a WMA additive is added at the HMA plant, ensure that the addition of the additive will not negatively impact the grade of asphalt binder. The ME will evaluate the impacts to performance grade of the asphalt binder based upon certification from manufacturer in conjunction with laboratory data indicating the effects of the additive on the asphalt binder properties. Follow the manufacturer’s recommendations for the dosage of WMA additive needed and approved blending method(s).

Ensure that a technical representative of the WMA additive manufacturer is on-site or available for consultation during the production and placement of the AR-OGFC with the warm mix additive.

2. Mixing.  Using the asphalt-rubber binder blending equipment in 1009.03, produce the asphalt-rubber binder to contain at least 17 percent ground rubber by the weight of total asphalt binder (asphalt + crumb rubber).  Ensure that the temperature of the asphalt cement is between 350 and 400 °F at the time of addition of the ground rubber.  Ensure that there are no agglomerations of rubber particles in excess of two inches in the least dimension in the mixing chamber.

   Document that the proportions are accurate and that the rubber has been uniformly incorporated into the mixture.  Report as directed by the ME. Ensure that the crumb rubber and asphalt-cement are thoroughly mixed before beginning the one-hour reaction period.  Rubber floating on the surface or agglomerations of rubber particles is evidence of insufficient mixing.  Maintain the temperature of the asphalt-rubber binder immediately after mixing between 325 and 375 °F.  Maintain the temperature of the asphalt-rubber binder for at least one hour before using.

2. Properties.  Prepare asphalt-rubber binder using the “wet process.”  Physical properties are required to comply with the requirements of ASTM D 6114, Type II, except for the properties specified in Table 902.07.02-2.

   Table 902.07.02-2  Asphalt-Rubber Binder Properties
   Property	Test Procedure	Requirement
   Resilience: 77 °F; %, minimum	ASTM D 5329	25
   Rotational Viscosity1 350 °F; cP	NJDOT B-12	2000 – 4000
   The viscotester used must be correlated to a Rion (formerly Haake) Model VT-04 viscotester using the No. 1 Rotor.   The Rion viscotester rotor, while in the off position, is required to be completely immersed in the binder at a temperature from 350 ± 3 °F for a minimum heat equilibrium period of 60 seconds, and the average viscosity determined from three separate constant readings (± 500 cP) taken within a 30 second time frame with the viscotester level during testing and turned off between readings.  Continuous rotation of the rotor may cause thinning of the material immediately in contact with the rotor, resulting in erroneous results.

4. Handling and Testing.  Once the asphalt-rubber binder has been mixed, thoroughly agitate during periods of use to prevent settling of the rubber particles.  During production, maintain asphalt-rubber binder between 325 and 375 °F.  Ensure that asphalt-rubber binder is not held at 325 °F or higher for more than 16 hours.  Allow asphalt-rubber binder held for more than 16 hours to cool.  To reuse, gradually reheat to between 325 and 375 °F.  Do not cool and reheat more than one time.  Do not store asphalt-rubber binder above 250 °F for more than four days.

   For each load or batch of asphalt-rubber binder, provide the RE with the following:

   1. The source, grade, amount, and temperature of the asphalt cement before the addition of rubber.
   2. The source and amount of rubber and the rubber content expressed as percent by the weight of the asphalt cement.
   3. Times and dates of the rubber additions and resultant viscosity test.
   4. A record of the temperature, with time and date reference for each load or batch.  The record begins at the time of the addition of rubber and continue until the load or batch is completely used.  Take readings and record every temperature change in excess of 20 °F, and as needed to document other events that are significant to batch use and quality.

902.07.03  Mix Design

Submit binder and mix designs including JMF for each mixture performed by an AASHTO accredited lab with at least five successfully completed asphalt-rubber open-graded friction course projects greater than 5,000 tons each.  Include a statement naming the source of each component and a report with the results for the criteria specified in Table 902.07.03-1. Include a report detailing the rotational viscosity of the asphalt-rubber binder at 60, 90, 135, 240, and 1440 minutes. Submit lab qualifications and references to the ME for approval prior to beginning work.

Design the mix to meet the criteria in Table 902.07.03-1.

Determine and verify the JMF according to NJDOT B-8. Ensure that the JMF is within the master range specified in Table 902.07.03-1.

Prepare compacted test specimens for submittal to the ME at least 30 days before the initial production date.  Prepare these specimens from material mixed according to the final JMF, using 50 gyrations of the Superpave gyratory compactor according to AASHTO T 312.

The ME will test 2 specimens to verify stone-on-stone contact according to NJDOT B-8 and that the final JMF produces a mixture that has a minimum void content as specified in Table 902.07.03-1.  The ME will determine percent air voids according to AASHTO T 209 and AASHTO T 331.

The ME will test 2 test specimens for abrasion and impact resistance using a modified L.A. Abrasion Test according to NJDOT B-8.  The maximum allowable loss as calculated by this method is 30 percent.

Do not modify, which includes changing the asphalt cement supplier, the JMF unless the ME approves the modification.

902.07.04  Sampling and Testing

1. General Acceptance Requirements.  The RE or ME may reject and require disposal of any batch or shipment that is rendered unfit for its intended use due to contamination, segregation, improper temperature, lumps of cold material, or incomplete coating of the aggregate.  For other than improper temperature, visual inspection of the material by the RE or ME is considered sufficient grounds for such rejection.

   For AR-OGFC with WMA additive, ensure that the temperature of the mixture at discharge from the plant or surge and storage bins meets the WMA additive manufacturer’s recommendations. Do not allow the mixture temperature to exceed 300 °F at discharge from the plant.

   Combine and mix the aggregates and asphalt-rubber binder to ensure that at least 95 percent of the coarse aggregate particles are entirely coated with asphalt-rubber binder as determined according to AASHTO T 195.  If the ME determines that there is an on-going problem with coating, the ME may obtain random samples from 5 trucks and will determine the adequacy of the mixing on the average of particle counts made on these 5 test portions.  If the requirement for 95 percent coating is not met on each sample, modify plant operations, as necessary, to obtain the required degree of coating.

2. Quality Control Testing.  The HMA producer is required to provide a quality control (QC) technician who is certified by the Society of Asphalt Technologists of New Jersey as an Asphalt Technologist, Level 2.  The QC technician may substitute equivalent technician certification by the Mid-Atlantic Region Technician Certification Program (MARTCP).  Ensure that the QC technician is present during periods of mix production for the sole purpose of quality control testing and to assist the ME.  The ME will not perform the quality control testing or other routine test functions in the absence of, or instead of, the QC technician.

   The QC technician is required to perform sampling and testing according to the approved quality control plan, to keep the mix within the limits specified for the mix being produced.  The QC technician may use acceptance test results or perform additional testing as necessary to control the mix.

   For each acceptance test, perform maximum specific gravity testing according to AASHTO T 209 on a test portion of the sample taken by the ME.  Sample and test coarse aggregate, fine aggregate and mineral filler according to the approved quality control plan for the plant.

3. Acceptance Testing.  During production, the ME will take one random acceptance sample from each 700 tons of production to verify composition.  The ME will perform sampling according to NJDOT B-2 or ASTM D 3665, and will perform testing for composition according to AASHTO T 308 or NJDOT B-5.  Perform testing for air voids according to T 209 and either B-6 or T 331. Perform testing for draindown according toNJDOT B-8.

   Conduct air voids and draindown tests as directed by the ME.

   If the composition testing results are outside of the production control tolerances specified in Table 902.07.04-1 for an acceptance sample, determine if a plant adjustment is needed and immediately run a quality control sample.  If the quality control sample is also outside of the control tolerances in Table 902.07.04-1, immediately take corrective action to bring the mix into compliance.  Take additional quality control samples after the corrective action to ensure that the mix is within the production control tolerances.  If two consecutive acceptance samples are outside the tolerances specified in Table 902.07.04-1, immediately stop production.  Obtain ME approval of a plant correction plan before resuming production.  Upon restarting production, do not transport mixture to the Project Limits before the results of a QC sample from the mixture indicate that the mixture meets JMF tolerances.  The ME will reject mixture produced at initial restarting that does not meet tolerances.

   Table 902.07.04-1  Production Control Tolerances for AR-OGFC Mixtures
   Sieve Sizes	Production Control Tolerances from JMF1
   1/2"	±6.0
   3/8"	±5.5
   No. 4	±5.5
   No. 8	±4.5
   No. 200	±2.0
   Asphalt-rubber binder, % (AASHTO T 308)	±0.40
   Asphalt-rubber binder, % (NJDOT B-5)	±0.15
   Minimum % Air Voids	1.0% less than design requirement
   1.   Production tolerances may fall outside of the wide band gradation limits in Table 902.07.03-1.

    

902.08 HIGH PERFORMANCE THIN OVERLAY (HPTO)

902.08.01 Composition of Mixture

Mix HPTO in a plant that is listed on the QPL and conforms to the requirements for HMA Plants as specified in 1009.01. The composition of the mixture for HPTO is coarse aggregate, fine aggregate, and asphalt binder, and may also include mineral filler.  Do not use Reclaimed Asphalt Pavement (RAP), Ground Bituminous Shingle Material, Remediated Petroleum Contaminated Soil Aggregate, or Crushed Recycled Container Glass (CRCG). Use asphalt binder and aggregates that meet the following requirements:

1. For the asphalt binder, use PG 76-22 as specified in 902.01.01.
2. Use coarse aggregate that is argillite, gneiss, granite, quartzite, or trap rock and conforms to 901.05.01.
3. For fine aggregate, use stone sand conforming to 901.05.02 and has an uncompacted void content of at least 45 percent when tested according to AASHTO T 304, Method A.  In addition, the minimum sand equivalent is 45 percent when tested according to AASHTO T 176.
4. If necessary, use mineral filler as specified in 901.05.03.

902.08.02 Mix Design

At least 45 days before initial production, submit a job mix formula for the HPTO on forms supplied by the Department.  Include a statement naming the source of each component and a report showing the results meet the criteria specified in Tables 902.08.03-1 and 902.08.03-2.

For the job mix formula for the HPTO mixture, establish the percentage of dry weight of aggregate passing each required sieve size and an optimum percentage of asphalt binder based upon the weight of the total mix.  Determine the optimum percentage of asphalt binder according to AASHTO R 35 and M 323 with an Ndes of 50 gyrations.  Before maximum specific gravity testing or compaction of specimens, condition the mix for 2 hours according to the requirements for conditioning for volumetric mix design in AASHTO R 30, Section 7.1.  If the absorption of the combined aggregate is more than 1.5 percent according to AASHTO T 84 and T 85, condition the mix for 4 hours according to AASHTO R 30, Section 7.2 prior to compaction of specimens (AASHTO T 312) and determination of maximum specific gravity (AASHTO T 209).  Ensure that the job mix formula is within the master range specified in, Table 902.08.03-1.

Ensure that the job mix formula provides a mixture that meets a minimum tensile strength ratio (TSR) of 85 percent when prepared according to AASTHO T 312 and tested according to AASHTO T 283 with the following exceptions:

1. Before compaction, condition the mixture for 2 hours according to AASHTO R 30 Section 7.1.
2. Compact specimens with 40 gyrations.
3. Extrude specimens as soon as possible without damaging.
4. Use AASHTO T 269 to determine void content.
5. Record the void content of the specimens.
6. If less than 55 percent saturation is achieved, the procedure does not need to be repeated, unless the difference in tensile strength between duplicate specimens is greater than 25 pounds per square inch.
7. If visual stripping is detected, modify or readjust the mix.

For each mix design, submit three gyratory specimens and one loose sample corresponding to the composition of the job mix formula, including the design asphalt content.  The ME will use these samples for verification of the properties of the job mix formula.  Compact the specimens to the design number of gyrations (Ndes).  To be acceptable all three gyratory specimens must comply with the gradation and asphalt content requirements in Table 902.08.03-1 and with the control requirements in Table 902.08.03-2.  The ME reserves the right to be present at the time of molding the gyratory specimens.

In addition, submit 6 gyratory specimens and a 5 gallon bucket of loose mix to the ME.  Compact the additional gyratory specimens according to AASHTO T 312.  Ensure that the 6 gyratory specimens are 77 millimeters high and have an air void content of 5.0 ± 0.5 percent.  The ME will use the additional samples for performance testing of the HPTO mix.  The ME will test the specimens using an Asphalt Pavement Analyzer according to AASHTO TP 63 at 64 °C, 100 pounds per square inch hose pressure, and 100 pound wheel load.  The ME will approve the job mix formula if the average rut depth for the 6 specimens in the asphalt pavement analyzer testing is not more than 4 millimeters in 8,000 loading cycles.  If the job mix formula does not meet the APA criteria, redesign the HPTO mix.

If unsatisfactory results for any specified characteristic of the work make it necessary, establish a new job mix formula for approval.  In such instances, if corrective action is not taken, the ME may require an appropriate adjustment.

If a change in sources is made or a change in the properties of materials occurs, the ME will require that a new job mix formula be established and approved before production can continue.

902.08.03  Sampling and Testing  

1. General Acceptance Requirements.  The RE or ME may reject and require disposal of any batch or shipment that is rendered unfit for its intended use due to contamination, segregation, improper temperature, lumps of cold material, or incomplete coating of the aggregate.  For other than improper temperature, visual inspection of the material by the RE or ME is considered sufficient grounds for such rejection.

   Ensure that the temperature of the HPTO at discharge from the plant or surge and storage bins is maintained between 300 and 330 °F.

   Combine and mix the aggregates and asphalt binder to ensure that at least 95 percent of the coarse aggregate particles are entirely coated with asphalt binder as determined according to AASHTO T 195.  If the ME determines that there is an on-going problem with coating, the ME may obtain random samples from 5 trucks and will determine the adequacy of the mixing on the average of particle counts made on these 5 test portions.  If the requirement for 95 percent coating is not met on each sample, modify plant operations, as necessary, to obtain the required degree of coating.

2. Sampling.  The ME will take 5 stratified random samples of HPTO for volumetric acceptance testing from each lot of approximately 3500 tons of a mix.  When a lot of HPTO is less than 3500 tons, the ME will take samples at random for each mix at the rate of one sample for each 700 tons.  The ME will perform sampling according to AASHTO T 168, NJDOT B-2, or ASTM D 3665.

   Use a portion of the samples taken for composition testing, unless composition is determined by hot bin analysis.  If using hot bin analysis at a fully automated batch plant, take 5 samples from each lot corresponding to the volumetric acceptance samples, under the supervision of the ME.

3. Quality Control Testing.  The HMA producer is required to provide a quality control (QC) technician who is certified by the Society of Asphalt Technologists of New Jersey as an Asphalt Technologist, Level 2.  The QC technician may substitute equivalent technician certification by the Mid-Atlantic Region Technician Certification Program (MARTCP).  Ensure that the QC technician is present during periods of mix production for the sole purpose of quality control testing and to assist the ME.  The ME will not perform the quality control testing or other routine test functions in the absence of, or instead of, the QC technician.

   The QC technician is required to perform sampling and testing according to the approved quality control plan, to keep the mix within the limits specified for the HPTO mix being produced.  The QC technician may use acceptance test results or perform additional testing as necessary to control the mix.

   To determine the composition, perform ignition oven testing according to AASHTO T 308.  For fully automated plants, the QC technician may determine composition using hot bin analysis according to NJDOT B-5.  Use only one method for determining composition within a lot.

   For each acceptance test, perform maximum specific gravity testing according to AASHTO T 209 on a test portion of the sample taken by the ME.  Sample and test coarse aggregate, fine aggregate, mineral filler, and RAP according to the approved quality control plan for the plant.

4. Acceptance Testing and Requirements.  The ME will determine volumetric properties at Ndes for acceptance from samples taken, compacted, and tested at the HMA plant.  The ME will compact HPTO to 50 gyrations, using equipment according to AASHTO T 312.  The ME will determine bulk specific gravity of the compacted sample according to AASHTO T 166.  The ME will use the most current QC maximum specific gravity test result in calculating the volumetric properties of the HPTO.

   The ME will determine the dust-to-binder ratio from the composition results as tested by the QC technician.

   Ensure that the HMA mixture conforms to the requirements specified in Table 902.08.03-2, and to the gradation requirements in Table 902.08.03-1.  If 2 samples in a lot fail to conform to the gradation or volumetric requirements, immediately initiate corrective action.

   The ME will test a minimum of 1 sample per lot for moisture, basing moisture determinations on the weight loss of an approximately 1600-gram sample of mixture heated for 1 hour in an oven at 280 ± 5 °F.  Ensure that the moisture content of the mixture at discharge from the plant does not exceed 1.0 percent.

5. Performance Testing.  Provide 6 gyratory specimens and a 5 gallon bucket of loose mix to the ME.  Compact the additional gyratory specimens according to AASHTO T 312.  Ensure that the 6 gyratory specimens are 77 millimeters high and have an air void content of 5.0 ± 0.5 percent. The first sample is required to be taken in the first lot of production.  Thereafter, every third lot is required to be sampled.  The ME will use the samples for performance testing of the HPTO mix.  The ME will test the specimens using an Asphalt Pavement Analyzer according to AASHTO TP 63 at 64 °C, 100 pounds per square inch hose pressure, and 100 pounds wheel load.  If the HPTO mix exceeds the APA criteria of 4 mm in 8000 loading cycles, the ME may stop production until corrective action is taken.  If the HPTO mix exceeds the APA criteria of 12 mm in 8000 loading cycles, the RE may require removal and replacement of the lot of HPTO.

   Table 902.08.03-1  HPTO Grading of Total Aggregate
   Sieve Size	Percent Passing by Mass
   3/8”	100
   #4	65-85
   #8	33-55
   #16	20-35
   #30	15-30
   #50	10-20
   #100	5-15
   #200	5.0-8.0
   Minimum Percent Asphalt by Mass of Total Mix	7

   
   

    

   Table 902.08.03-2  Volumetric Requirements for Design and Control of HPTO
   	Required Density		Voids in Mineral Aggregate	Dust to Binder Ratio	Draindown AASHTO T 305
   	(% of Max. Sp. Gr.)
   	Ndes (50 gyrations)	Nmax (100 gyrations)	(VMA)
   Design Requirements	96.5	≤ 99.0	≥ 18.0 %	0.6 - 1.2	≤ 0.1 %
   Control Requirements	95.5 - 97.5	≤ 99.0	≥ 18.0 %	0.6 – 1.3	≤ 0.1 %

    

   
   

Section 903 – Concrete

903.01 Cement  

Use cement, listed on the QPL, that is either portland cement or blended hydraulic cement and conforms to the following:

The Contractor may only use Type III portland cement for class V concrete, prestressed Items, or precast Items.

For blended hydraulic cement, the Contractor may use portland cement pre-blended with a maximum of 25 percent fly ash, by weight, or a maximum of 5 percent silica fume by weight, or with a maximum of 50 percent slag by weight. If more than 30 percent slag is used, ensure that a scaling test according to ASTM C 672 is completed on the mix design and the concrete has a visual rating less than 3 after 50 cycles.

When blended hydraulic cement is used, do not add additional mineral admixtures at the concrete plant unless approved by the ME.

Do not mix different brands of cement, the same brand of cement from different mills, or different types of cement.

Provide suitable means for storing and protecting the cement against dampness. The ME will reject cement that has become partially set or that contains lumps of caked cement. Ensure that the temperature of the cement at the time of delivery to the mixer does not exceed 160 °F.

903.02 Concrete Admixtures  

903.02.01 Air-Entraining Admixtures

Use air-entraining admixtures for concrete that are listed on the QPL and conform to AASHTO M 154, except that the tests for bleeding and volume change are not required.

The ME will test for uniformity through the use of infrared spectrophotometry, pH values, specific gravity, and solids content.

Keep all bulk storage tanks inside a heated area with an ambient temperature of not less than 32 °F. Do not reuse air-entraining admixture that has been allowed to freeze until it has been agitated and retested.

903.02.02 Chemical Admixtures

Use chemical admixtures for concrete that are listed on the QPL and conform to AASHTO M 194.

Use chemical admixtures of the following types:

1. Type A – Water-reducing admixtures
2. Type B – Retarding admixtures
3. Type C – Accelerating admixtures
4. Type D – Water-reducing and retarding admixtures
5. Type E – Water-reducing and accelerating admixtures
6. Type F – Water-reducing, high range admixtures
7. Type G – Water-reducing, high range, and retarding admixtures

Do not use chemical admixtures that contain calcium chlorides or any other chlorides that may initiate or promote corrosion of the reinforcement steel.

Locate all bulk storage tanks for chemical admixtures inside a heated area with an ambient temperature of not less than 32 °F. Do not use chemical admixtures that have been allowed to freeze until they have been agitated and retested.

The ME may require certification from the manufacturer stating that the material is identical to that originally approved and has in no way been changed or altered. The ME will test for uniformity through the use of infrared spectrophotometry, pH values, specific gravity, and solids content.

903.02.03 Mineral Admixtures

1. Fly Ash. Ensure that fly ash for use as a pozzolan in concrete is listed on the QPL and conforms to ASTM C 618, Class C or Class F, except that the loss on ignition shall not exceed 3 percent. Use Class F fly ash to control alkali-silica reactivity.
   
   The supplier shall determine conformance to the requirements for loss on ignition and fineness for each truck load of fly ash delivered to the mixing site and shall include the test values on the delivery ticket.
   
   Submit certificate of compliance as specified in 106.07.
   
   
2. Slag. Slag for use as a cementitious material is ground, granulated blast furnace slag. Use slag that is listed on the QPL and conforms to the requirements of AASHTO M 302, Grade 120. The Contractor may use Grade 100 with the written permission of the ME.
   
   The Contractor may use slag as a replacement for cement as specified in 903.01, up to a maximum replacement level of 50 percent by weight of the total cementitious material. If more than 30 percent of cement is replaced, test the concrete mix design for scaling as specified in ASTM C 672, and ensure that it complies with a visual rating less than 3.
   
   Submit certificate of compliance, as specified in 106.07, indicating that the slag conforms to the requirements of AASHTO M 302, Grade 120.
   
   
3. Silica Fume Admixture. Ensure that silica fume admixture for use in concrete is listed on the QPL and conforms to AASHTO M 307. Use only 1 brand of silica fume admixture for the entire duration of the Contract. The Contractor may supply silica fume admixture either in dry or in slurry form. If the slurry form is used, ensure that it is homogeneous and agitated to prevent separation.
   
   Submit certificate of compliance as specified in 106.07.

903.02.04 Viscosity Modifying Admixture

If needed for self-consolidating concrete, use a viscosity modifying admixture that is listed on the QPL and that, when evaluated according to the test methods and mix design proportions in AASHTO M 194, conforms to the following physical requirements:

1. For initial and final set times, the allowable deviation of the test concrete from the reference concrete is not more than 1.0 hour earlier or 1.5 hours later.
2. For compressive and flexural strengths, the minimum allowable strength of the test concrete is 90 percent of the reference concrete strength at 3, 7, and 28 days.
3. The maximum allowable length change of the test concrete is 135 percent of the reference concrete. However, if the length change of the reference concrete is less than 0.030 percent, the maximum allowable length change of the test concrete is 0.010 percentage units more than the reference concrete.
4. The minimum allowable relative durability factor of the test concrete is 80 percent.

903.02.05 Corrosion Inhibitor Admixture

When required, use a calcium nitrite based corrosion inhibitor admixture to reduce the potential of corrosion of embedded steel. Use the following guidelines for calcium nitrite:

1. Ensure that the calcium nitrite does not contact other admixtures before entering the concrete mix. Use air entraining, water reducing, and retarding admixtures that are compatible with the calcium nitrite solution. Thoroughly mix the calcium nitrite solution before incorporating it into the concrete mix.
2. Strictly adhere to the manufacturer’s written recommendations regarding the use of the calcium nitrite admixture including storage, transportation, and method of mixing. The manufacturer of the calcium nitrite admixture shall have a representative available to assist the Contractor.
3. The ME will test for the presence of the calcium nitrite admixture in the plastic concrete as specified in NJDOT C-3. Provide the test kit that is required to perform the plastic test to the ME.
4. Use admixture that is 30 ± 2 percent calcium nitrite by weight of solution. Include a high range water reducing chemical admixture in the concrete when using a calcium nitrate admixture.
5. Add the calcium nitrite at a rate of 3 gallons per cubic yard of concrete.
6. Use a calcium nitrite admixture listed on the QPL.

903.03 Concrete  

903.03.01 Composition

Compose concrete of cement, coarse aggregate, fine aggregate, admixtures, and water. Concrete may include fly ash, slag or silica fume.

Use chemical admixtures according to the admixture manufacturer’s recommendation for the mix design and anticipated field conditions, including the admixture dosage rate and the location and method for introducing it into the mixture.

If fly ash is added to control alkali-silica reactivity, use at least 15 percent fly ash by weight of the total cementitious material. If AASHTO T 303 testing results in an expansion greater than 0.40 percent, use at least 20 percent fly ash. If slag is used to control alkali-silica reactivity, use at least 25 percent slag by weight of the total cementitious material. If a low alkali cement is used to control alkali-silica reactivity, use cement with equivalent alkali of less than 0.60 percent.

Use the combined weight of fly ash, slag, silica fume, and cement content to determine compliance with the minimum cement content and water-cement ratio requirements specified in Table 903.03.06-3. Include free water from the aggregates and the water in the admixtures and additives along with the mixing water when calculating the water-cement ratio.

903.03.02 Mix Design and Verification

Design at least 1 mix to equal or exceed the required verification strengths specified in Table 903.03.06-3 for each class of concrete included on the Project. A single mix design may satisfy the requirements for more than 1 class of concrete. Compute and set up the designs according to ACI Standard 211.1 or 211.2, as applicable.

At least 45 days before the start of concrete placement, submit each mix design on concrete mix design forms provided by the ME. Identify the sources of materials and test data on the forms.

The ME will be present at the time of verification batching to confirm that the proportions and ingredients batched are according to the proposed mix designs. If directed by the ME, mix at least 3 cubic yards of concrete in a central mix plant or transit truck for verification. The ME will direct that the verification batch be mixed in the top half of the allowable slump and air content ranges. Test for and report the slump and air content of the trial batch. The ME will reject the verification batch if the slump, air content, or yield is not acceptable. Prepare at least six 4 × 8-inch test cylinders from each acceptable batch and cure according to AASHTO T 23 or AASHTO R 39. Between 2 and 5 days after molding, deliver the cylinders to the ME for testing. The ME will test 3 cylinders at 7 days and 3 cylinders at 28 days to determine the 7-day and 28-day compressive strengths, respectively.

At the ME’s option, verification may be done on an annual basis for a concrete plant rather than on a project-to-project basis, provided the properties and proportions of the materials do not change. If the Contractor submits written verification that the same source and character of materials are to be used, the ME may waive the requirement for the design and verification of previously approved mixes.

Provide concrete conforming to the approved mix design. If using a previously approved mix design, notify the ME at least 1 day before making the change. Do not change the source, type, or proportions of materials until approved and the requirements for design and verification have been satisfied.

903.03.03 Mixing for Central-Plant and Transit Mixing

1. Handling, Measuring, and Batching Materials. Mix concrete at a concrete plant that is listed on the QPL and conforms to the requirements specified in 1010.01. Ensure that the plant’s location, layout, equipment, and provisions for transporting material will ensure a continuous supply of concrete to the work.
   
   Stockpile aggregates as specified in 901.02. Separately weigh the fine aggregate and each size of coarse aggregate into hoppers according to the amounts in the job mix design.
   
   Measure cement by weight, using separate scales and hoppers with a device to indicate the complete discharge of the batch of cement into the batch box or container. Ensure that the weighing hopper and scale are of adequate size, completely encased, and have provisions for locking. Operate the weighing hopper discharge gate so as to not affect the scale balance. Suspend the discharge chute, boot, or other such device from the encasement, not from the weighing hopper. Discharge the cement so that it does not lodge in the weighing hopper and there is no loss of cement by air currents. Ensure that the required cement content is added to each batch.
   
   Store mineral admixtures, unless pre-blended cement is supplied, at the batching plant in a separate storage facility. Batch mineral admixtures to tolerances equivalent to those specified for cement. When mineral admixtures are weighed cumulatively with the cement, add the mineral admixtures last in the batching sequence.
   
   When silica fume and dyes are added, demonstrate, prior to production, that the batching sequence will produce a uniform mix. If using mineral admixtures packaged in bags, empty the bag into the mix. Do not put degradable bags in the mix.
   
   Add chemical, air-entraining, and corrosion inhibiting admixtures to the mixing water or sand. Use a water measuring device that automatically registers and stops the flow of the water when the designated quantity has been delivered into the mixing drum.
   
   
2. Batch Tolerances. For individual batches, conform to the following tolerances based on the required scale reading:
   
   
   1. Cement and Mineral Admixtures: ±1.0 percent of the required weight of material or ±0.3 percent of scale capacity, whichever is greater.
   2. Aggregates 1-1/2 inches or smaller: ±2.0 percent of the required weight of material or ±0.3 percent of the scale capacity, whichever is greater.
   3. Aggregates larger than 1-1/2 inches: ±3.0 percent of the required weight of material or ±0.3 percent of scale capacity, whichever is greater.
   4. Water: ±1.0 percent of the required weight of material.
   5. Chemical, Air-entraining, and Corrosion Inhibiting Admixtures: ±3.0 percent of the required weight of material or ±1 ounce, whichever is greater.
   
   
3. Delivery Tickets. Supply a delivery ticket for each load of concrete. Ensure that the delivery ticket contains the following information:
   
   
   1. Use tickets that are serially numbered and bear the printed heading of the supplier and the location of the batch plant.
   2. Show the name of the Project, the name of the Contractor, the quantity and class of concrete, the batch time as imprinted on the ticket by an automatic clock, the date, and the truck number.
   3. After the truck has been discharged, fill in the time when the concrete was completely discharged, the amount of mixing water and the amount of tempering water, if used, and the total number of mixing revolutions for transit mix.
   4. An authorized representative of the supplier shall sign each ticket and give copies to the ME and the RE.
   
   In addition, for each truck or batch, provide a batching ticket to the ME, indicating the amount, brand name, and type of cementitious material; the amount and source of the fine aggregate; the amount, sizes, and sources of the coarse aggregates; the amount of mixing water; and the amounts, brand names, and types of admixtures.
   
   
4. Mixing Requirements. Do not allow the elapsed time from batching to the discharge of all the concrete from the mixer to exceed 90 minutes, except that under conditions contributing to quick stiffening of the concrete or when the temperature of the concrete is above 85 °F, the time limit is changed to 60 minutes. Under very severe conditions, the RE may further reduce the time limits. Measure batching time from the time cement is introduced to the mixer.
   
   If the concrete cannot be entirely discharged within 10 minutes, keep the concrete in the drum plastic and workable by revolving the truck drum at the manufacturer’s designated speed for agitation for at least 2 minutes in each 10 minute period.
   
   Use one of the following mixing methods unless mixing on the Project as specified in 903.03.04:
   
   
   1. Mixing at a Central-Mixing Plant. For central-mix concrete, proportion and mix concrete at a central plant and transport to the point of use in an agitator approved by the ME. If approved by the ME, non-agitating vehicles may be used to transport concrete at precast/prestressed concrete fabricators. Use central-mixing plant mixers that are of the type and capacity capable of combining the required materials into a thoroughly mixed and uniform mass within the specified mixing time and of discharging the mixture with a satisfactory degree of uniformity. Operate the plant according to N.J.A.C 7:27-6.1 et seq.
      
      Mix for at least 1 minute, with mixing time measured from the time all cement and aggregates are in the drum. Charge the batch into the mixer so that sufficient water enters in advance of cement and aggregates to prevent caking. Ensure that all water is in the drum by the end of the first quarter of the mixing time.
      
      When the temperature of the mixing water exceeds 100 °F, modify the loading sequence by mixing all the water and the aggregates and then the cement. Begin mixing immediately following the complete charging of the drum, and continue for not less than 1 minute.
      
      Restrict the volume of mixed concrete in the agitating truck to not exceed the manufacturer’s rating or 80 percent of the gross drum volume, whichever is less.
      
      Before acceptance testing, the Contractor may add mixing water, air entraining agent, or chemical admixture incrementally in order to achieve the proper slump or air content range as specified in Table 903.03.06-1 or Table 903.03.06-2.
      
      
   2. Transit Mixing. For transit mix concrete, proportion materials, including water, into a truck mixer from a 1-stop or 2-stop batching plant and mix in the truck. A one-stop batching plant is a plant where the dry ingredients for each batch of concrete are loaded into the mixer truck while water is being introduced. A 2-stop batching plant is a plant where the ingredients for each batch of concrete are loaded into the mixer truck at 2 separate locations.
      
      When loaded for mixing concrete, restrict the volume of concrete to no more than 63 percent of the gross drum volume of the transit truck mixer.
      
      Immediately begin mixing after the complete charging of the drum and continue for not less than 50 or more than 100 revolutions of the drum at the mixing speed recommended by the manufacturer of the transit truck mixer. After completing the minimum number of mixing revolutions at the plant, reduce the speed of the drum to the agitation speed recommended by the manufacturer. When using Type F or G admixtures, mix the load at the minimum specified number of mixing revolutions as recommended by the manufacturer.
      
      Before acceptance testing, the Contractor may add mixing water, air entraining agent, or chemical admixture incrementally in order to achieve the proper slump or air content range as specified in Table 903.03.06-1 or Table 903.03.06-2.
   
   
5. Rejection Criteria. The RE will reject concrete for any of the following reasons:
   
   
   1. The information for batching and delivery tickets is not complete, does not agree with the mix design, or is not supplied to the ME.
   2. The mixer fails to maintain the manufacturer’s stated speed of rotation for both mixing and agitation, or is not able to properly discharge the concrete.
   3. The RE observes improper batching, lack of uniform distribution of constituents throughout the load, or balling of the cement and aggregates.
   4. Water has been added while the truck is en route to the work site.
   5. The concrete is not discharged within the specified time limit, or if the revolution counter shows a total of more than the 300 revolutions. However, if the load has been partially discharged and if the concrete yet to be discharged conforms to the specified ranges for slump and entrained air without further addition of water or admixtures, then the RE may allow the use of the concrete.
   6. The slump or air content does not comply with requirements specified in 903.03.05.C.
   7. The concrete has been tempered after the ME has performed the final acceptance testing.
   8. Water is added after the truck has partially discharged regardless of ME testing.
   9. The indicator on the revolution counter shows that the instrument has been turned off or tampered with.
   10. The temperature of the concrete does not comply with requirements.
   11. The water-cement ratio of the load is greater than the allowable maximum water-cement ratio for the class of concrete.

903.03.04 Mixing on the Project

1. Mobile Mixers. Mix the concrete in a mixing unit that is part of the truck carrying the dry ingredients and conforms to the requirements for a mobile mixer as specified in 1010.03. Use a mixing unit that is an auger type incorporated in the truck’s discharge chute or other approved mixing mechanism. Produce concrete of uniform consistency and discharge the mix without segregation.
   
   Provide a means for storing the additives on the truck and incorporating them into the mix. Include a way to check the rate of flow of the additive into the mix and a meter to register the total volume of additive incorporated into the mix during each mixing operation. The ME will not allow use of trucks not having functional meters on the Project.
   
   Handle, measure, and batch materials according to the following:
   
   
   1. Stockpile aggregates as specified in 901.02.
   2. Proportion, measure, and batch cement and aggregates by a volumetric weight equivalent method. Mix the materials in the continuous-mixing-type truck mixer.
   3. Provide delivery tickets to the ME for each truckload of ingredients. On the delivery tickets, show the brand name and type of cement, the calibrated cement constant of the mixer in terms of the indicator revolution count, the source of aggregates, and the size of the coarse aggregate. A responsible officer or employee of the concrete supplier shall sign the delivery tickets. For each class of concrete and for each separate mixing operation, the mixer operator shall enter on the tickets the name of the Project, the name of the Contractor, the revolution counter indicator readings indicating the volumetric weight equivalent of cement discharged during that mixing operation, the concrete additive meter reading indicating the total volume of additive discharged into the mix during that mixing operation, the aggregate dial settings, the water and concrete additive flow rates, and the class of concrete delivered. The operator shall sign each completed ticket and provide a copy to the ME.
   
   
2. Small Mixers. With the RE’s approval, use small mixers only for small quantities of concrete that must be mixed on the Project. Unless provisions are made for accurately weighing bulk cement, use full bags of cement in each batch. Only use pre-blended mineral admixtures. Proportion aggregates and water by weight unless a calibrated volumetric method has been approved by the RE. Use accurate volumetric measuring devices to proportion chemical and air-entraining admixtures.
   
   Charge the mixer with the aggregates and part of the mixing water, and begin mixing. Add cement and admixtures with another portion of the mixing water. Mix until uniform. Temper with the remaining allowable mixing water to obtain the necessary consistency. Do not exceed the quantity of water required by the mix design.

903.03.05 Control and Acceptance Testing Requirements

1. Sampling and Testing Methods. Use the sampling and testing methods for concrete as specified in Table 903.03.05-1.




Table 903.03.05-1 Sampling and Testing Methods
Designation	Test Method
AASHTO T 221	Compressive Strength of Cylindrical Concrete Specimens (Including the Annex providing for use of neoprene caps)
AASHTO T 232	Making and Curing Concrete Test Specimens in the Field
AASHTO T 243	Obtaining and Testing Drilled Cores and Sawed Beams of Concrete
AASHTO T 97	Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading)
AASHTO T 119	Slump of Hydraulic Cement Concrete
AASHTO T 121	Weight Per Cubic Foot, Yield and Air Content (Gravimetric) of Concrete
AASHTO T 1414	Sampling Fresh Mixed Concrete
AASHTO T 152	Air Content of Freshly Mixed Concrete by the Pressure Method
AASHTO T 196	Air Content of Freshly Mixed Concrete by the Volumetric Method
AASHTO T303	Accelerated Detection of Potentially Deleterious Expansion of Mortar Bars Due to Alkali-Silica Reaction.
AASHTO R 39	Making and Curing Concrete Test Specimens in the Laboratory
ASTM C 567	Unit Weight of Structural Lightweight Concrete
ASTM C 3115	Sampling and Testing Fly Ash or Natural Pozzolans for Use as a Mineral Admixture in Portland Cement Concrete.
NJDOT C-1	Determination of Yield of Concrete Produced by Mobile Truck Mixers

1	Use 4 × 8-inch (diameter × height) compression test cylinders, except use 6 × 12-inch (diameter × height) test cylinders for concrete mixes containing coarse aggregate sizes exceeding a nominal maximum size of 1 inch.
2	Cure compression test cylinders for strength acceptance according to the Standard Cure Method in AASHTO T 23. For determining early strength for form removal, early loading of members, or opening to traffic, cure compression test cylinders according to the Field Cure Method in AASHTO T 23.
3	Obtain and prepare cores for compressive strength testing according to AASHTO T 24, except for the provisions for moisture conditioning. For moisture conditioning, soak cores in a lime bath at 73.4 ± 3 °F for at least 40 hours immediately prior to testing. After making any necessary corrections to the core results for ratio, the ME will divide each core result by 0.85 before reporting the final compressive strength.
4	Sample according to AASHTO T 141, except do not take a composite sample to represent a truck. Take the sample after approximately 1 cubic yard of concrete has been discharged from the truck to be sampled.
5	The Department may modify the sampling rate for individual and composite samples.



2. Quality Control. The concrete supplier shall have a quality control plan approved annually by the ME. The producer shall ensure that the plan conforms to the “Requirements for a Portland Cement Concrete Plant Quality Control Plan”, which may be obtained from the ME. During production of concrete for the Project, the supplier shall perform quality control testing as required in the approved plan. If a concrete supplier does not have an approved plan or does not follow the approved plan, the ME will remove the supplier from the QPL.
   
   Ensure that the QC technician, certified by ACI as a Concrete Field Technician, Grade 1, is present at the plant or the Project Limits during production. During production of concrete for the Project, perform quality control testing as required in the approved plan and as needed to ensure compliance with the requirements for the concrete.
   
   
3. Acceptance Testing Procedures for Slump and Air Entrainment. The ME will perform sampling and testing for slump (AASHTO T 119) and air entrainment (AASHTO T 152 or T 196), except for precast, prestressed concrete Items, for which the Contractor shall perform sampling and testing for slump and air entrainment. For pumped concrete, take the sample of concrete at the point of discharge and deliver it to the ME.
   
   At a minimum, the ME will perform slump and air-entrainment tests at the rate specified for strength tests in Table 903.03.06-4 and on the same samples of material from which the compressive tests cylinders are molded. The ME will perform additional slump and air-entrainment tests as necessary to ensure the quality of the concrete. While these tests are being performed, halt discharge from the truck. Discharge from other trucks not scheduled for testing may proceed unless otherwise directed by the ME.
   
   If the measured value of either slump or air entrainment exceeds the upper limit, the ME will perform a second test on a different portion of material from the same load. If the average of the 2 test results for either slump or air entrainment exceeds the upper limit, the ME will reject the load. Remove rejected loads from the Project Limits.
   
   If neither of the measured values of the slump or air entrainment exceeds the upper limit, the Contractor may temper the concrete once, prior to discharge into the work. Temper by addition of water, air entraining agent, or any chemical admixture included in the mix design as recommended by the manufacturer. Ensure that quantities added will result in slump and percent air entrainment within the specified ranges throughout the duration of discharge of the load. After tempering, rotate the drum at the recommended mixing speed for a minimum of 30 revolutions. Meet the specified maximum water-cement ratio and comply with the time and revolution limits specified in 903.03.03. Report quantities added to the ME.
   
   Following any allowed tempering, the ME will disregard the original test results and perform a single test for slump and air entrainment. If the measured values for slump and air-content are not within the ranges specified in Table 903.03.06-1 or Table 903.03.06-2, the RE will reject the load of concrete.
   
   Do not make additions to the load after the acceptance testing has been completed. For loads not scheduled for acceptance testing, make additions as specified in 903.03.03 before discharge into the work.
   
   
4. General Acceptance Testing Requirements for Strength. The ME will perform sampling and testing for strength, except for precast, prestressed concrete Items for which the Contractor shall perform sampling and testing for strength. For pumped concrete, take the sample of concrete at the point of discharge and deliver it to the ME.
   
   Provide, for the sole use of the ME, a sufficient number of curing facilities for the storage and curing of concrete test cylinders within the Project Limits for the first 24 hours according to AASHTO T 23. Ensure that the curing facilities are provided with minimum-maximum thermometers and are securable with lock and key. During the period from May 1 through October 31, provide water tanks or tubs of sufficient capacity and rigidity to hold the cylinders in an upright position, fully submerged and without contact between cylinders. During the remaining months of the year, or as directed by the RE, provide securable, insulated boxes, of similar capacity and rigidity. During the initial 24 hours, ensure that the test specimens are undisturbed and maintained within the specified temperature range. If, within 10 days of the RE’s request, the facilities are not provided, do not place any concrete.
   
   The ME will cure concrete test specimens that are to be used for determination of early strengths for removing forms, opening to traffic, or otherwise placing the concrete into service according to the field curing provisions in AASHTO T 23.
   
   An initial strength test result is defined as the average strength of two 4 × 8-inch compression test cylinders, cured for 28 days, and tested by the ME. The Contractor may have cylinders for precast concrete tested at the fabricator’s plant under the supervision of the ME. The ME will sample and test at the rate specified in Table 903.03.06-4. If either of the cylinders comprising a test shows definite evidence (other than low strength) of improper sampling, molding, handling, curing, or testing, the ME will discard it and use the strength of the remaining cylinder as the test result. If the difference in compressive strength between 2 cylinders comprising a test equals or exceeds 600 pounds per square inch, the ME will disregard the lower value and use the higher value as the test result. If both cylinders comprising a test are discarded, the ME will evaluate the lot on the basis of the reduced number of tests.
   
   If the ME takes additional unscheduled compression cylinders, as specified in 106.05, the ME will include the results with the regularly scheduled compression cylinder results and will evaluate the lot on the basis of the increased number of tests.
   
   
5. Acceptance Testing for Strength for Pay-Adjustment Items. The Special Provisions will identify the concrete Items, if any, that are subject to pay adjustment and their base prices.
   
   The ME will test the cylinders in the lot of concrete and compute the pay adjustment in the following steps:
   
   
   1. Compute Average Lot Strength (ALS) and Standard Deviation (S). If only a single test result is available, the standard deviation (S) is assumed to equal 200 pounds per square inch.
   
   
   

   	Where:
   	∑ = Summation
   	Xi = Individual test result (average strength of a test cylinder pair)
   	N = Number of test results for the lot

   
   
   2. Compute Quality Index (Q).
   
   
   

   	Q  =	ALS − CDS
   		S

   Where:

   CDS = Class design strength in pounds per square inch from Table 903.03.06-3 for the specified class of concrete.

   
   
   3. Determine Percent Defective (PD). Using NJDOT ST for the appropriate sample size, the ME will determine PD associated with Q calculated in the previous step.
      
      
   4. Compute Percent Pay Adjustment (PPA).
   
   
   

   	Quality	Percent Pay Adjustment
   Equation 1	PD < 50	PPA = 3.0 − 0.3 PD
   Equation 2	PD ≥ 50	PPA = 26.0 − 0.76 PD

   
   The amount of pay-adjustment in dollars is the product of the Item base price times the lot quantity times the percent pay-adjustment (expressed as a decimal) given by Equation 1 or 2.
   
   For lots having percent defective (PD) levels less than 10 percent, Equation 1 provides positive adjustments to the contract price. For lots having exactly 10 percent defective, there is no adjustment to the contract price. For lots having greater than 10 percent defective, Equations 1 or 2, as appropriate, subtract progressively larger amounts from the contract price.
   
   If, based on the initial series of tests, the lot quality of a pay-adjustment item is estimated to be PD = 50 or greater, the ME may reevaluate by coring or other suitable means. When this provision is applied to precast/prestressed concrete, the ME will evaluate each item in the bed separately.
   
   If the re-evaluation is accomplished by a method other than coring, the ME will use the results only to determine what further action is to be taken. If all non-core test results equal or exceed the class design strength, the ME may elect to accept the lot at 100 percent payment.
   
   If the Department elects not to core, the Contractor may accept the PPA calculated by Equation 1 or 2, as appropriate, or, when approved by the Department, the Contractor may take cores as specified in Table 903.03.06-4. Take the cores within 90 days from the date of concrete placement. If electing to core, perform the coring as directed by the ME, and provide the cores to the ME for testing.
   
   If cores are taken, the Department will use the core results to determine the final disposition of the lot. If, based on the core results, the lot is determined to be at a quality level of PD < 75, the Department will compute the pay-adjustment by Equation 1 or 2, as appropriate. If the lot is confirmed to be at a quality level of PD ≥ 75, the ME will reject the lot and the RE may do one of the following:
   
   
   1. Require the Contractor to remove and replace the defective lot.
   2. Allow the Contractor to leave the defective lot in place and receive a PPA computed by Equation 2.
   3. Allow the Contractor to submit a plan, to the RE for approval, for corrective action.
   
   
6. Acceptance Testing for Strength for Non-Pay-Adjustment Items. Non-pay-adjustment Items are those concrete Items not specifically designated as pay-adjustment Items, as specified in 903.03.05.E, but may be accepted by pay-adjustment under certain circumstances. Such an item is eligible for 100 percent payment (PPA = 0) if each individual test result in a lot meets the retest limit specified in Table 903.03.06-4.
   
   If any individual test value (average of a cylinder pair) falls below the retest limit for non-pay-adjustment concrete in Table 903.03.06-4, the ME may reevaluate by coring or other suitable means. When this provision is applied to precast/prestressed concrete, the ME will evaluate each item in the bed separately.
   
   If the re-evaluation is accomplished by a method other than coring, the ME will use the results only to determine what further action is to be taken. If all non-core test results equal or exceed the class design strength, the ME may elect to accept the lot at 100 percent payment.
   
   If the Department elects not to core, the Department may allow the Contractor to take cores as specified in Table 903.03.06-4. Take the cores within 90 days from the date of concrete placement. If electing to core, perform the coring as directed by the ME, and provide the cores to the ME for testing.
   
   If cores are taken, the Department will use the core results to determine the final disposition of the lot. If, based on the core results, the lot is determined to be at a quality level of PD < 75, the Department will compute the pay-adjustment as specified in 903.03.05.E. If the lot is confirmed to be at a quality level of PD ≥ 75, the ME will reject the lot and the RE may do one of the following:
   
   
   1. Require the Contractor to remove and replace the defective lot
   2. Allow the Contractor to leave the defective lot in place and receive a PPA computed by Equation 2.
   3. Allow the Contractor to submit a plan, for approval, for corrective action.
   
   If retesting is not performed by the Department or the Contractor, the Department will calculate the PPA as for a pay-adjustment item as specified in 903.03.05.E, except that the Department will use the item bid price instead of an item base price in the computation of the pay-adjustment.
   
   When computing a pay-adjustment for any of the Items listed in Table 903.03.05-2, which are only partially composed of concrete, the ME will multiply the amount of pay-adjustment, if any, by the Estimated Percentage of Concrete (expressed as a decimal) as shown in Table 903.03.05-2.
   



Table 903.03.05-2 Estimated Percentage of Concrete in Items
Item	Estimated Percentage of Concrete
INLET, TYPE ___	30
INLET, TYPE ___, USING EXISTING CASTING	30
MANHOLE, ___' DIAMETER	30
MANHOLE, USING EXISTING CASTING	30
MANHOLE, SANITARY SEWER	30
MANHOLE, SANITARY SEWER, USING EXISTING CASTING	30
GRANITE CURB	25
RESET GRANITE CURB	25
BEAM GUIDE RAIL TERMINALS AND ANCHORAGES	25
CHAIN-LINK FENCE, ___' HIGH	25
CHAIN-LINK FENCE, ALUMINUM-COATED STEEL, ___' HIGH	25
CHAIN-LINK FENCE, PVC-COATED STEEL, ___' HIGH	25
GATE, CHAIN-LINK FENCE, ___' WIDE	25
GATE, CHAIN-LINK FENCE, ALUMINUM-COATED STEEL, ___' WIDE	25
GATE, CHAIN-LINK FENCE, PVC-COATED STEEL, ___' WIDE	25
TEMPORARY CHAIN-LINK FENCE, ___' HIGH	25
GUIDE SIGN, TYPE GA, BREAKAWAY SUPPORTS	20
GUIDE SIGN, TYPE GA, NON-BREAKAWAY SUPPORTS	20


The amount of pay-adjustment for Items not listed in Table 903.03.05-2 is the product of the unit bid price times the lot quantity times the percent pay-adjustment determined according to Equation 1 or 2.

903.03.06 Tables

903.04 Pavement Repair Mixes Class V and E  

903.04.01 Composition

Use Class V or E concrete for concrete pavement repair and replacement. Ensure that the composition of Class V and E concrete complies with 903.03.01 except that Class V concrete is required to use an accelerating admixture and a high range water-reducing admixture.

Ensure that the composition of Class V or E concrete conform to the composition requirements specified in 903.03.01, except use an accelerating admixture and a high range water-reducing admixture for Class V concrete.

903.04.02 Mix Design and Verification

Design and verify Class V and E concrete as specified in 903.03.02, except for the following:

1. Design Class V and E concrete to conform to the requirements in Table 903.04.02-1.
2. Include 6.5-hour flexural beam testing in the verification testing for Class V concrete. Test two 6 ´ 6 ´ 21-inch flexural beams according to AASHTO T 97. The ME will witness the flexural beam testing. The ME will approve the mix design if both beams meet the verification strength.
3. Include 72-hour compressive strength testing in the verification testing for Class E concrete.
   



Table 903.04.02-1 Mix Design Requirements
	Class V	Class E
Class Design Strength
28-day Compressive Strength, psi	3700	3700
6.5-Hour Flexural Strength, psi	350	–
72-Hour Compressive Strength, psi	–	3000
Verification Strength
28-day Compressive Strength, psi	4500	4500
6.5-Hour Flexural Strength, psi	390	–
72-Hour Compressive Strength, psi	–	3700
Maximum Water-Cement Ratio (lb/lb)	.40	.40
Minimum Cement Content (lb/cy)	611	611

903.04.03 Mixing

Mix Class V and E concrete as specified in 903.03.03 or 903.03.04.

903.04.04 Control and Acceptance Testing Requirements

1. Sampling and Testing Methods. Use the sampling and testing methods specified in 903.03.05.A.
   
   
2. Acceptance Testing Procedures for Slump and Air Entrainment. The ME will perform acceptance testing for slump and air entrainment as specified in 903.03.05.C.
   
   
3. Acceptance Testing Procedures for Strength. The ME will test Class V and E concrete to ensure conformance to the requirements specified in 903.03.05.D and 903.03.05.F for control and acceptance testing of non-pay adjustment Class B concrete for 28-day compressive strength.
   
   For each day’s production of Class V concrete, the ME will field cure two 6 × 6 × 21-inch beams according to AASHTO T 23 and will test the beams’ 6.5-hour flexural strength according to AASHTO T 97. If either beam is below the required strength of 350 pounds per square inch at 6.5 hours, the ME will perform a retest on 2 beams at 8 hours. If either beam is below the required strength of 350 pounds per square inch at 8 hours, the ME will reject the day’s production.
   
   For Class E concrete, the ME will field cure cylinders according to AASHTO T 23 for use in 72-hour compressive strength testing. The ME will sample for 72-hour compressive strength testing at the same rate as for the 28-day compressive strength. The ME will perform compressive strength testing to ensure that the required 72-hour compressive strength of 3000 pounds per square inch is in compliance. Each test is comprised of 2 cylinders.

903.05 High Performance Concrete (HPC)  

903.05.01 Composition

Produce HPC conforming to the composition requirements specified in 903.03.01, except for the following:

1. When using more than 1 admixture, ensure that they are compatible. If using admixtures from different manufacturers, submit letters from each manufacturer certifying that their admixtures are compatible with all others in the mix design.
2. Pozzalonic material maximum percentage limitations specified in 903.01 and 903.02.03 are waived for HPC mix designs.
3. In the design of HPC, in order to achieve the desired resistance to chloride penetration, provide an appropriate pozzalonic or other cementitious material, such as silica fume, fly ash, or slag in the mix design.
4. Do not use silica fume as a sole material to achieve the desired resistance to chlorides. Do not use more than 5 percent of silica fume by weight of the total cementitious material. If using fly ash in conjunction with silica fume, use 10 to 15 percent fly ash by weight of the total cementitious materials. If using slag in conjunction with silica fume, use up to 40 percent slag by weight of the total cementitious materials.

903.05.02 Mix Design and Verification

Design an HPC mix that conforms to the requirements in Table 903.05.02-1. Submit a report documenting these results to the ME. Obtain the results of these standard tests from an AASHTO accredited testing agency that is accredited for the test being performed. Design mixes according to the HPC-1 criteria for use in bridge decks, parapets, and bridge sidewalks. Design mixes meeting the HPC-2 criteria for use in pier column protection.

At least 90 days before the planned start of the concrete placement, submit the mix design to the ME for approval and verification as specified in 903.03.02. Include the results of the required performance testing in the submission.

In addition to verifying the compressive strength of the HPC mix, the ME will verify the chloride permeability testing according to AASHTO T 277. Submit 4 additional cylindrical samples, having a 4-inch diameter and a length of at least 8 inches, to the ME for this verification testing. The ME will average the values of tests on 2 specimens for each mix design.

903.05.03 Mixing

Mix HPC concrete as specified in 903.03.03. During production, do not change the components of the mix in any way from the approved mix design. If the components must be changed, redesign and re-verify the mix.

903.05.04 Control and Acceptance Testing Requirements

With the exception that the ME may perform compression testing at 56 days, the ME will enforce the requirements specified in 903.03.05 for control and acceptance testing of non-pay adjustment Class A concrete in the fabrication of the HPC elements.

Produce HPC that conforms to the acceptance testing criteria in Table 903.05.04-1.

The ME will test 2 specimens for chloride permeability and will average the results of the 2 specimens to determine the test result. The ME will perform 2 tests on each lot from samples taken from 2 randomly selected delivery trucks. The lot is eligible for 100 percent payment provided that the test results are equal to or below 2000 coulombs.

If, upon testing at 56 days, 1 or more individual test results exceed 2000 coulombs, the RE may:

1. Require that the Contractor remove and replace the defective lot, or
2. Allow the Contractor to submit a corrective action plan for approval.

903.06 Self-Consolidating Concrete (SCC)  

903.06.01 SCC for Drilled Shafts

1. Composition. Produce SCC conforming to the composition requirements specified in 903.03.01, except use a Type F admixture and a viscosity modifying admixture (VMA). Use Type F and VMA admixtures, as specified in 903.02.02 and 903.02.04, at a dosage to produce a flowable concrete that does not require vibration for consolidation. Proportion the aggregates so that the fine aggregate is less than 50 percent by weight of the total aggregate.
   
   
2. Mix Design and Verification. Design the mix as specified in 903.03.02 to conform to the strength requirements, water-cement ratio, and cement content for a Class A concrete and the requirements specified in Table 903.06.01-1.




Table 903.06.01-1 Requirements for SCC for Drilled Shafts
Property	Test Method	Requirement
Air Content
Coarse Aggregate No. 57	AASHTO T 152	6.5 ± 2.0 percent
Coarse Aggregate No. 67		6.5 ± 2.0 percent
Coarse Aggregate No. 8		7.5 ± 2.0 percent
Slump Flow	NJDOT C-4	21 ± 3 inches
Visual Stability Index
Plastic Concrete	NJDOT C-4	1 maximum
Hardened Concrete	NJDOT C-5	1 maximum


Perform mix design verification as specified in 903.03.02. For the verification batch, ensure that the air content is in the top half of the allowable range and the slump flow is between 21 and 24 inches. Perform air content, slump flow, and visual stability index (plastic concrete) testing on the verification batch. Make concrete cylinders for compression testing as specified in 903.03.02 and make 2 additional 4 × 8-inch cylinders for evaluation of the visual stability index of the hardened concrete. Saw the additional cylinders length-wise according to NJDOT C-5. The ME will perform the compressive strength testing and the visual evaluation to assign a visual stability index in order to approve the mix.


3. Verification of Pumpability. Verify pumpability at least 10 days before pouring the SCC concrete in the drilled shaft. Demonstrate the pumpability of the SCC to the ME by pumping a trial batch through the pump proposed for placing the SCC into the drilled shaft. Use the proposed methods for mixing the concrete including any anticipated time delays. The ME will test the SCC before and after pumping to verify that the SCC meets the requirements of Table 903.06.01-1 after pumping.
   
   
4. Mixing. Mix SCC as specified in 903.03.03.
   
   
5. Control and Acceptance Testing. Perform quality control testing as specified in 903.03.05.
   
   The ME will perform acceptance testing as specified in 903.03.05 for a non-pay adjustment Class A concrete, except that the provisions for slump testing are replaced with requirements for slump flow testing and visual stability index on the plastic concrete. The ME will perform the slump flow testing and the visual stability index according to NJDOT C-4, at the sampling rate specified for slump testing of Class A concrete. The ME will perform visual stability index on the hardened concrete according to NJDOT C-5 at a rate of at least 1 per day. If the visual stability index on the hardened concrete does not conform to the criteria in Table 903.06.01-1, the ME will require redesign of the mix.
   
   In the performance of quality control or acceptance testing, fill cylinder molds, slump flow cones, and air buckets in one lift. Do not vibrate, rod, or tap to consolidate the SCC.

903.06.02 SCC For Precast Concrete

1. Composition. Produce SCC conforming to the composition requirements specified in 903.03.01, except use a Type F admixture or a combination of a Type F and a viscosity modifying admixture (VMA). Use Type F and VMA admixtures, as specified in 903.02.02 and 903.02.04, at a dosage to produce a flowable concrete that does not require vibration for consolidation. Proportion the aggregates so that the fine aggregate is less than 50 percent by weight of the total aggregate.
   
   
2. Mix Design and Verification. Design the mix, as specified in 903.03.02 or 903.05.02, to conform to the strength, water-cement ratio, cement content, and air content requirements for the specified class of concrete for the item that is being cast. In addition, ensure that the SCC conforms to the requirements specified in Table 903.06.02-1.
   



Table 903.06.02-1 Requirements for SCC for Precast Concrete
Property	Test Method	Requirement
Slump Flow	NJDOT C-4	24 to 28 inches
Visual Stability Index
Plastic Concrete	NJDOT C-4	1 maximum
Hardened Concrete	NJDOT C-5	1 maximum


Perform mix design verification as specified in 903.03.02 or 903.05.02. For the verification batch, ensure that the air content is in the top half of the allowable range and the slump flow is between 26 and 28 inches. Perform air content, slump flow, and visual stability index (plastic concrete) testing on the verification batch. Make concrete cylinders for compression testing as specified in 903.03.02 or 903.05.02 and make 2 additional 4 × 8 inch cylinders for visual stability index on the hardened concrete. Saw the additional cylinders length-wise according to NJDOT C-5. The ME will perform the compressive strength testing and the visual evaluation to assign a visual stability index in order to approve the mix.


3. Mixing. Mix SCC as specified in 903.03.03.
   
   
4. Control and Acceptance Testing. Perform quality control testing as specified in 903.03.05.
   
   The ME will perform acceptance testing as specified in 903.03.05 for specified class of concrete for the item, except that the provisions for slump testing are replaced with requirements for slump flow testing and visual stability index on the plastic concrete. The ME will perform the slump flow testing and the visual stability index according to NJDOT C-4, at the sampling rate specified for slump testing for the specified class of concrete. The ME will perform visual stability index on the hardened concrete according to NJDOT C-5 at a rate of at least one per day. If the visual stability index on the hardened concrete does not conform to the criteria specified in Table 903.06.02-1, the ME will require redesign of the mix.
   
   In the performance of quality control or acceptance testing, without remixing the sample, fill cylinder molds, slump flow cones, and air buckets in one lift. Do not vibrate, rod, or tap to consolidate the SCC.

903.07 Quick-Setting Patch Materials

Use quick-setting patch material that is listed on the QPL and is ready for mixing according to the manufacturer’s recommendations. Follow the manufacturer’s recommendations regarding the required water demand for the patching material. Use patching material that is concrete gray in color and contains no calcium chloride or other ingredients that cause corrosion to steel reinforcement. If adding coarse aggregate to patching material, use broken stone conforming to 901.03.01. Ensure that the material is quick-setting for use in concrete patching where fast setting, rapid strength gain, non-shrink, and high bond strength characteristics are needed. The ME will add products to the QPL only after testing and evaluation in the field, after service for 1 year.

The classifications for quick-setting patch materials are as follows:

1. Type 1. Suitable for use above water. Type 1 products are used neat or with up to 15 pounds of coarse aggregate size No. 8 added to a 50-pound bag of material. The ME will test the patch material neat. At the work site, the Contractor may add up to 15 pounds of coarse aggregate size No. 8 to a 50-pound bag of the patch material to increase yield, provided that the product properties are not adversely affected.
   
   
2. Type 1A. Suitable for use above water. Type 1A products have manufacturer specified mix proportions with aggregates that would preclude it from being classified as a Type 1. The ME will approve the mix proportions before adding the material to the QPL. The manufacturer shall provide mixing proportions, including the required type and size of aggregate and the proportion of patching material, aggregate/sand, and water. At least 10 days before the start of placement, propose aggregates for verification trial batching based on the manufacturer’s pre-approved proportions. The ME will verify that the proposed quick setting patch mixture meets the required physical properties.
   
   
3. Type 1B. Suitable for use above water. Type 1B products are those products that have course aggregate, sand, or both pre-packaged with the cementitious material. The ME will test this material, including a field trial, prior to adding it to the QPL. The manufacturer shall designate the amount of aggregate and shall maintain the total aggregate within ±10 percent of this stated amount. The ME will randomly test the aggregate to ensure that the overall percentage of aggregate is within ±10 percent of the total and that the gradation on individual sieves does not vary more than ±10 percent from the gradation of the originally approved sample. The manufacturer shall use an aggregate supplier that is listed on the QPL. The ME will disapprove quick-setting patch material that fails to comply with the aggregate consistency requirements. If the manufacturer makes any changes to the formulation, the ME will require that the material be resubmitted for approval. Do not add additional aggregate in the field.
   
   
4. Type 2. Suitable for vertical and overhead repairs that are not formed and poured. The ME will test the patch material neat.

If liquid activator, other additives, adhesive, or bonding agents are integral to the performance of the patch material, the manufacturer shall provide the material so that 1 package of additive, activator, adhesive or bonding agent is required for 1 package of patch material. Mix patch material as specified in 903.03.04.

Use quick setting patch material that meets the requirements in Table 903.07-1 when tested according to NJDOT C-2. Mix quick-setting patch according to the manufacturer’s recommendations.

903.08 Mortar and Grout  

903.08.01 Mortar

To produce mortar, mix 1 part cement to 2 parts fine aggregate. Add water to form the proper consistency. Do not temper or use mortar after it has begun to set.

903.08.02 Grout

1. Non-Shrink Grout. Use non-shrink grout of a plastic consistency that is listed on the QPL and conforms to ASTM C 1107 with the following amendments:
   
   
   1. Ensure that the grout has a working time of at least 30 minutes from the time the water is added.
   2. Match the color of the hardened grout, where visible, to the color of the adjacent hardened concrete.
   3. Include 1-day strength tests as part of the performance requirements of ASTM C 1107.
   4. Ensure that the grout contains no more than 0.05 percent chlorides or 5.0 percent sulfates by weight.
   
   
2. Epoxy Grout. Use epoxy grout that is listed on the QPL and conforms to the requirements of ASTM C 881, Type 1, Grade 3, Class B or C.

903.08.03 Grout for Undersealing of Concrete Pavement

1. Pozzolan Grout.




Provide materials as specified:
	Cement, Type I, II, III	903.01
	Chemical Admixtures	903.02.02
	Fly Ash	903.02.03.A
	Water	919.08


Ensure that the mix for grout conforms to the following proportions by volume:


1. 1 part cement
2. 3 parts fly ash
3. Water to achieve required fluidity
4. Admixtures as needed to obtain required grout characteristics

Submit materials proposed for use to the RE for approval. Include in the submittal the mill certification for cement, physical and chemical analysis of fly ash, and tests of the pozzolan grout by an AASHTO accredited testing laboratory. Ensure that the laboratory report includes the 1-day, 3-day, and 7-day compressive strengths; flow cone time; shrinkage/expansion; and time of initial set. Ensure that the grout conforms to the requirements specified in Table 903.08.03-1.



Table 903.08.03-1 Requirements for Pozzolan Grout
Property	Test Method	Requirements
Compressive Strength, 7-Day (psi)	AASHTO T 106	600 minimum
Flow Cone Time (s)	ASTM C 939	9 - 16



2. High-Density Polyurethane Grout. Submit to the RE for approval all materials proposed for use. Include in the submittal a certification of physical and chemical analysis by an AASHTO accredited testing laboratory. Provide certification that the materials will not shrink or deteriorate for a period of 10 years from the date of injection.
   
   Ensure that the high-density polyurethane conforms to the requirements specified in Table 903.08.03-2.




Table 903.08.03-2 Requirements for High-Density Polyurethane Grout
Property	Test Method	Requirements
Density (pcf)	ASTM D 1622	5.65 to 5.90
Compressive Strength (psi)1	ASTM D 1621	65 to 95
Tensile Core (psi)	ASTM D 1623	70 to 100
Shear Strength (psi)	ASTM C   273	40 to 85
Closed Cell Content %	ASTM D 2858	85 to 95
Percent Volume Change
Humid - 28 Days (158 °F, 95% Humidity)	ASTM D 2126	+5.0 to +11.0
Freeze - 5 Days (−20°F, Dry)		−0.1 to −0.9

1	Ensure high-density polyurethane grout reaches 90 percent of the full compressive strength within 15 minutes of injection.

903.09 Controlled Low Strength Material (CLSM)

Use CLSM that consists of a mixture of cement, water, fine aggregate, and admixtures. Proportion the CLSM mixture to provide a backfill material that is self-compacting and capable of being excavated with hand tools at a later date. Proportion the CLSM to produce a 28-day compressive strength of 50 to 150 pounds per square inch. If fast-setting CLSM is required, use an accelerating admixture to produce a fast setting flowable mixture. Ensure that the CLSM for backfilling of conduit and piping has a permeability of 1.7 × 10⁻³ ± 0.2 × 10⁻³ centimeters per second when tested according to ASTM D 5084.

At least 45 days before the start of any CLSM placement, prepare trial batches of CLSM of the same materials and proportions proposed for use in the Contract. Submit each mix design on concrete mix design forms provided by the Department, naming the sources of materials and test data.

The ME will be present at the time of verification batching to confirm that the proportions and materials batched conform to the proposed mix designs. Prepare at least six 6 × 12-inch compression test cylinders for each batch to be tested according to ASTM D 5971 for 28-day strengths except for fast setting mixes. Test fast-setting CLSM at the specified cure time. If fly ash is used in the CLSM, the ME will take an additional set of cylinders to ensure that the strength of the CLSM does not exceed 150 pounds per square inch in 90 days.

For acceptance testing, the ME will take 1 sample per day but may waive the testing if less than 20 cubic yards is placed in a day. If strength does not comply, the ME may require a new mix design for the CSLM.

903.10 Curing Materials  

903.10.01 Burlap Cloth

Use burlap cloth made from jute or kenaf conforming to AASHTO M 182, Class 4. The ME may sample 1 square yard of burlap cloth from each source for testing. If requested by the RE, submit a certification of compliance as specified in 106.07.

903.10.02 Liquid Membrane-Forming Compound

Use liquid membrane-forming compounds conforming to AASHTO M 148, Type 1-D, clear or translucent with fugitive dye. The ME may sample 1 quart of liquid membrane-forming compound from each lot for testing. If requested by the RE, submit a certification of compliance as specified in 106.07.

903.10.03 White Polyethylene Sheeting

Use white polyethylene sheeting conforming to AASHTO M 171 for white opaque polyethylene film. The ME may sample a 1-foot strip (cut across full width) from each source for testing. If requested by the RE, submit a certification of compliance as specified in 106.07.

Section 904 – Precast and Prestressed Concrete

904.01 Non-Structural Precast Concrete  

904.01.01 Component Materials

Welded steel wire fabric used for reinforcement need not be galvanized.

904.01.02 Fabrication

Fabricate precast concrete at a plant as specified in 1011.01.

1. Placing Reinforcement Steel. Before placing the concrete, place reinforcement steel in position as shown on the approved working drawings and as specified in 504.03.01. Firmly tie the reinforcement to prevent displacement during placing of the concrete.
   
   
2. Placing Concrete. Place concrete as specified in 504.03.02.D and 504.03.02.E. Before placing concrete, ensure that reinforcement steel and any other embedded materials are free of loose rust, frost, dirt, oil, or contaminants that may prevent a bond with the concrete. Consolidate concrete with internal vibrators. The fabricator may use external vibration to supplement internal vibration. If using SCC, minimize or eliminate the use of vibrators to prevent segregation.

904.01.03 Curing

Cure according to the PCI MNL-116, except for steam curing. Do not strip forms until the piece has attained a stripping strength of 2000 pounds per square inch.

If steam curing, delay the application of steam within the enclosure for 4 hours or until the concrete has attained an initial set as determined according to ASTM C 403. Maintain an ambient temperature between 50 °F and 90 °F during the delay. Ensure that the maximum rate of temperature increase in the enclosure is 40 °F per hour. Monitor the temperature in the enclosure using recording thermometers placed at a minimum of 2 locations. Ensure that the enclosure temperature is maintained between 90 °F and 150 °F until 2 concrete test cylinders, field cured according to AASHTO T 23, have attained the stripping strength.

904.01.04 Removing Forms and Finishing

Ensure that items remain in forms for the duration of the curing operation. Remove forms when concrete has attained the stripping strength. If handling devices are used, remove and fill the holes with concrete or mortar. Provide a Class 1 finish as specified in 504.03.02.H.1. Complete surface finishing operations before placing the piece in storage.

904.01.05 Shipping and Handling

Store, stack, and transport the pieces using methods that do not cause the development of cracks or other damage. Do not ship pieces until the class design strength as specified in Table 903.03.06-3 has been attained.

904.01.06 Quality Control and Acceptance Requirements

Notify the ME before start of production.

For quality control, keep applicable records according to PCI Division 1, Quality Control, or NPCA requirements, and supply copies of these records to the ME as requested. Ensure that the quality control technician performing all tests is certified as an ACI Field Testing Technician, Grade 1.

Submit certification of compliance as specified in 106.07.

If the concrete piece is spalled, honeycombed, chipped, or otherwise defective, the ME or RE will reject the piece.

904.02 Precast Concrete Retaining Walls  

904.02.01 Component Materials

Welded steel wire fabric used for reinforcement need not be galvanized.

904.02.02 Fabrication

Use a system listed on the QPL to fabricate prefabricated modular walls or mechanically stabilized earth walls. Fabricate precast concrete at a plant as specified in 1011.01.

1. Placing Reinforcement Steel. Place reinforcement steel as specified in 504.03.01. Before placing the concrete, place reinforcement in position as shown on the approved working drawings, and firmly tie the reinforcement to prevent displacement during placing of the concrete.
   
   
2. Forms. Cast the units in steel forms to ensure the production of uniform units. Place the forms on a flat surface with the front face of the form down.
   
   
3. Placing Concrete. Place concrete as specified in 504.03.02.D and 504.03.02.E. Before placing concrete, ensure that reinforcement steel and other embedded materials are free of loose rust, frost, dirt, oil, or contaminants that may prevent a bond with the concrete. Consolidate concrete with internal vibrators. The fabricator may use external vibration to supplement internal vibration.
   
   If using SCC, minimize the use of vibrators to prevent segregation.
   
   
4. Fabrication Requirements. Fabricate posts and panels free of honeycombing or voids and true to the size and dimensions specified in Table 904.02.02-1. Clearly mark the name of manufacturer, name of contract, date of manufacture, mark numbers, and type of unit, as shown on the approved working drawings, in the inside or back face of each unit.




Table 904.02.02-1 Dimensional Tolerances
For MSE Walls
All Panel Dimensions	±1/4 inch
Deviation from Vertical	1/8 inch per 5 feet
For Modular Walls
Length and Height of Face	±3/16 inch
Deviation from Square for Units < 10 feet wide1	5/16 inch maximum
Deviation from Square for Units ≥ 10 feet wide1	3/4 inch maximum

1	Measure deviation from square on the diagonal.

904.02.03 Curing

Cure as specified in 904.01.03, except that the required stripping strength is 3000 pounds per square inch.

904.02.04 Form Removal and Finishing

Remove forms and finish concrete as specified in 904.01.04.

904.02.05 Shipping and Handling

Handle and ship as specified in 904.01.05.

904.02.06 Quality Control and Acceptance Requirements

Notify the ME in writing at least 21 days before start of production.

For quality control, keep applicable records according to PCI Division 1, Quality Control, or NPCA requirements, and supply copies of these records to the ME as requested. Ensure that the quality control technician performing all tests is certified as an ACI Field Testing Technician, Grade 1.

During production, the ME will inspect the quality of materials and the process of manufacture. The ME will accept the concrete as specified in 903.03.05 and will inspect the finished pieces before shipping for dimensional tolerances and damage. The ME will reject units for any of the following:

1. Variations in the exposed face that substantially deviate in appearance.
2. Dimensions not conforming to the tolerances specified in Table 904.02.02-1.
3. Honeycombed or open texture not properly repaired.
4. Defects that would affect the structural integrity of the unit.
5. Stained front face due to excess form oil or other reasons.
6. Broken or cracked corners.

904.03 Structural Precast Concrete  

904.03.01 Component Materials

904.03.02 Fabrication

Fabricate precast concrete at a plant as specified in 1011.01. Provide an office for the ME as specified in 1011.03.

1. Placing Reinforcement Steel. Before placing the concrete, place all reinforcement steel in position as shown on the approved working drawings and as specified in 504.03.01. Firmly tie the reinforcement steel to avoid displacement during placing of the concrete.
   
   For longitudinal distribution reinforcement steel, the fabricator may use welded wire fabric or deformed billet steel bars. Ensure that welded wire fabric is shipped in mats.
   
   In precast concrete box culverts, the ME will allow lifting devices in each precast unit for the purpose of handling and erection. If using lifting hooks or lugs, galvanize the devices according to ASTM A 153.
   
   
2. Placing Concrete. Place concrete as specified in 504.03.02.D and 504.03.02.E. Before placing concrete, ensure that reinforcement and any other embedded material are free of loose rust, frost, dirt, oil, or contaminants that may prevent a bond with the concrete. Consolidate concrete with internal vibrators. The fabricator may use external vibration to supplement internal vibration.
   
   If using SCC, minimize the use of vibrators to prevent segregation.
   
   
3. Fabrication Requirements. Identify each precast concrete unit with a permanent marking. Manufacture the precast concrete units in steel forms.
   
   For precast culverts, ensure that units conform to the requirements specified in Table 904.03.02-1. Provide 2 rows of threaded inserts or bar extensions in the last precast culvert section for the cast-in-place end section and the wingwall attachment and for the headwall attachment, if necessary.




Table 904.03.02-1 Fabrication Requirements for Culverts
Wall Thickness	8 inches minimum
Top and Bottom Slab Thickness	10 inches minimum
Concrete Cover for Walls and Bottom Slab	1-1/2 inches minimum
Concrete Cover for Top Slab	2 inches minimum


For precast concrete arch structures, ensure that units comply with Table 904.03.02-2.



Table 904.03.02-2 Fabrication Requirements for Precast Concrete Arch Structures
Concrete Cover Outside Face	2 inches minimum
Concrete Cover Inside Face	1.5 inches minimum
Internal Dimension Tolerance	±1% or ±2 inches, whichever is less
Wall Thickness Tolerance1	−5% or −1/2 inch, whichever is more
Difference in Side Lengths2	±3/4 inch

1	The ME will not reject structures having thicknesses that exceed that shown in the approved working drawing.
2	Requirement waived for skewed ends for laying curves.

904.03.03 Curing

Cure as specified in 904.01.03, except that the required stripping strength is 4000 pounds per square inch.

904.03.04 Removing Forms and Finishing

Ensure that units remain in their steel forms for the duration of the curing operation.

Upon removal of the forms, provide a Class 1 finish as specified in 504.03.02.H.1 to the entire precast concrete culvert unit, including exterior, interior, and lap surfaces. For culverts, after approval of the Class 1 finish, apply 1 coat of an epoxy waterproofing on the exterior of the roof slab. Apply this coating in the precaster’s plant not earlier than 72 hours after fabrication, and after the concrete compressive strength has reached 4000 pounds per square inch. Ensure that the concrete surfaces of the precast units are dry during application of the epoxy waterproofing. Apply the epoxy waterproofing according to the product manufacturer’s recommendations.

904.03.05 Shipping and Handling

Handle and ship as specified in 904.01.05.

904.03.06 Quality Control and Acceptance Requirements

Notify the ME in writing at least 21 days before start of production.

For quality control, keep applicable records according to PCI Division 1, Quality Control, or NPCA requirements, and supply copies of these records to the ME as requested. Ensure that the quality control technician performing all tests is certified as an ACI Field Testing Technician, Grade 1.

During production, the ME will inspect the quality of materials and the process of manufacture. The ME will accept the concrete as specified in 903.03.05 and will inspect the finished pieces prior to shipping for dimensional tolerances and damage. If the concrete piece is spalled, honeycombed, chipped, or otherwise defective, the ME may reject the piece or approve repairs.

904.04 Prestressed Concrete  

904.04.01 Component Materials

In the construction of prestressed concrete I-beams or prestressed concrete slab and box beams, when the use of galvanized reinforcement steel is planned for the deck construction, galvanize all reinforcement steel that will provide composite action.

For prestressed concrete piles in a marine environment, use grit impregnated epoxy-coated prestressing steel strands as specified in 905.02. When storing, cover the strands with an opaque polyethylene sheeting or other suitable protective material to protect the reinforcement from exposure to sunlight, salt spray, and weather. For stacked bundles, drape the protective covering around the perimeter of the stack. Adequately secure the covering; however, allow air circulation to prevent condensation under the covering. Do not store epoxy-coated prestressing steel within 1000 feet of ocean or tidal water for more than 2 months.

904.04.02 Fabrication

Fabricate prestressed concrete at a plant as specified in 1011.02. Provide an office for the ME as specified in 1011.03.

1. Placing Reinforcement and Prestressing Steel. Store reinforcement above ground, and cover strand packs when not in use. Place reinforcement steel as specified in 504.03.01 and as shown in the working drawings. Position or loosely tie reinforcement steel until prestressing strands have been positioned. After pre-stressing, firmly tie the reinforcement prior to placing concrete.
   
   If using an anti-bonding agent on the forms to facilitate their removal, protect the prestressing strands against contamination by the anti-bonding agent. Use supports, spaced a maximum of 10 feet apart, to support bottom strands and side reinforcement steel. If necessary, provide horizontal and vertical spacers to hold the wires in place in the enclosures.
   
   
2. Prestressing. Provide protection, for the ME inspecting the prestressing operation, adequate to stop a flying strand. Use shields, placed at both ends of the bed, made of steel, reinforced concrete, heavy timbers, or other material to provide protection acceptable to the ME.
   
   Apply stress to each cable as shown on the working drawings using either the single strand or the multi-strand jacking method.
   
   If performing prestressing by the multi-strand jacking method, bring the individual strands to a uniform initial tension before applying the full pretensioning. Measure the initial tension of each strand using a dynamometer, a gauge, or other such means. After the initial tensioning, stress the strands until the specified elongation and jacking pressure are attained.
   
   If performing prestressing by the single strand jacking method, do not construct more than 1 splice per strand. When multi-strand jacking is used, either splice all strands or splice no more than 10 percent of the strands. Ensure that spliced strands are similar in physical properties, are from the same source, and have the same twist or lay. Position splices outside of the prestressed members. Do not torch cut the ends of the strand lengths to be spliced.
   
   For prestressing draped strands, apply stress by either partially jacking at the end of the bed, followed by raising or lowering the strands to their final position, or entirely by the jacking operation. Regardless of the method of prestressing, use low-friction devices at all points of slope change in the strand trajectory. If the strands are tensioned in their draped position, support the strands using lubricated rollers with bronze bushings or roller bearings at all hold-up points, and low-friction, free-turning rollers at all hold-down points. When strands are deflected after partial tensioning, simultaneously raise or depress the strands at all points or in an approved specified sequence.
   
   Replace broken strands if the allowable number of wire breaks specified in Table 904.04.02-1 is exceeded. Locate and tie wire breaks directly to the strand to prevent raveling during the vibration of the concrete.
   



Table 904.04.02-1 Maximum Allowable Wire Breaks
Number of Strands	Maximum Allowable Wire Breaks
Less than 20 strands	0
20 to 39 strands	1
40 to 59 strands1	2
60 and more strands1	3

1	Replace the strand if more than 1 break occurs in an individual strand.

If concrete is not placed within 72 hours of prestressing, the ME may require the bed to be checked for proper stresses before placement of concrete.

After final stressing, position strands and uniformly distribute the stress in the strands throughout the bed length.


3. Placing Concrete. Before placing concrete, ensure that the prestressing is acceptable to the ME and that reinforcement and any other embedded materials are free of loose rust, frost, dirt, oil, or contaminants that may prevent a bond with the concrete. Place concrete as specified in 504.03.02.D and 504.03.02.E. Consolidate concrete with internal vibrators. The fabricator may use external vibration to supplement internal vibration. Only place concrete in the presence of, or as directed by, the ME.
   
   For prestressed concrete box beams, place voids in the forms after the ME has inspected the concrete poured to encase the strands in the bottom portion of the beam.
   
   
4. Fabrication Requirements. Fabricate the prestressed concrete members to plan dimensions within the tolerances specified in applicable sections of PCI MNL-116. The ME will reject members having dimensions outside the tolerance limits, unless the Contractor performs corrective measures. Obtain approval from the Department before taking any corrective measures. Adhere to beam camber tolerances so that preformed transverse tie holes for prestressed box and slab beams line up correctly during erection, facilitating the placement of transverse ties.
   
   Cast a permanent, unique, identification mark and the date of the casting in the top of members. Upon removal of the forms, mark the ends of members with the same identification marking.
   
   
5. Detensioning. Do not detension the bridge members until the strength tests indicate that the concrete has reached a compressive strength of at least 4000 pounds per square inch for Class P, 4500 pounds per square inch for Class P-1, and 5000 pounds per square inch for Class P-2 concrete.
   
   Before detensioning, submit to the ME a plan for the pattern and schedule for releasing the strands. Strip or loosen forms that may tend to restrict the horizontal or vertical movement of the member.
   
   For detensioning, use either the multiple strand release method or the single strand release method.
   
   If the multiple strand method of release is used, gradually and simultaneously release all of the strands or a symmetrical group of strands. Transfer the load on the strands from the anchorage to the jacking system. Gradually release the jack or jacks until the strands are relaxed.
   
   For the single strand release method, detension the strands in the sequence of the pattern and schedule of release by slow-heat cutting. Use a low-oxygen flame applied along the strand for a minimum of 5 inches until the metal gradually loses its strength. Apply the heat at a rate to induce failure of the first wire in the strand at least 5 seconds after the heat is applied.
   
   The ME will reject pieces if the fabricator fails to follow the detensioning procedure.

904.04.03 Curing

Cure as specified in 904.01.03, except that the required stripping strength is 4000 pounds per square inch for Class P, 4500 pounds per square inch for Class P-1, and 5000 pounds per square inch for Class P-2 concrete. In addition, when the ambient air temperature is above 100 °F, initiate a water cure or other approved method as soon as the concrete is able to receive the water without physical damage to its surface. The fabricator may discontinue this cure upon introduction of steam, provided that a relative humidity of 100 percent is maintained.

904.04.04 Removing Forms and Finishing

Do not remove side forms until the strength of 2 cylinders, similarly cured as the member, achieves at least 2500 pounds per square inch. Do not move the member from the bottom forms before detensioning.

Upon the removal of forms, the ME may reject any member that has 1 prestressing strand exposed for a length in excess of 24 diameters, or 2 or more strands visually exposed. In addition, the ME may reject any unit that is honeycombed to such an extent that chipping away from honeycombed concrete results in the conditions described for exposed strands. If the ME determines that the defective areas can be repaired, submit a repair procedure to the ME for approval. Perform approved patching before detensioning.

Provide a Class 1 finish, as specified in 504.03.02.H.1, on formed surfaces of the concrete members. For surfaces of concrete exposed to view in the finished structure, perform additional finishing by rubbing mortar on the surface using burlap. Ensure that the rubbing produces a smooth surface of uniform color and texture. Transversely score the top surface of members using a stiff wire brush. After the removal of hold-down devices from the bottom of the beams, coat the resulting holes with an epoxy bonding compound, and plug the holes with mortar while the epoxy bonding compound is still tacky. If the epoxy bonding compound dries out before the placement of the mortar, sandblast the area and reapply the bonding compound. Patch vent holes for box beams upon removal from forms after the internal void drains are opened.

Treat portions of prestressed concrete beams as shown on the Plans with an epoxy waterproofing. Do not apply the epoxy waterproofing to the top surface of a beam. Use an epoxy waterproofing that closely matches the color of the concrete. Do not apply the epoxy waterproofing sooner than 72 hours after detensioning. Ensure that the concrete surface is dry and clean of oil, grease, and dirt before applying the coating. Apply the epoxy waterproofing by brush only, unless otherwise approved by the ME. Ensure that the epoxy waterproofing is applied uniformly and provides adequate coverage.

904.04.05 Shipping and Handling

The fabricator may handle members immediately after completion of detensioning. Before placing members in storage, ensure that surface finishing operations are completed and the member is approved by the ME. Do not remove a girder from the bed unless the differential between girder and air temperature is less than 80 °F. Before box and slab beams are moved to storage, inspect nonmetallic draining devices and open to provide for passage of water.

Notify the ME at least 2 days before shipping. Do not ship until the class design strength as specified in Table 903.03.06-3 has been attained and a minimum of 72 hours have elapsed following detensioning. Determine shipping strength by testing a complete set of cylinders that represent the lot of concrete and were cured with the item.

Transport girders in an upright position. Ensure that the points of support and directions of the reactions with respect to the girder are approximately the same during transportation and storage as in its final erection position. Request the Department’s approval for transportation or storage of girders in any other position.

904.04.06 Quality Control, Quality Assurance, and Acceptance Requirements

Notify the ME in writing at least 21 days before start of production.

For quality control, keep applicable records in conformance with PCI Division 1, Quality Control, or NPCA requirements, and supply copies of these records to the ME as requested. Ensure that the quality control technician performing all tests is certified as an ACI Field Testing Technician, Grade 1.

During production, the ME will inspect the quality of materials and the process of manufacture. The ME will accept the concrete as specified in 903.03.05 and will inspect the finished pieces prior to shipping for dimensional tolerances and damage. If concrete is placed on the same bed at different times in the day, the ME will split the day’s production into separate lots. If the concrete member is spalled, honeycombed, chipped, or otherwise defective, the ME may reject the piece or approve repairs.

Section 905 – Reinforcement Metals

905.01 Reinforcement Steel  

For uncoated reinforcement steel, submit a certification of compliance as specified in 106.07. Attach copies of the mill certifications for each heat of reinforcement steel. The ME will randomly sample and test heats of uncoated reinforcement steel for quality assurance.

The ME will inspect galvanized and epoxy coated reinforcement steel before and after fabrication. For coated steel reinforcement bars, the ME will inspect the coating and take four 2-1/2-foot samples from each production heat for testing. For coated welded wire reinforcement, the ME will inspect the coating and take one 2-square foot sample from each production heat for testing. Provide the ME with mill certifications for each heat of reinforcement steel.

905.01.01 Reinforcement Bars

Use deformed bars according to ASTM A 615, Grade 60. Fabricate using the detailing dimensions for hooks, bends, and tolerances according to the CRSI Manual of Standard Practice. Bend bars using the cold method with positive powered machines in the shop or field. Compute the weight of reinforcement steel according to ASTM A 615.

If specified, galvanize according to ASTM A 767, Class I. Fabricate bends and details before galvanizing.

If specified, apply epoxy coating according to ASTM A 775.

905.01.02 Spiral Reinforcement

Use spiral reinforcement that is plain round hot-rolled steel bars according to ASTM A 615, Grade 60. Compute the weight of reinforcement steel according to ASTM A 615.

905.01.03 Welded Wire Reinforcement

Use plain steel welded wire reinforcement according to ASTM A 185 or deformed steel welded wire reinforcement according to ASTM A 497. When used for concrete pavement, use welded wire reinforcement mats at least 5 feet in width.

When approved as an alternate to galvanized reinforcement bars, use galvanized welded wire reinforcement that meets the requirements of ASTM A 641, Table 1, Class 1.

905.01.04 Structural Shapes, Plates, and Bars

Ensure that structural shapes, plates, and bars used for reinforcement or other miscellaneous embedded metal work conform to the requirements for structural steel specified in 906.01. Galvanize according to ASTM A 123.

905.01.05 Dowels

Use plain reinforcement bars according to ASTM A 615, Grade 60. Galvanize according to ASTM A 123.

905.02 Prestressing and Post-Tensioning Reinforcement  

The ME will sample and test each heat of steel reinforcement prior to use for acceptance. For prestressing strand, the ME will test two 4-foot cables with flame cut ends and one 1-foot piece with sawcut ends from each heat. For high-strength alloy bars, the ME will test one 6-foot bar from each heat. For post-tensioning, the ME will test one 6-foot cable (between fittings) from each reel or one 6-foot bar (between threads) from each lot. Provide a certification of compliance as specified in 106.07. Attach the mill certification for each heat used with the certification of compliance.

905.02.01 High-Tensile-Strength 7-Wire Prestressing Strand

Use high-tensile-strength, low-relaxation 7-wire strand for prestressing reinforcement according to ASTM A 416, Grade 270. When specified, use grit impregnated epoxy-coated steel strands according to ASTM A 882.

905.02.02 High-Tensile Strength Alloy Bars

Use high-tensile strength alloy bars for prestressing or post-tensioning according to ASTM A 722.

905.02.03 Post-Tensioning Reinforcement

1. Bars. For transverse ties for prestressed concrete voided slab and box beams, use steel bars according to ASTM A 722, 3/4-inch diameter. Commercial blast clean bars (SSPC-SP 6), and coat with coal tar epoxy paint as specified in 912.01.03. The fabricator may epoxy coat bars according to ASTM A 775.
   
   Ensure that end anchorages (nuts, washers, and anchor plates) used with high-tensile strength steel rod bars are shown on the working drawings. Use end anchorages compatible with the tie rod system. Galvanize according to ASTM A 123.
   
   
2. Strands. Use high-tensile-strength, low-relaxation 7-wire strand for prestressing reinforcement according to ASTM A 416, Grade 270. Ensure that anchorages and end fittings for 1/2-inch diameter strands and the corrosion protection method for the end fittings are shown on the working drawings.

905.03 Reinforcement for Concrete Pavement  

905.03.01 Tie Bars and Joint Ties

For tie bars and joint ties in longitudinal joints for concrete pavement, use epoxy coated deformed reinforcement steel bar as specified in 905.01.01.

Provide certifications of compliance as specified in 106.07. Attach a mill certification for each heat used to the certification of compliance.

905.03.02 Tie Bolts

For tie bolts in longitudinal joints for concrete pavement, use epoxy coated plain reinforcement steel bar that meets the requirements as specified in 905.01.01. Perform all required bending of tie bolts in a fabrication shop. Do not field bend tie bolts. Use rebar coupling devices as specified in 905.04.

Provide certifications of compliance as specified in 106.07. Attach a mill certification for each heat used to the certification of compliance.

905.03.03 Dowel Bars

For dowel bars in transverse joints, use epoxy-coated, Grade 60, plain reinforcement steel according to ASTM A 615.  If shown on the Plans, use dowel bars fitted with end caps.  Ensure that the end caps are non-metallic and designed to prevent the entrance of grout or mortar into the expansion void. 

Provide certifications of compliance as specified in 106.07. Attach a mill certification for each heat used to the certification of compliance.

905.04 Rebar Coupling Devices  

To splice reinforcement steel, use a rebar coupling device that is listed on the QPL. Ensure that the mechanical coupling device develops a minimum of 125 percent of the specified yield strength of the reinforcement steel. If the reinforcement steel has either galvanizing or epoxy coating, use a mechanical coupling device with a matching coating system. Provide certifications of compliance as specified in 106.07.

Section 906 – Structural Steel

906.01 Structural Steel Materials  

Provide structural steel materials conforming to the requirements in Table 906.01-1 and as shown on the Plans.

Before using, submit to the ME a representative sample of each size for material testing and approval. Provide a mill certification that indicates the chemical and physical properties for each heat of material. For SIP forms, steel forgings and shear connector studs, submit certifications of compliance, as specified in 106.07, with the mill certifications attached.

906.02 Steel Piles  

Use materials as specified in 906.01. When used in a marine environment, coat piles with coal tar epoxy paint as specified in 912.01.03.

Ensure that the closure plate for steel pipe piles is equal to the pile outside diameter and has a minimum thickness of 3/4 inch. Weld around the entire circumference.

For H-pile tips, use steel castings that conform to AASHTO M 103, Grade 65-35 or 70-36 or high-strength steel castings that conform to ASTM A 148.

Submit certifications of compliance, as specified in 106.07, with mill certifications attached.

906.03 Steel Casings for Drilled Shafts  

Use materials as specified in 906.01. Ensure that the casing is capable of withstanding handling and driving stresses and the pressures of the concrete and surrounding earth. Use a casing with an inside diameter that is at least as large as the indicated shaft size. The Contractor may increase the size of the casing to facilitate construction operations.

For permanent casings, clean and coat the exterior surfaces with prime coat of an inorganic zinc coating system as specified in 906.06.

Submit certifications of compliance, as specified in 106.07, with mill certifications attached.

906.04 Structural Steel Fabrication  

906.04.01 AISC Certification

Ensure that the structural steel fabricating plant is certified under the AISC Quality Certification Program in the following categories by the type of work performed:

1. Simple Steel Bridge Structures (SBr). Includes highway sign support structures, parts for bridges (such as cross frames), unspliced rolled steel bridges, steel bridge bearings, and HLMR bearing assemblies.
   
   
2. Major Steel Bridges (MBr). Includes all bridge structures other than unspliced rolled beam bridges.
   
   
3. Fracture Critical Members Endorsement (F). Able to perform procedures required to produce critical members according to a fracture control plan, as defined by AASHTO or American Railway Engineering and Maintenance of Way Association.

Structural steel fabricators that are certified by AISC for Major Steel Bridges are automatically certified for Simple Steel Bridges.

906.04.02 Fabrication

Before fabrication, submit a copy of the proposed welding procedures to the ME for approval. Follow the approved welding procedures and ensure that welders are qualified according to ANSI/ AWS D1.5.

Use structural steel materials as specified in 906.01 and bolting materials as specified in Section 908. Fabricate according to AASHTO LRFD Bridge Construction Specifications and as shown on the working drawings. Construct welds according to the requirements of ANSI/ AASHTO/ AWS D1.5 Bridge Welding Code, as modified by the following:

1. Do not use electro-slag welds on main structural members.
2. Remove all steel weld backing on the outside faces of fascia girders. Grind or finish the joints smooth.

Induce camber in structural steel girders at the mill, or fabricate structural steel girders in the shop in a manner that provides a true curve without abrupt changes.

In the shop, completely pre-assemble stringers involving field splices and built-up girders with field splices.

Submit to the Department, for approval, all changes in the number or location of shop or field splices.

Without the Department’s approval, do not weld to members or parts of members subject to tension or reversal of stress. If necessary to weld in these areas, ensure that the actual stress range (FSR) at the point of attachment does not exceed the value for Category F according to the AASHTO LRFD Bridge Design Specification.

Obtain the ME’s approval for all shop fabrication and assembly before blast cleaning and coating.

906.04.03 Cleaning and Coating

1. Weathering Steel (Grade 50W or HPS70W). As soon after fabrication as practical, blast-clean all structural steel components including diaphragms, cross frames, and welded connections, according to SSPC-SP6. Ensure that the steel is kept free and clean of all foreign materials, such as grease, oil, concrete spatter, chalk marks, crayon marks, dirt, and any foreign matter that may affect the natural oxidation of the steel.
   
   If foreign matter gets on the steel after it has been blast cleaned, remove as soon as possible with solvent according to SSPC-SP 1.
   
   Clean and paint weathering steel, as specified in 906.06, in the following areas:
   
   
   1. Cap Girders. Clean and paint the exterior surfaces of the top and the sides, including the brackets.
      
      
   2. Structural Steel Adjacent to Deck Joints. With the exception of steel designated to be galvanized, clean and paint all structural steel from the ends of the girder to a distance of 3 times the depth of the girder. For steel designated to be galvanized, galvanize as specified in 912.02.01.
      
      
   3. Integral Abutment Construction. On structures that include integral abutment construction, clean and paint the ends of the girder for a distance that extends 1 foot beyond the concrete diaphragm.
   
   
2. Non-weathering Steel. If coating is specified or shown on the Plans, clean and paint as specified in 906.06 or galvanize as specified in 912.02.01.

906.04.04 Shipping and Handling

Notify the ME at least 3 days before shipping to the Project so that a final quality inspection can be performed. The ME will seal all materials approved for shipping and provide written approval to the fabricator.

Ensure that members are loaded, hauled, and unloaded so that they are not deformed, damaged, or subjected to stresses in excess of those provided for in the design. When hauling and storing steel members, to the extent possible, place the members in a position similar to their final erected position.

Ensure that all steel girders are shipped and stored with their webs vertical, unless their size precludes vertical shipment. Place points of bearing within 20 percent of the length of the girder from the ends, and secure with chain tie downs. If not provided for in the design, brace long members during shipment with temporary vertical stiffeners extending the full height of the web on both sides of the member. Place the temporary stiffeners at the bearing points, mid-span, and at additional locations to ensure that the maximum interval between bracing does not exceed 25 feet. Ensure that temporary stiffeners are in full contact with the web and both flanges. Pad the temporary stiffeners with a material that will minimize damage to the painted surface.

For girders requiring shipment with their web horizontal, or for girders that will extend over 20 percent of the length beyond points of bearing, submit working drawings for approval. Include the following information:

1. Drawings or sketches, fully describing the shipping and handling procedures.
2. Calculations showing the dead load plus impact stresses induced by the loading and transportation procedure. Ensure that impact stresses do not exceed 200 percent of the dead load stress.
3. Location of all support points.
4. Type and locations of tie-downs. Include a sufficient number of tie downs for redundancy to ensure that if any one tie-down fails, the member will remain stable.
5. Temporary stiffeners, if used.
6. Details of a 4-way articulating bolster for each truck transporter to ensure that truck movements will not produce unnecessary stresses in the structural steel.

906.04.05 Quality Control and Acceptance

Notify the ME, in writing, at least 15 days before beginning work at the fabrication shop. The ME may reject any work done in his absence if proper notification was not received.

Perform at least the minimum specified number of quality control inspections according to the applicable ANSI/ AASHTO/ AWS specification and any other tests and inspections necessary to control the quality of the work. The ME will perform non-destructive testing quality assurance inspections following the non-destructive testing quality control (QC) inspection performed by the fabricator.

Ensure that all quality control inspectors are AWS Certified Welding Inspectors, qualified according to the provisions of AWS QC1.

Inspect and test structural steel bridge members according to ANSI/ AASHTO/ AWS D1.5 Bridge Welding Code, as modified by the following:

1. Assembly and fabrication may not continue until completed work has been inspected and accepted by the ME.
2. Grind flush butt welds scheduled for ultrasonic testing.
3. For acceptance, the ME will test 100 percent of complete joint penetration groove and butt welds, including butt welds in longitudinal stiffeners.

906.05 Sign Structures Fabrication  

906.05.01 Fabrication

Ensure that the fabricating plant is certified under the AISC Quality Certification Program as specified in 906.04.01. Before fabrication, submit a copy of the proposed welding procedures to the ME for approval. Follow the approved welding procedures, and ensure that welders are qualified according to ANSI/AWS D1.1 or ANSI/AWS D1.2, as appropriate.

To fabricate sign structures, use structural steel materials as specified in 906.01, bolting materials as specified in Section 908, and aluminum materials conforming to ASTM B 308, Alloy 6061-T6. Weld and fabricate according to AWS D1.1, Structural Welding Code. For aluminum members, weld and fabricate according to ANSI/AWS D1.2 Structural Welding Code – Aluminum. Do not flame cut aluminum alloy materials. For cantilever sign support structures, ensure that the splice plates and truss chords do not warp during fabrication.

After fabrication and welding, hot-dip galvanize the steel assemblies as specified in 912.02.01. After galvanizing, but before shipment to the Project, return the truss and posts to the fabricator for final shop assembly to verify camber, alignment, and contact of splice mating surfaces.

906.05.02 Shipping and Handling

Notify the ME at least 3 days before shipping to the Project or galvanizer so that a final quality inspection can be performed. The ME will seal all materials approved for shipping and provide written approval to the fabricator.

Ensure that members are loaded, hauled, and unloaded so that they are not deformed, damaged, or subjected to stresses in excess of those provided for in the design.

906.05.03 Quality Control and Acceptance

Notify the ME, in writing, 15 days in advance of beginning work at the fabrication shop, so that arrangements for inspection may be made.

Perform at least the minimum specified number of quality control inspections according to the applicable ANSI/ AASHTO/ AWS specification, and any other tests and inspections necessary to control the quality of the work. The ME will perform non-destructive testing quality assurance inspections following the non-destructive testing quality control (QC) inspection performed by the fabricator.

Ensure that all quality control inspectors are AWS Certified Welding Inspectors, qualified according to the provisions of AWS QC1.

Inspect and test according to ANSI/ AASHTO/ AWS D1.1 Welding Code and the following:

1. Perform magnetic particle testing at a frequency of 10 percent of the number of welds per unit. For cantilever sign support structures, perform magnetic particle testing at a frequency of 100 percent on all chord splice assembly welds and post base welds.
2. Before shipping, assemble the completed and accepted truss units in the shop and check the truss span for dimensions, straightness, alignment, and camber. Measure the camber with the truss units on their sides.

906.06 Cleaning and Painting of Structural Steel in the Shop  

906.06.01 Painting Materials

Use an Inorganic Zinc coating system (IEU) of an inorganic zinc-rich primer, epoxy intermediate coat, and a urethane finish coat. Ensure that the coating system is as specified in 912.01.01.

In the fabrication of steel box girders, apply the IEU coating system to all exterior surfaces. Coat the interior of the box girders with only a prime coat of an organic zinc primer selected from an organic zinc coating system (OEU) listed on the QPL and as specified in 912.01.01. Unless approved by the ME, use an organic zinc primer from the same manufacturer as the IEU system for the exterior of the girder.

906.06.02 Surface Preparation

Before blasting, remove any oil and grease, according to SSPC-SP 1, using No. 1 solvent. Reclean after blasting if contamination remains.

Blast-clean all surfaces to a near-white condition, as defined in SSPC-SP 10. Ensure that the surface area of steel being blast cleaned is not greater than the surface area of steel that can be prime coated in the same day. If shot blast is used, use a NACE No. 2 Visual Standard T.M.-01-75 or Maryland Pictorial Standard to define the near-white blast condition. If sand or grit is used, use SSPC Pictorial Standard VIS-1 (Grade 2-1/2) to define the near-white condition. Blast clean to an anchor profile, from 1.5 mils to 3.0 mils deep. Grind any flame cut edges that do not attain the required anchor profile. Determine the profile depth using the elcometer surface profile gauge or Testex replica tape. Ensure that the pH of the abrasive is within the range of 6.0 to 8.5.

Remove fins, tears, slivers, and burred or sharp edges that are present, or that appear during the blasting operations, by grinding, and ensure that the reblasted area provides the required anchor profile.

Before blast cleaning steel, ensure that all reaming and drilling of holes in the steel has been completed, and the steel is free of burrs or other imperfections, such as torn or ragged edges. Remove all abrasive residue and dust from steel surfaces, and keep the surfaces clean until the prime coat is applied. Protect freshly coated surfaces from subsequent blast cleaning operations. Repair blast damaged primed surfaces using a wire brush, or, if visible rust occurs, reblast the surface to a near-white condition, re-clean, and re-prime the repaired area.

906.06.03 Conditions for Painting

Perform shop painting in an enclosure that is maintained at the required atmospheric conditions and that prevents exposure to inclement weather before the paint has completely cured. Perform painting according to the conditions specified in SSPC-PA 1 and the following:

1. Apply paint to clean dry surfaces. Do not apply paint for the prime and final coats when the temperature of the air, paint, or steel is below 40 °F, or when the temperature is expected to fall below 40 °F before the paint is dried. Ensure that the temperature is at least 50 °F when applying the intermediate coat. Do not apply coatings when the relative humidity is greater than 85 percent or when a combination of temperature and humidity conditions could cause moisture to condense on the surface being coated. During the drying time of the inorganic type primers, ensure that the relative humidity is at least 50 percent.
2. Do not apply paint when the steel surface temperature is less than 5 °F above the dew point. Determine the dew point using a psychrometer.
3. Remove all contaminants before applying subsequent coats of paint. Clean the primed surfaces with a high pressure water washing (800 pounds per square inch minimum).

906.06.04 Paint Application

Mix paint according to the manufacturer’s recommendations. Apply paint as specified in SSPC-PA 1 and the following:

1. Apply the prime coat after the ME inspects and accepts the blast cleaned surface. Before the application of the full prime coat, apply a prime coating (striping) to all edges of plates and rolled shapes, corners, crevices, welds, rivet heads, and exposed parts of bolts. Before applying the full prime coat, allow the striping to set to touch. Apply the primer within 8 hours after cleaning the metal. If any blast cleaned metal remains unpainted after 8 hours, blast clean the metal again before priming. Do not apply succeeding coats until the previous coat is approved by the ME. Follow the manufacturer’s recommendation for minimum and maximum drying time between coats. Allow additional time before applying succeeding coats in cooler temperatures. If the maximum time interval between coats is exceeded, submit to the ME the manufacturer’s written recommendation for corrective action. Remove all dry spray, by sanding if necessary, before applying the succeeding coat.
2. Ensure that paint is applied to at least the minimum specified thickness, and ensure that the final appearance is uniform and smooth. If the coating is too thin in areas, follow the manufacturer’s recommendations for recoating. Repair areas that run, bubble, sag, or mud crack by removing the coating back to soundly bonded coating and recoating to the required thickness and appearance.
3. Apply only a prime coat of paint to surfaces of steel that will be embedded in or in contact with concrete. Apply only a prime coat to contact surfaces at field bolted connections. Mask these surfaces during subsequent coating operations. Do not paint surfaces within 2 inches of field welds, except for stud shear connectors. Apply a light coat of rust-inhibitive coating to these surfaces, and mask these surfaces during subsequent coating operations.
4. Remove all bolted shop connections before blasting and coating girders. Separately blast and prime the parts, then reassemble the parts and fully tension the bolts. Do not paint the inside of bolt holes.

906.06.05 Number of Coats and Film Thickness

Apply all 3 coats in the shop. Ensure that the dry film thickness meets the minimum requirement as specified in Table 906.06.05-1 but does not exceed the manufacturer’s recommendation for maximum thickness. Determine dry film thickness according to SSPC-PA 2.

Ensure that the dry film thickness of the prime coat at the contact surfaces of bolted friction splices on main members, and the top of top flanges where stud shear connectors are to be welded, is within the range of 1 to 2.5 mils.

906.06.06 Stenciling

After the final coat has dried, stencil the following information in 4-inch high, C series, letters and numerals on the outside web of both fascia beams, on both ends of the structure:

1. The 7-digit structure number.
2. The month and year of completion.
3. The paint system code number.

Stencil using a black paint that is the same type of paint as the finish coat. Locate the information at least 2 inches above the lower flange and within 3 feet from the abutment.

906.06.07 Additional Handling Requirements for Painted Members

Allow the paint to dry before loading and shipping the steel. Protect the coated steel from the binding chains using softeners. Use padded hooks and slings to hoist steel. Space diaphragms and similar pieces to prevent damage to the coating during shipment. Before shipping, submit to the RE for approval, all shipping and work site storage details.

906.06.08 Quality Control and Acceptance

Notify the ME, in writing, at least 15 days in advance of beginning work at the fabrication shop, so that arrangements for inspection may be made.

The ME will reject the coating system if rusting occurs; the paint lifts, blisters, wrinkles, or has excessive runs or sags; workmanship is poor; or unapproved paint is used. In addition, the ME will reject the total coating system if it is determined by measurement with a Tooke gauge that the dry film thickness of the prime, intermediate, or finish coat is less than the minimum specified or if the total dry film thickness is less than the 8.5-mil minimum for the 3-coat system.

906.07 4-Bar Open Steel Parapet

For 4-bar open steel parapet, provide anchor studs, washers, and exposed bolts according to ASTM F 568, Class 8.8, and all other bolts and nuts according to ASTM F 568, Class 4.6. Also, provide rail bars according to ASTM A 500 or A 501, rail post according to ASTM A 709, Grade 50, and all other shapes and plates according to ASTM A 709, Grade 36.

Fabricate 4-bar steel parapet according to 906.04 and paint according to 906.06.

Section 907 – Bearing Assemblies

907.01 Structural Bearing Assemblies  

907.01.01 General Requirements

Provide high-load multi-rotational (HLMR) or seismic isolation bearing assemblies conforming to the loads shown on the Plans. Provide the design from the manufacturer for each HLMR or seismic isolation bearing assembly.

Ensure that the materials and fabrication of bridge bearing assemblies conform to Section 18 of the AASHTO LRFD Bridge Construction Specification.

Ensure that the fabricating plant is certified under the AISC Quality Certification for Simple Steel Bridge Structures. Consider steel bridge bearings and HLMR bearing assemblies to be main load carrying members. Perform welding and ensure that welders are qualified according to the ANSI/ AASHTO/ AWS D1.5 Bridge Welding Code.

Unless otherwise specified, provide hot-dipped galvanized steel bearing components as specified in 912.02.01. When painting of steel surfaces is required, paint as specified in 906.06.

907.01.02 Types

1. High-Load Multi-Rotational (HLMR) Bearing Assemblies. HLMR bearings consist of a rotational element of the pot type, disc type, or spherical type when used as a fixed bearing and that may, in addition, have sliding surfaces to accommodate translation when used as an expansion bearing. The Contractor may use guide bars to constrain translation to a specified direction. Fabricate HLMR bearing assemblies according to Section 18 of the AASHTO LRFD Bridge Construction Specifications.
   
   
2. Seismic Isolation Bearing Assemblies.
   
   
   1. Assembly Requirements. Use seismic isolation bearing assemblies consisting of seismic isolation bearings (isolators), sole plates, masonry plates, mounting plates, lead core, steel shims, bolts, washers, and anchor bolts. Fabricate seismic isolation assemblies according to Section 18 of the AASHTO LRFD Bridge Construction Specifications. Use one of the following types of isolation bearing assemblies:
      
      
      1. Elastomeric Type. The isolator consists of alternate layers of natural rubber and steel plates with a preformed hole at the center of the unit filled tight with a pure lead plug core. For the isolator, use elastomer type NR, Grade 3, according to ASTM D4014. Use lead for the core that is a minimum of 99 percent pure.
         
         
      2. Sliding Type. The isolator consists of polytetrafluoroethylene (PTFE) stainless steel surfaces that are to be used in conjunction with an optional spring/damping assembly. Use polyether urethane for the elastomer of the sliding bearing.
      
      
   2. Testing Requirements. Provide the ME with the required test load for each isolator type. Determine the test load for each isolator type from the maximum design dead load plus the live load that is to be applied to that particular isolator type. Identify all isolator test results by the supplier identification number.
      
      During the compression and combined compression/shear tests on completed isolators, closely inspect each isolator for indications of a lack of rubber to steel bond, laminate placements faults, or for the appearance of 3 or more separate surface cracks that are wider or deeper than 1/16 inch. Do not use isolators showing such indications.
      
      Evaluate the results of each isolator test for the following performance requirements:
      
      
      1. The effective stiffness (Keff) falling within a range of ±15 percent of the predicted value.
      2. The slope of the loading curve (K) being greater than or equal to 90 percent of the predicted value.
      3. The average value of energy dissipated per cycle being greater than or equal to 90 percent of the predicted value.
      
      
   3. Certification. Submit certifications of compliance, as specified in 106.07, for the isolators. Submit the following data for acceptance of the isolators:
      
      
      1. Test results as defined in the AASHTO Guide Specifications for Seismic Isolation Design.
      2. Copy of the manufacturing specifications.
      3. The name of the firm manufacturing the system.
      4. Shake table test results demonstrating viability of the complete system.
      5. Analytical results showing maximum seismic forces and displacements at all locations, according to the AASHTO Guide Specifications for Seismic Isolation Design.
      6. Conformance to the design and construction requirements specified in Section 14 of the AASHTO LRFD Bridge Design Specifications and Section 18 of the AASHTO LRFD Bridge Construction Specifications.

907.01.03 Marking, Packaging, Shipping, and Handling

Mark each structural bearing in indelible ink on 2 sides with the Department Project Number, the structure number, location, orientation, order number, lot number, bearing identification number, and elastomer type and grade. For seismic isolation bearings, make a permanent mark on 2 of the 4 sides of each isolator, consisting of an isolator number specified by the supplier, the date of fabrication (month and year), the isolator type, and the supplier (name and address).

Ensure that the bearings are packaged to be protected against damage from handling, shipping, and storage. Securely bolt, strap, or otherwise fasten to prevent all relative movement. Wrap the bearings in moisture resistant and dust resistant material to protect them from weather.

When providing seismic isolation bearing assemblies, assemble the isolators and their mounting plates at the shop. Provide temporary assembly ties so that the entire assembly is shipped, in protective packaging, as a unit. Provide the RE with elastomeric bearing test results for both compression stiffness and combined compression and shear according to Section 15 of the AASHTO Guide Specifications for Seismic Isolation Design.

Enclose a copy of the materials, fabrication, and testing compliance certifications with each shipment. Supply a separate sheet showing the materials, critical dimensions, and clearances for each bearing.

907.01.04 Quality Control and Acceptance

Notify the ME, in writing, 15 days before the start of fabrication, so that arrangements for inspection may be made.

Ensure that quality control inspectors are AWS Certified Welding Inspectors, qualified according to the provisions of AWS QC1.

Test and inspect structural bearing assemblies according to Section 18 of the AASHTO LRFD Bridge Construction Specifications. Provide test results to the ME at the time of inspection.

Provide to the ME certifications of compliance, as specified in 106.07, for all non-ferrous metals, PTFE, adhesives, dowel bars, and bolts. Include with the certifications mill test reports for all steels used and material test reports for all elastomeric components.

907.02 Reinforced Elastomeric Bearing Assemblies  

Provide reinforced elastomeric bearings conforming to the requirements shown on the Plans. Reinforced elastomeric bearing assemblies consist of circular or rectangular reinforced elastomeric bearings that are Grade 3 with a durometer hardness of 60. Fabricate reinforced elastomeric bearing assemblies according to Section 18 of the AASHTO LRFD Bridge Construction Specifications.

Ensure that the materials and fabrication of bridge bearing assemblies conform to Section 18 of the AASHTO LRFD Bridge Construction Specification.

Enclose a copy of the materials, fabrication, and testing compliance certifications with each shipment. Supply a separate sheet showing the materials, critical dimensions, and clearances for each bearing.

Provide to the ME certifications of compliance, as specified in 106.07. Include material test reports.

907.03 Bearing Pads  

Provide elastomeric pads conforming to the requirements shown on the Plans. Provide elastomeric bearing pads that are a Grade 2 with a durometer hardness of 60 according to Section 18.2 of the AASHTO LRFD Bridge Construction Specifications.

Ensure that the materials and fabrication of bridge bearing pads conform to Section 18 of the AASHTO LRFD Bridge Construction Specifications.

Provide to the ME certifications of compliance, as specified in 106.07. Include material test reports.

Section 908 – Bolts and Bolting Material

908.01 Steel Bolting Materials  

Before using, submit a sample of each size of bolt, anchor, washer, and nut to the ME for testing and approval. Provide a mill certification for each heat.

908.01.01 Bolts

Use steel bolts conforming to ASTM A 307. If galvanizing is specified, use the hot-dipped method according to ASTM A 153.

908.01.02 Nuts and Washers

Use nuts and washers according to ASTM A 194 or ASTM A 563. Ensure that plain nuts are Grade 2H, DH, DH3, 2, C, D, or C3. Ensure that galvanized nuts are Grade 2H, DH, or DH3. Use washers with high-strength steel bolts conforming to ASTM F 436.

If galvanizing is specified, use the hot-dipped method according to ASTM A 153.

908.01.03 Anchor Bolts

For anchor bolts intended for anchoring structural supports to concrete foundations, including piers, columns, column supports for sign support structures, lighting fixtures, traffic signals, steel bearing plates, and similar applications, use ASTM A 307, Grade C, or ASTM F 1554, Grade 36, 55, or 105, anchor bolts, as shown on the Plans.

If galvanizing is specified, use the hot-dipped method according to ASTM A 153.

908.01.04 Adhesive Anchor Bolt Systems

Use anchor bolts conforming to ASTM A 307, Grade C. If galvanizing is specified, use the hot-dipped method according to ASTM A 153. Ensure that the adhesive anchor bolt system conforms to the following proof loading requirements:

After concrete has achieved a minimum compressive strength of 3000 pounds per square inch, perform proof loading on 10 percent of the installed adhesive anchors at each location where the anchors have been placed. Provide calibration certificates for the test equipment before testing. Perform all testing in the presence of the RE. Tension test the anchor bolt system according to ASTM E 488 to 90 percent of the yield strength of the anchor bolts. If the location of the anchor bolts precludes the proof loading of anchor bolts according to ASTM E 488, propose an alternate testing method to the RE for approval. Repair all spalls or cracks caused by the testing.

Based on satisfactory performance in proof loading, the RE will approve the adhesive anchor bolt installation. The RE will reject the anchor bolt installation for failure to conform to the proof loading requirements. With the approval of the RE, replace the adhesive anchor bolt installation by using larger size anchors, increasing the embedment depth, or using another anchor bolt system.

908.02 High-strength Steel Bolting Materials  

908.02.01 Material Requirements

For structural steel erection and for steel to steel chord splices of sign structures, use high-strength steel bolts, including nuts and plain hardened washers according to ASTM A 325 or ASTM A 490.

When galvanizing is specified, use the hot-dipped method according to ASTM A 153. Treat galvanized bolts, washers, and nuts as an assembly. Store and ship the assembly in plastic bags placed inside wood or metal containers.

Use ASTM A 325, Type 3 high-strength steel bolts for bolting unpainted corrosion resistant (weathering) steel.

908.02.02 Sampling and Testing Requirements for Bolt Assemblies

1. Sampling and Certification. Before use, submit a sample for each manufacturer’s lot, size of bolt, anchor, washer, and nut to the ME for testing and approval. Provide a mill certification for each heat.
   
   
2. Tensile, Proof Load, Hardness, and Coating Thickness Tests. For each lot, the manufacturer shall perform tensile, proof load, and hardness tests and shall measure galvanized coating according to ASTM A 325.
   
   Proof load test bolts according to ASTM F 606, Method 1. Perform wedge tension testing of full size bolts according to ASTM F 606. If bolts are to be galvanized, test after galvanizing.
   
   Proof load test nuts according to ASTM F 606; if galvanized, test after galvanizing, overtapping, and lubricating.
   
   If galvanized washers are supplied, perform hardness testing after galvanizing; however, remove galvanized coating before taking hardness measurements.
   
   Report the results of all tests and submit with certifications. Also report the location and date of testing.
   
   
3. Rotational-Capacity Test. Perform the rotational-capacity test on each lot of bolt, nut, and washer assemblies by the manufacturer or distributor before shipping and by the Contractor within the Project Limits before installation. Test high-strength steel bolt assemblies for the rotational capacity requirements according to NJDOT S-1 or NJDOT S-2 and the following:
   
   
   1. Test a minimum of 2 assemblies per rotational-capacity lot.
   2. Test each combination of bolt production lot, nut lot, and washer lot as an assembly. Where washers are not required by the installation procedures, they need not be included in the lot identification.
   3. Assign a rotational-capacity lot number to each combination of lots tested.
   4. Assemble the bolt, nut, and washer assembly in a Skidmore-Wilhelm calibrator or an acceptable equivalent device for testing as specified in NJDOT S-1.
   5. For bolts that are too short to be assembled in the Skidmore-Wilhelm calibrator, use a steel joint and test according to NJDOT S-2.
   
   
After testing according to NJDOT S-1 or NJDOT S-2, loosen and remove the nut and examine the threads on the nut and bolt. If, for either assembly tested, there are any signs in the nut or bolt of thread shear failure, stripping, or torsional failure, the lot fails and is to be replaced.

908.02.03 Test Reports and Certification

Record the results of all tests. Also report the date and location of testing.

1. Mill Certifications. Provide mill certifications for each heat of steel used in the manufacture of the bolts, nuts, or washers. Indicate the place where the material was melted and manufactured.
   
   
2. Manufacturer Certified Test Reports. Provide manufacturer certified test reports from the manufacturer of the bolts, nuts, and washers. Include the following:
   
   
   1. The lot number of each of the items tested.
   2. The rotational-capacity lot number and test results, as specified in 908.02.02.C, if performed by the manufacturer.
   3. The results of all tests required in 908.02.02.B.
   4. The date and location of testing.
   5. The location where the bolt assembly components were manufactured.
   
   
3. Distributor Certified Test Reports. If the rotational-capacity test is performed by a distributor instead of a manufacturer, provide the test results on the distributor certified test reports. Report the rotational capacity lot number and test results as specified in 908.02.02.C and attach the manufacturer certified test reports.

908.02.04 Shipping and Handling

Ship bolts, nuts, and washers from each rotational-capacity lot in the same container. If there is only one production lot number for each size of nut and washer, the manufacturer or distributor may ship the nuts and washers in separate containers. Permanently mark each container with the rotational-capacity lot number to allow identification at any stage before installation.

Treat galvanized bolts and nuts as an assembly and ship together.

Supply mill certifications, manufacturer certified test reports, and distributor certified test reports for each rotational-capacity lot to the RE and ME.

908.03 Direct Tension Indicators (DTI)  

Use direct tension indicators conforming to ASTM F 959. If galvanizing of the bolt assembly is required, mechanically galvanize DTIs according to ASTM B 695, Class 50. If DTIs are used with ASTM A 325, Type 3 bolts, coat the DTIs with a black epoxy. Test DTIs according to ASTM F 959 and verify according to NJDOT S-3.

Provide manufacturer’s certification and attach test results.

908.04 Stainless Steel Bolting Materials  

Use stainless steel bolts, screws, studs, anchor bolts, nuts, and washers that conform to ASTM A 320, Class 1, Grade B8. Prior to use, submit a sample of each size of bolts, anchors, washers, and nuts to the ME for testing and approval. Provide a mill test report for each heat.

908.05 Aluminum Alloy Bolting Materials  

Use bolts, nuts, set screws, and pins that conform to ASTM B 211, Alloy 2024-T4 with No. 205 Alumilite Finish. Ensure that bolt heads and nuts are American National Standard, Regular Series, hexagonal, semi-finished, conforming to ANSI B18.2.1 to B18.2.2, and that threads are American National Standard, Coarse Series, Class 2 Fit, conforming to ANSI B1.13M. Finish bolts with an anodic coating thickness of not less than 0.0002 inches and chromate seal.

Use washers conforming to ASTM B 209, Alloy 2024-T3.

Before using, submit a sample of each size of bolts, set screws, pins, washers, and nuts to the ME for testing and approval. Provide a mill test report for each heat.

Section 909 – Drainage

909.01 Pipe Bedding  

909.01.01 Class A Bedding

Use concrete as specified in 903.03.

909.01.02 Class B Bedding

Use sand or sandy soil with 100 percent passing the 3/8-inch sieve and no more than 10 percent passing the No. 200 sieve.

909.01.03 Class C Bedding

Use a granular soil conforming to the gradation requirements in Table 909.01-1.

909.01.04 Class D Bedding

Use coarse aggregate No. 8 as specified in 901.03.

909.02 Pipe  

909.02.01 Reinforced Concrete Pipe

In the manufacture of reinforced concrete pipe, use concrete that is composed of cement, coarse aggregate, fine aggregate, and water. Concrete may include admixtures, fly ash, or slag.

If fly ash is used to control alkali-silica reactivity, use Class F fly ash.

Manufacture reinforced concrete culvert pipe, storm drain, and sewer pipe to conform to AASHTO M 170, Class III, Wall B, unless otherwise designated. For jacked pipe, use reinforced concrete culvert pipe conforming to AASHTO M 170, Class V, Wall B. Manufacture reinforced concrete elliptical culvert, storm drain, and sewer pipe to conform to AASHTO M 207, Class HE-III, unless otherwise designated.

If required for watertight flexible joints, use preformed flexible joint sealants conforming to AASHTO M 198.

Notify the ME at least 2 days before shipping pipe to the Project. The ME will inspect and approve pipe in the supplier’s yard after manufacture. For approval of the concrete pipe, perform 3-point loading in the supplier’s yard at a frequency directed by the ME.

909.02.02 HDPE Pipe

Use corrugated HDPE drainage pipe that conforms to AASHTO M 294 and is Type S (smooth interior with annular corrugations) with gasketed silt-tight joints.

Use HDPE pipe from a manufacturer who is an Eastern States Consortium (ESC) qualified manufacturer of HDPE. For a list of qualified manufacturers, see the ESC website at www.nh.gov/dot/espc/.

Submit a certification of compliance, as specified in 106.07, for HDPE pipe.

909.02.03 Plastic Drainage Pipe

Use corrugated polyethylene drainage pipe according to AASHTO M 252, or use PVC drainage pipe according to ASTM D 2729.

Submit a certification of compliance, as specified in 106.07, for plastic drainage pipe.

909.02.04 Corrugated Aluminum Alloy Culvert Pipe and Pipe Arches

Use corrugated aluminum alloy culvert pipe and pipe arches conforming to ASTM B 745, Types I or II, and the following:

1. Type I. Fabricate corrugated aluminum alloy culvert pipe using 0.060-inch-thick sheet metal, unless other thicknesses are designated.
   
   Use only helical corrugations, unless annular corrugations are designated.
   
   Join the pipe in the field with locking bands conforming to ASTM B 745, except that coupling bands with projections (dimples) are not allowed.
   
   
2. Type II. Fabricate corrugated aluminum alloy pipe arches using 0.060-inch-thick sheet metal, unless other thicknesses are designated.

Submit a certification of compliance, as specified in 106.07, for corrugated aluminum alloy pipe and pipe arches.

909.02.05 Corrugated Aluminum Alloy Underdrain Pipe

Use corrugated aluminum alloy underdrain pipe conforming to ASTM B 745, Type III. Fabricate the pipe using 0.048-inch-thick sheet metal.

Submit a certification of compliance, as specified in 106.07, for corrugated aluminum alloy underdrain pipe.

909.02.06 Corrugated Steel Pipe and Pipe Arches

Use corrugated steel pipe and pipe arches conforming to ASTM A 760, Types I and II. Use special sections, such as elbows and flared end sections, that conform to ASTM A 760 and are of the same thickness as the conduit to which they are joined. Ensure that corrugated steel pipe and pipe arches and special sections also comply with the following:

1. Type I. Fabricate corrugated steel pipe from 0.079-inch-thick sheet metal, unless other thicknesses are designated.
   
   Use only helical corrugations, unless annular corrugations are designated.
   
   Field join the pipe with locking bands conforming to ASTM A 760, except that coupling bands with projections (dimples) are not allowed.
   
   Ensure that corrugated steel pipe and coupling bands, elbows, and flared end sections have a polymeric coating conforming to AASHTO M 246, Grade 36/11 (interior 0.010 inches and exterior 0.003 inches).
   
   
2. Type II. Fabricate corrugated steel pipe arches from 0.079-inch-thick sheet metal, unless other thicknesses are designated.

Ensure that corrugated steel pipe, coupling bands, elbows, and flared end sections have a polymeric coating conforming to AASHTO M 246, Grade 36/11 (interior 0.010 inches and exterior 0.003 inches).

Submit a certification of compliance, as specified in 106.07, for corrugated steel pipe and pipe arches.

909.02.07 Steel Alloy Pipe for Bridge Storm Drains

Fabricate steel alloy pipe and fittings from alloy steel conforming to the chemical analysis of ASTM A 53, Grade B or ASTM A 500. The Contractor may use ductile iron pipe conforming to ASTM A 377 (ANSI/ AWWA C151/ A21.51) as an alternate. Ensure that the pipe and fittings are zinc-coated (galvanized) according to ASTM A 123. Weld steel pipe and fittings together before galvanizing.

If ductile iron pipe is used, ensure that ductile iron pipe fittings conform to ASTM A 48, Class 30. Bend pipe using the long radius type of bend. Form pipe joints using groove-type couplings, consisting of a housing clamp keyed into a groove cut around the full pipe circumference. Provide a gasket of molded or extruded butyl rubber or ethylene propylene diene monomer to create a sealed joint. Use track-type bolts, conforming to ASTM A 183, with oval necks and heavy hexagonal standard nuts. Galvanize the assembly according to ASTM A 153.

Submit a certification of compliance, as specified in 106.07, for steel alloy pipe.

909.02.08 Ductile Iron Water Pipe

Use ductile iron water pipe conforming to ANSI/ AWWA C151/ A21.51. Use threaded flanges conforming to ANSI/ AWWA C115/ A21.15, and fittings conforming to ANSI/ AWWA C110/ A21.10 or C153/ A21.53. Do not field weld ductile iron pipe. Perform required welding of a ductile iron pipe assembly in a fabrication shop.

Submit a certification of compliance, as specified in 106.07, for ductile iron water pipe.

909.02.09  Fiberglass Pipe for Bridge Strom Drainage

Fabricate fiberglass pipe conforming to ASTM D2996, RTRP-12EA1-2122 and fiberglass pipe fittings conforming to ASTM D3840.

Ensure that all fiberglass pipe, fittings and adhesives use pigmented resin throughout the wall and the color is concrete gray or designated color with UV stabilized resin.   Painted gel-coat or exterior coating is not acceptable. 

Ensure that adhesives are in accordance with the pipe manufacturer and adhesive manufacturer’s recommendations. 

909.03 Castings and Components for Drainage Structures  

Ensure that castings, grates, extension rings, extension frames, and covers for inlets and manholes are capable of withstanding HS-25 loading when tested as a complete, assembled unit and conform to the following:

1. Gray Iron Castings. Use gray iron castings conforming to AASHTO M 306, except that the manufacturer may use gray cast iron conforming to AASHTO M 105, Class 30B or Class 35B. Ensure that castings are true to pattern in form and dimensions and are free from pouring faults, sponginess, cracks, blowholes, and other defects in composition affecting their strength or integrity.
   
   To present a smooth, clean, and uniform surface, sandblast or clean the castings to remove sand and scale.
   
   
2. Carbon Steel Extension Frames and Rings. Use carbon steel extension frames and rings for inlets and manholes. When specified, galvanize the extension frames and rings according to AASHTO M 111. Perform welding of fabricated steel shapes and structures according to AWS D1.1. Do not punch, drill, ream, weld, or cut extension frames and rings in the field. Repair any damage to the galvanized coating.
   
   
3. Scuppers and Other Bridge Drainage. Use structural steel shapes and carbon steel castings conforming to AASHTO M 103, Grades 65-35 or 70-36, and carbon steel forgings conforming to AASHTO M 102, Class D.
   
   
4. Ductile Iron Castings. Use ductile iron castings conforming to ASTM A 536, Grade 65-45-12 or Grade 80-55-06.
   
   
5. Epoxy Bedding Compound. Use an epoxy bedding compound that is listed on the QPL and is a 2-part, non-sag gel, rapid-setting epoxy adhesive conforming to the requirements of ASTM C 881, Type 4, Grade 3, Class B or C and is listed on the QPL. Use the epoxy in an ambient temperature range of 40 to 100 °F.
   
   
6. Ladder Rungs. For ladder rungs, use steel reinforced copolymer polypropylene. Use a 1/2-inch diameter reinforcement steel bar conforming to ASTM A 615, Grade 60, and a polypropylene coating conforming to classification PP0344B33534Z02 according to ASTM D 4101.

For gray iron castings, notify the ME at least 2 days before shipping to the Project. The ME will inspect and approve castings in the supplier’s yard after fabrication. For approval of the gray iron casting, perform proof load or test bar testing according to AASHTO M 306 in the supplier’s yard at a frequency directed by the ME.

For Items other than gray iron castings, submit certifications of compliance as specified in 106.07.

Section 910 – Masonry Units

910.01 Clay or Shale Brick  

Use clay or shale brick conforming to AASHTO M 114, Grade MW, with the dimensions as specified in Table 910.01-1.

Submit a certification of compliance as specified in 106.07.

910.02 Concrete Block for Inlets and Manholes  

In the manufacture of concrete block, use cement as specified in 903.01 and aggregates conforming to the requirements for concrete aggregates as specified in 901.06. Manufacture concrete block according to ASTM C 139. The manufacturer shall sample and test concrete block according to ASTM C 140.

Manufacture blocks to be either rectangular in shape or curved with the inside and outside surfaces curved to the required radii, whichever is appropriate for the shape of the structure. Ensure that the length is between 12 and 18 inches, the height is between 5 and 8 inches, and the width is at least 6 inches.

For the reduction of cross-sectional area of the cones or tops of manholes, the Contractor may use blocks of special shapes and heights. The Contractor may also use blocks of special shapes and heights in the top courses of all structures so that the head castings is set at the required elevation on a mortar bed not more than 1/2 inch thick without cutting the blocks.

Ensure that all blocks have an interlocking-type joint at the ends and are sound and free from cracks or other defects.

Submit a certification of compliance as specified in 106.07.

910.03 Concrete Brick  

In the manufacture of concrete brick, use cement as specified in 903.01 and aggregates conforming to the requirements for concrete aggregates as specified in 901.06. Manufacture concrete brick to conform to ASTM C 139 and to the dimensions specified in Table 910.01-1. The manufacturer shall sample and test concrete brick according to ASTM C 140.

Submit a certification of compliance as specified in 106.07.

910.04 Stone Curb  

Use stone curbs that are of a lithology, color, and texture as specified in the Special Provisions. Fabricate stone curb from a commercially available material with an established history of satisfactory durability and resistance to weathering. Use curb stones from a single quarry with the same color and texture. The Department may allow reasonable variations in color and texture if the variations do not affect the architectural qualities or the structural properties of the stone.

1. Quarry-Split Stone. Ensure that the top face of quarry-split stone for curbs is machine-finished or dressed to an even surface, without depressions or projections of more than 3/8 inch below or above the plane of the face. Ensure that the edges are straight and even, and the ends are cut square for the entire depth of the exposed curb face. Dress curb stones so that joints are not more than 3/8 inch wide from top to gutter line and not more than 1 inch wide below the gutter line.
   
   
2. Dressed Stone. Ensure that dressed stone for curbs is dressed to an even, smooth finish on the top face, on the front face for the entire depth of the exposed curb face, on the back face to a depth of 2 inches, and on the ends to a depth of 1 inch. Ensure that projections and depressions on the various faces do not exceed the allowances in Table 910.04-1.
   
   Extend the rough-dressed part of end faces to 1 inch below the gutter line. Ensure that the back edge of the top is parallel to the front face, the top and front faces are sloped, and the front edge is rounded. Fabricate the stones to have the width specified at the top, and to have a bottom width of not less than 1 and not more than 3 inches different from the top width. Provide stones in lengths of between 4 and 8 feet.
   



Table 910.04-1 Maximum Allowable Deviations for Dressed Stone
	Depression (inches)	Projection (inches)
Top	1/4	1/4
Front, dressed part	1/4	1/4
Front, undressed part	1-1/2	1/2
Back, dressed part	1/2	1/2
Back, undressed part	1-1/2	1-1/2
Ends, dressed part	1/4	1/4
Ends, rough-dressed part	1/2	1/4
Ends, undressed part	1-1/2	1/4

The Contractor may use straight-cut stone for curved curb having a radius of more than 50 feet, but shall dress the curb to true radius after it is set in place. For curved curb having radii smaller than 50 feet, cut the stone to the required radius, and cut the ends so that the joints are less than 1/4 inch wide for the full depth.

Submit a certification of compliance as specified in 106.07.

910.05 Stone Facing for Pier Shafts  

Use stone facing for pier shafts that is of a lithology, color, and texture as specified in the Special Provisions. Ensure that the stone is sound, durable, and free from flaws, discoloration, and structural defects. Granite and stone of similar lithologies normally exhibit a relatively uniform color and texture. The Department may allow a reasonable variation in color and texture and an occasional irregular distribution of the component minerals of the granite, termed waves, or knots, if the variations do not impair the architectural qualities or affect the structural properties of the stone. Quarry the stone from quarries that have ample production capacity both as to quantity and quality.

Submit 1 × 1-foot duplicate samples to the Department to indicate the range of color, texture, and surface finish of the stone to be provided. After approval of the samples, the Department will return 1 set of samples for guidance. Ensure that all stone used in the Project matches the samples.

Ensure that the stone provided is capable of withstanding a crushing stress of 20,000 pounds per square inch on 2-1/2-inch diameter cores tested air-dry.

Submit a certification of compliance as specified in 106.07. Include with the certification a performance history indicating that the stone proposed for use has satisfactorily withstood prolonged exposure in environments similar to that of the Project.

910.06 Stone Paving Block  

For stone paving block, use new or used stone block of good quality. Ensure that the color, texture, and uniformity conform to the requirements specified in the Special Provisions. Ensure that reclaimed blocks are free of bituminous and cement grout coatings and other foreign matter.

Submit a certification of compliance as specified in 106.07.

Section 911 – Signs, Sign Supports, and Delineators

911.01 Signs  

911.01.01 Materials

1. Aluminum Components. Use aluminum materials conforming to the requirements in Table 911.01.01-1.




Table 911.01.01-1 Aluminum Sign Components
Aluminum Items	Test Method	Alloy and Temper
Flat Sign Sheets1 (0.080", 0.100", 0.125" thicknesses)	ASTM B 209	5052-H38 or 6061-T6
Extruded Sign Panels1,2	ASTM B 221	6063-T6
Demountable Letters, Numerals, Symbols (0.040" thickness)	ASTM B 209	5052-H38 or 6061-T6
Bars and Rods	ASTM B 221	6063-T6
Washers, Alclad	ASTM B 209	2024-T4
Flange Splicing Material	ASTM B 209	6061-T6
Shims	ASTM B 209	1100-O
Posts, Truss Chords, Truss Bracing Members	ASTM B 221	6061-T6
Post and Chord Caps	ASTM B  26	356.0-T6
Post Clips	ASTM B  26	356.0-T6
Structural Shapes (Z-Bar Reinforcement)	ASTM B 308	6061-T6
Nuts, 5/16 inch and larger	ASTM B 211	6061-T6
Tamperproof Nuts, 1/4 inch and under	ASTM B 211	2017-T4
Rivets (size and length recommended by the manufacturer)	ASTM B 316	5052-0
Bolts (finished bolts with at least 0.002" chromated sealed anodic coating)	ASTM B 211	2024-T4

1	For flat sign sheets and extruded sign panels, ensure that aluminum is chromate conversion coated according to ASTM B 449, Class 2.
2	For extruded panels, use lightweight panels.



2. Retroreflective Sheeting. Use retroreflective sheeting that is listed on the QPL and conforms to ASTM D 4956. Use sheeting types as specified in Table 911.01.01-2.
   
   If overlay film is used, ensure that the combination of the overlay film with the background retroreflective sheeting conforms to the requirements of ASTM D 4956 for the required type of sheeting as specified in Table 911.01.01-2. Ensure that the color combination of the retroreflective sheeting with the overlay film meets the required color for the sign background. Use retroreflective sheeting and overlay film from the same manufacturer.
   



Table 911.01.01-2 Allowable Sign Sheeting Types
Sign Type	Test Method	Type
Regulatory and Warning Signs	ASTM D 4956	Type III
Guide Signs Mounted on Steel “U” Posts	ASTM D 4956	Type III
Guide Signs Mounted on Overhead Sign Structures, Breakaway Sign Supports, or Non-breakaway Sign Supports	ASTM D 4956	Type VIII or Type IX



3. Color Processing Ink. If a screening process is used for non-retroreflective legends and borders, use only inks recommended by the retroreflective sheeting manufacturer.

911.01.02 Fabrication

1. Sign Panels. Use flat sign panels or extruded panels to fabricate signs. Ensure that cut edges are true and smooth and free from excessive burrs or ragged breaks. Do not flame cut aluminum.
   
   Fabricate flat sheet signs from a single piece of sheet aluminum without joints, using the thicknesses specified in Table 911.01.02-1. Drill or punch 3/8-inch diameter holes in the sign blank for attachment to sign supports. Locate holes according to the MUTCD Manual of Standard Highway Signs. If the panel is larger than 5 feet in any dimension, reinforce the panel with z-bars.
   



Table 911.01.02-1 Requirements for Sheet Aluminum Thickness for Flat Panel Signs
Sign Type	Thickness (inches)
Signs measuring less than 8.0 square feet (except One-Way signs)	0.080
Signs measuring 8.0 square feet or greater	0.100
One Way Signs	0.125


For multiple panel signs, use 1-foot wide extruded sections bolted together. Join sign panel sections together at the flanges with 3/8-inch bolts. Attach the sign panels to vertical supports, ensuring that the span between vertical supports is a maximum of 18 feet. Do not use extruded sign panels with steel “U” post sign supports. Use the same material and color for trim molding that is used for the sign face.


2. Applying Retroreflective Sheeting. Apply sheeting according to the manufacturer’s recommendations. If necessary, use 2 or more pieces of retroreflective sheeting to cover the sign face. Match color at the time of sign fabrication to provide uniform appearance. If using overlay film, use retroreflective sheeting that is the color of the proposed lettering or border. Butt-splice the sheeting and ensure that the gap between sheets does not exceed 1/32 inch. Cut sheeting flush with the edges of the panel.
   
   
3. Legends and Borders. The legend for each sign consists of letters, numerals, shields, and other symbols. Use Series E Modified 2000 lettering that conforms to the MUTCD Manual of Standard Highway Signs. Ensure that the lettering is aligned, spaced and sized according to MUTCD Manual of Standard Highway Signs and the working drawings. Apply the legend and borders using the following methods:
   
   
   1. Demountable. Use sheeting type to match the required retroreflective sheeting for the sign. Apply the sheeting to cutout aluminum for demountable sign legend or border. Mount legend and border to the sign face.
      
      
   2. Direct Applied Retroreflective Sheeting. Using sheeting type to match the required retroreflective sheeting for the sign, cutout legend, or border from the sheeting. Apply the legend or border according to the manufacturer’s recommendations.
      
      
   3. Overlay Film. If using overlay film to color background retroreflective sheeting, computer generate legend cutouts in the overlay film. Apply the overlay film according to the manufacturer’s recommendations.
      
      
   4. Non-Retroreflective Legend and Border. The fabricator may apply non-retroreflective legend or border using ink and application technique according to the retroreflective sheeting manufacturer’s recommendations.

911.01.03 Packaging, Storing, and Shipping

Package, ship, and store panels on edge and according to the sheeting manufacturer’s recommendations. Ensure that all signs are packaged so that they are protected from moisture and damage during shipment and storage.

911.01.04 Acceptance Inspection

Notify the ME at least 3 days before shipping to the Project so that arrangements for inspection can be made. The ME will reject signs not fabricated according to the MUTCD Manual of Standard Highway Signs and the Plans. The ME will ensure that finished signs are clear and legible without smudging, blisters, delamination, loose edges, or other blemishes. The ME will also ensure that the colors have a consistent chromaticity across all signs of the same color.

At the time of the inspection, provide copies of mill certifications for the aluminum components and copies of certification of compliance, as specified in 106.07, for the sign sheeting.

911.02 Sign Supports  

911.02.01 Steel “U” Post Sign Supports

Use steel “U” post sign supports conforming to ASTM A 499, Grade 50 or 60, with the length of post and minimum pounds per foot as shown on the Plans. Provide 18-8 stainless steel 5/16 × 18 UNC hexagonal headed bolts and nuts conforming to ASTM A 320, Grade B8, Class 1, for securing the signs to the steel “U” post. Provide sign mounting bolts that are sized to extend beyond the end of each nut by no more than 3/4 inches when fully tightened.

Submit a certification of compliance, as specified in 106.07, for “U” posts.

911.02.02 Breakaway Sign Supports for Ground Mounted Signs

Fabricate and construct breakaway sign supports for ground mounted signs using materials conforming to the requirements in Table 911.02.02-1.

Submit mill certificates for the component materials.

911.02.03 Non-Breakaway Sign Supports for Ground Mounted Signs

THE text of this subpart is deleted.
This subpart is INTENTIONALLY left blank

911.02.04 Timber Sign Supports

Use timber posts conforming to the requirements for sawn timber posts as specified in 915.01.

911.02.05 Mounting Materials for Overhead, Bridge-Mounted, and Cantilever Signs

Provide brackets for mounting signs (including future signs) to the structure. Ensure that the brackets are adjustable to allow mounting of the sign faces at any angle between a truly vertical position and 3 degrees from vertical. Obtain this angle by rotating the front lower edge of the sign forward of the top edge. Fabricate brackets to lengths equal to the height of the signs being supported.

Submit mill certifications for the brackets.

911.03 Flexible Delineators  

Ensure that flexible delineator units are made of a fiberglass reinforced, thermosetting, high-density polymer resin or an extruded polycarbonite resin, which are resistant to ultraviolet and infrared radiation, and which meet the following minimum physical and performance requirements:

1. Delineator Dimensions.
   
   
   1. Ground Mounted. Ensure that the unit for ground mounted flexible delineators has a minimum width of 3 inches and a minimum thickness of 1/8 inch. Use delineators that have a length to allow the top of the reflective area to be positioned 4 feet above the near roadway edge.
      
      
   2. Guide Rail Mounted. Ensure that the unit for beam guide rail mounted flexible delineators has a minimum width of 3 inches and a minimum thickness of 0.100 inch.  Use units of a height that will ensure that the top of the reflective area is 5 ± 2 inches above the top of post.

      Design the base of the unit to mount over the I-beam blockout or to the top of a wood or synthetic blockout, of the beam guide rail.

   3. Barrier Curb Mounted. For barrier curb mounted flexible delineators, use a delineator that is 3-1/2 × 3-1/2 inches, with a minimum thickness of 0.100 inch, and that has a base that forms a “T” shape with the panel for mounting on the side of the barrier curb, and is flexible or hinged so as to return to its original position after being struck.
      
      
   4. Construction Barrier Curb Mounted.  For construction barrier curb top mounted flexible delineators, use a delineator that is 6 x 12 inches with a minimum thickness of 0.100 inch. For construction barrier curb side mounted flexible delineators, use a delineator that is 3-1/2 x 3-1/2 inches with a minimum thickness of 0.100 inch, and that has a base that forms a “T” shape with the panel for mounting on the barrier curb and is flexible or hinged so as to return to its original position after being struck.
   
   
2. Delineator Color. Use flexible delineators that are white in color.
   
   
3. Impact Resistance for Ground Mounted Delineators. Use flexible delineator units that are self-erecting to within 10 degrees of original upright position within 15 minutes after 5 vehicle impacts traveling at 55 miles per hour. Ensure that the re-erected unit retains the original cross-section, shows no evidence of shredding or splintering, and retains 80 percent of its original retroreflective sheeting when tested for both bumper impacts and wheel impacts and in both cold and hot weather.
   
   
4. Retroreflective Sheeting. Use retroreflective sheeting that is listed on the QPL and conforms to ASTM D 4956, Type VII or VIII. Affix yellow or white retroreflective sheeting to the traffic-facing side of the delineator according to the manufacturer’s recommendations.
   
   
   1. Ground Mounted. Ensure that sheeting is a maximum of 2 inches from the top of the delineator and is at least 3 × 12 inches.
      
      
   2. Guide Rail Mounted. Ensure that the sheeting is a minimum of 3 inches square and is mounted on the upper portion of the delineator.
      
      
   3. Barrier Curb Mounted. Ensure that the sheeting is 3-1/2 × 3-1/2 inches.
      
      
   4. Construction Barrier Curb Mounted.  Ensure that the sheeting for top mounted flexible delineators is 6 x 12 inches and the sheeting for side mounted flexible delineators is 3-1/2 x 3-1/2 inches.
      

Submit a certification of compliance, as specified in 106.07, for delineators.

Section 912 – Paints, Coatings, Traffic Stripes, and Traffic Markings

912.01 Paints and Stains  

912.01.01 Structural Steel Paint

Use paint systems for coating structural steel that are Northeast Protective Coating Committee (NEPCOAT) approved and listed on the QPL. Use the appropriate paint type for the application as follows:

1. Use an inorganic zinc, epoxy, urethane (IEU) paint system for coating new structural steel.
2. Use an organic zinc, epoxy, urethane (OEU) paint system for re-coating existing structural steel.
3. Use an epoxy mastic, urethane (EU) paint system for over-coating existing structural steel.

Ensure that the primer is tinted to contrast with the base metal. Use white or an approved color that contrasts with the prime and finish coats for the intermediate coat.

Use the finish color coat noted on the Plans. When the colors Lake Blue, Foliage Green, Brown, or Black are specified, match the color chips of FED-STD-595B as specified in Table 912.01.01-1.

Before using paint, submit each lot to the ME for quality assurance testing and approval. The ME will verify that the pigment content, total solids, and infrared curve match that of the initial qualifying material. Do not use paint until the ME has approved the paint lot.

912.01.02 Aluminum Paint

Use aluminum paint conforming to AASHTO M 69, Type II. Submit certifications of compliance as specified in 106.07.

912.01.03 Coal Tar Epoxy Paint

Use coal tar epoxy-polyamide paint that conforms to SSPC-Paint No. 16 and is black or dark red in color. Submit certifications of compliance as specified in 106.07.

912.01.04 Concrete Stain

To stain concrete, use a penetrating stain that is a single component, water-based, thermoplastic acrylic emulsion that carries its color and water repellent protection into the concrete. Ensure that the stain conforms to the requirements in Table 912.01.04-1.

Submit certifications of compliance as specified in 106.07.

912.02 Coatings  

912.02.01 Galvanizing (Zinc Coating)

Apply hot-dip galvanized coating to iron and steel plates, pipe, tube, and structural shapes according to ASTM A 123.

Apply hot-dip galvanized coating to iron and steel hardware according to ASTM A 153.

Repair hot dipped galvanized coating on iron and steel plates, pipe, tube, structural shapes, and hardware according to ASTM A 780.

912.02.02 Epoxy Waterproofing

For concrete waterproofing, use epoxy-resin that conforms to ASTM C 881, Type 7, Grade 1, 2, or 3, Class D, E, or F, and is listed on the QPL. Ensure that the color is gray to match the color of the adjacent concrete.

Submit certifications of compliance as specified in 106.07.

912.02.03 Asphalt Waterproofing

For use below ground level, use an asphalt waterproofing conforming to ASTM D 449, Type I. For use above ground level, use an asphalt waterproofing conforming to ASTM D 449, Type II or III. Use a primer conforming to ASTM D 41.

912.02.04 Coating for Non-Vegetative Surface

Formulate a color coating with a pure acrylic vehicle that is durable, weather resistant, and suitable for use on bituminous surfaces. Use lusterless brown tint matching Federal chip No. 30277.

912.03 Permanent Traffic Stripes and Markings  

912.03.01 Epoxy Traffic Stripes

1. Epoxy Resin. For long-life pavement striping, use an epoxy resin that is a 2 component, 100 percent solids formulation conforming to the following requirements:
   
   
   1. Color. Ensure that the material conforms to the initial color requirements in ASTM D 6628.
      
      
   2. Yellowness Index. When tested according to ASTM E 313 (with glass beads), ensure that the white epoxy resin exhibits a maximum 20.00 yellowness index after 72 hours of QUV exposure.
      
      
   3. Directional Reflectance. Ensure that the epoxy resin compound (without glass beads) has a minimum directional reflectance, relative to a magnesium oxide standard, of 80 percent for white and 50 percent for yellow when tested according to ASTM E 1347.
      
      
   4. Drying Time. Ensure that the epoxy resin compounds, when tested according to ASTM D 711, exhibit no pick-up after a 15 minute drying time.
      
      
   5. Abrasion Resistance. When the epoxy resin material is tested according to ASTM C 501, with a CS-17 wheel under a load of 1000 grams for 1000 cycles, ensure that the abrasive wear index is no greater than 80. The abrasive wear index is the weight in milligrams that is abraded from the sample under the specified test conditions.
      
      
   6. Hardness. After the epoxy resin material has cured between 72 and 96 hours at 70 °F, ensure that the Shore D hardness is between 75 and 100 when tested according to ASTM D 2240.
      
      
   7. Composition. Ensure that the epoxy resin meets the composition requirements in Table 912.03.01-1.
      
   
   

   Table 912.03.01-1 Composition of Epoxy Resin
   	Percent By Weight
   Pigment Composition	Minimum	Maximum
   White:
   Titanium Dioxide1 (ASTM D 476, Type II or III)	18.0	25.0
   Epoxy Resin	75.0	82.0
   Yellow:
   Organic Non-Lead Yellow	7.0	8.0
   Epoxy Resin	75.0	79.0
   Titanium Dioxide (ASTM D 476, Type II or III)	14.0	17.0

   1	Use titanium dioxide for the entire pigment composition for white epoxy.

   8. Packaging and Shipping. Ensure that the epoxy resin material is shipped in appropriate containers and plainly marked with the following information:
      
      
      1. Manufacturer’s Name and Address.
      2. Name of Product.
      3. Lot/Batch Number.
      4. Color.
      5. Net Weight and Volume of Contents.
      6. Date of Manufacture.
      7. Date of Expiration.
      8. Mixing Proportions and Instructions.
      9. Safety Information.
      
      
   9. Sampling and Certified Analysis. Test each batch of material for composition and IR mapping. Do not use material that deviates from the master IR curve. At least 15 days before use, submit to the ME the manufacturer’s certified test results for each batch of epoxy resin material to be used on the Project. In addition, the ME will randomly sample epoxy resin for testing.
   
   
2. Glass Beads. Submit certifications of compliance as specified in 106.07 for each lot of glass beads used on the contract. Ensure that glass beads do not contain more than 200 ppm of lead, 200 ppm of antimony, or 200 ppm of arsenic.
   
   
   1. Small Glass Beads. Use small beads conforming to AASHTO M 247, Type 1, with a moisture resistant coating.
      
      
   2. Large Glass Beads. Ensure that the large beads conform to AASHTO M 247, except as follows:
      
      
      1. Provide beads with a silane adherence coating.
      2. Ensure that the gradation is as specified in Table 912.03.01-2.
         
      
      

      Table 912.03.01-2 Gradation Requirements for Large Glass Beads
      Sieve Size	Percent Passing by Weight1
      No.10	100
      No. 12	95 – 100
      No. 14	80 – 95
      No. 16	10 – 40
      No. 18	0 – 5
      No. 20	0 - 2

      1	According to ASTM D 1214

912.03.02 Thermoplastic Traffic Markings

For long-life traffic markings, use either preformed or hot extruded thermoplastic conforming to AASHTO M 249, except that for preformed thermoplastic, the minimum thickness requirement is 90 mils. Use beads conforming to AASHTO M 247, Type 1, with a moisture resistant coating. Ensure that glass beads do not contain more than 200 ppm of lead, 200 ppm of antimony, or 200 ppm of arsenic.

Submit certifications of compliance, as specified in 106.07, for each batch of materials used on the contract.

912.03.03 Raised Pavement Markers (RPM)

Use raised pavement markers (RPMs) made of ductile iron castings with a 2-way, snow-plowable, replaceable prismatic reflector conforming to the following requirements:

1. Castings. Provide a ductile iron casting conforming to ASTM A 536, hardened to between 52 and 54 Rockwell “C”. Ensure that the castings provided are between 9.25 and 10 inches long, 5.5 and 5.85 inches wide, and 1.70 and 1.92 inches high, and weigh approximately 5.5 pounds. Ensure that each casting is permanently marked with the manufacturer’s name and model number.
   
   
2. Epoxy Resin Adhesive. Set castings in the pavement surfaces using an epoxy resin adhesive conforming to AASHTO M237, Type IV.
   
   
3. Lenses. Provide a lens conforming to ASTM D 4383 and Table 912.03.03-1.
   
   

Table 912.03.03-1 Requirements for Lenses
Property	Requirement
Nominal Dimensions	4 × 2 × 0.5 inch
Slope of reflecting surface	30 to 35 degrees
Area of each reflecting surface	1.44 to 1.87 square inches


Ensure that the lens has a thin untempered glass bonded to the front surface of the prismatic retroreflective lens face.


4. Lens to Casting Adhesive. Attach the reflector to the casting with an adhesive according to the reflector manufacturer’s recommendations.

Submit a certification of compliance as specified in 106.07.

912.04 Temporary Traffic Stripes and Markings  

912.04.01 Latex Paint

For temporary traffic stripes, use latex traffic paint that is a fast-drying white, or non-lead yellow, ready-mixed pigmented binder emulsified in water and capable of anchoring reflective glass beads that are separately applied. Ensure that the color matches FED-STD-595B color chip No. 33538 for yellow and No. 37886 for white. Ensure that the paint has a maximum no-track time of 120 seconds when applied in a wet film thickness of 15 ± 1 mil, at 140 °F, and with 12 pounds per gallon of glass beads. In addition, ensure that the finished product meets the following:

1. Volume of solids is a minimum 61 percent.
2. Total solids are a minimum of 77.5 percent total non-volatiles by weight, when tested according to ASTM D 2369.
3. Weight per gallon is a minimum 14 ± 0.2 pounds per gallon for each color.
4. Hegman Grind is a minimum of 2 Hegman when tested according to ASTM D 1210.
5. Viscosity is between 70 and 95 Krebs Units at 77 °F, when tested according to ASTM D 562.

Use glass beads conforming to AASHTO M247, Type 1, with a moisture resistance coating. Ensure that glass beads do not contain more than 200 ppm of lead, 200 ppm of antimony, or 200 ppm of arsenic.

If requested by the RE, provide a certification of compliance, as specified in 106.07, for latex or glass beads.

912.04.02 Removable Pavement Marking Tape

1. Temporary Pavement Tape. Use removable pavement marking tape consisting of polymeric backing materials with a retroreflective surface. Ensure that the underside of the tape is pre-coated with a pressure sensitive adhesive to bond the tape to the roadway surface and is capable of withstanding traffic immediately after installation and for the duration of the intended service. Use a primer only if recommended by the manufacturer.
   
   Provide tape that has a minimum skid resistance of 35 British petroleum number (BPN) when tested according to ASTM E 303. Do not use lead based pigment in traffic tape. Provide tape that conforms to the requirements specified in Table 912.04.02-1.
   



Table 912.04.02-1 Requirements for Temporary Pavement Tape
Property	White	Yellow
Minimum Specific Luminance (mcd/sq foot/foot-candles) ASTM D 40611	500	300
Minimum Tensile Stress (psi)2 ASTM D 638	40	40
FED-STD-595B Color Chip No.	37778	33538

1	Use an entrance angle of 88.76° and an observation angle of 1.05°.
2	Perform tensile stress testing with a testing speed of 6 inches per minute.

Use removable tape that is capable of being removed manually, intact or in large pieces, without the use of solvents, burning, grinding, or blasting and without damage to the underlying surface.

If requested by the RE, provide a certification of compliance, as specified in 106.07, for temporary pavement tape.


2. Removable Black Line Masking Tape. Use black line masking tape that is black in color, non-retroreflective, and a pliant polymer material. Ensure that the color conforms to FED-STD-595B color chip No. 37030. Provide tape that does not produce a sheen under day, night, or wet conditions. Ensure that the tape is capable of masking the underlying stripes so that they do not reflect through. Provide tape that has a minimum skid resistance of 30 BPN when tested according to ASTM E 303. Ensure that the underside of the tape is pre-coated with a pressure sensitive adhesive to bond the tape to the roadway surface and is capable of withstanding traffic immediately after installation and for the duration of the intended service.
   
   Ensure that the removable tape is capable of being removed manually, intact or in large pieces, at temperatures above 40 °F, without the use of solvents, burning, grinding, or blasting and without damage to the underlying surface.
   
   If requested by the RE, provide a certification of compliance, as specified in 106.07, for removable black masking tape.

912.04.03 Temporary Pavement Markers

Provide temporary pavement markers that have a maximum width of 4 inches perpendicular to traffic and a maximum height of 3/4 inch. Mold marker castings using acrylonitrile butadiene styrene, acrylic, polycarbonate, or high impact polystyrene of the same color as the retroreflective lens.

Use either mono-directional white or bi-directional yellow retroreflective lenses as shown on the Plans. Ensure that the lenses used for the retroreflective material are molded of methylmethacrylate conforming to ASTM D 788, PMMA0131V0, or PMMA0231V0 and meet the retroreflectance values specified in Table 912.04.03-1:

Ensure that the underside of the marker is precoated with a pressure sensitive adhesive to bond the marker to the roadway surface and is capable of withstanding traffic immediately after installation and for the duration of the intended service. Ensure that markers are capable of being removed without damage to the underlying surface.

If requested by the RE, provide a certification of compliance, as specified in 106.07, for temporary pavement markers.

Section 913 – Guide Rail, Fence, and Railing

913.01 Beam Guide Rail  

913.01.01 Rail Element

Fabricate rail element according to AASHTO M 180, Class A, Type I in Table 2. Ensure that the weight of the zinc coating conforms to AASHTO M 180, Type I in Table 1.

Notify the ME at least 3 days before shipment to the Project for inspection at the supplier’s yard. Provide mill certifications to the ME at the time of inspection.

913.01.02 End Treatments

Use non-gating, guide rail end treatments that are NCHRP 350 tested, test level 3 (TL-3), approved and are listed on the QPL. Ensure that the components of the end treatment comply with the NCHRP 350 approved end treatment details.

Notify the ME at least 3 days before shipment to the Project for inspection at the supplier’s yard. Provide mill certifications to the ME at the time of inspection.

913.01.03 Posts and Blockouts

For steel posts and blockouts, use structural steel conforming to ASTM A 709, Grade 36, that is galvanized according to ASTM A 123.

Use wood timber blockouts and posts as specified in 915.01.

Use synthetic routed blockouts that are NCHRP 350 tested, test level 3 (TL-3), approved and are listed on the QPL. Ensure that the name of the manufacturer and model number are stamped on each blockout and that the blockouts are of the same material and dimensions as the spacers that were NCHRP tested.

Notify the ME at least 3 days before shipment to the Project for inspection at the supplier’s yard. Provide mill certifications for steel components to the ME at the time of inspection. Provide certifications of compliance, as specified in 106.07, for wood and synthetic components.

913.01.04 Rub Rail

For rub rail, use steel channels or bent plate of structural steel conforming to ASTM A 36 and galvanized according to ASTM A 123.

Notify the ME at least 3 days before shipment to the Project for inspection at the supplier’s yard. Provide mill certifications to the ME at the time of inspection.

913.01.05 Miscellaneous Hardware

Ensure that connections or splices, nuts, bolts, washers, and plates conform to AASHTO M 180, except as follows:

1. If high-strength bolts are shown on the Plans for bridge guide rail, use high-strength bolts, nuts, and washers conforming to ASTM A 325, Type I, and galvanized according to ASTM A 153.
2. For base plate assemblies on bridge guide rail, use an adhesive anchor system with galvanized bolts as specified in 908.01.04 or galvanized anchor bolts, nuts, and washers as specified in 908.01.03.
3. Use plates for guide rail on bridges and buried guide rail terminals conforming to ASTM A 36 and galvanized according to ASTM A 123.

Notify the ME at least 3 days before shipment to the Project for inspection at the supplier’s yard. Provide mill certifications to the ME at the time of inspection.

913.02 Fence  

913.02.01 Chain-Link Fence

Ensure that the materials for chain-link fence conform to AASHTO M 181. Submit certifications of compliance, as specified in 106.07, for fence materials. Attach mill certification to the certification of compliance.

913.02.02 Caution Fence

Ensure that the materials for caution fence conform to the following:

1. Fabric. Fabricate the fabric for plastic caution fence from HDPE with a minimum tensile strength of 5000 pounds per square inch when tested according to ASTM D 648. Use fabric that is blaze orange in color that matches FED-STD-595B color chip No. 38915 and is ultraviolet stabilized.
   
   
2. Posts. Use posts made of high carbon steel with a flanged leg channel section or flanged leg U-bar section having a uniform thickness of metal of not less than 1/8 inch. Ensure that the posts weigh at least 2 pounds per linear foot, exclusive of ground plate, and are designed to be easily driven into the ground. Equip each post with at least 11 riveted lugs. Do not equip posts with punched or welded lugs. Galvanize posts.

913.02.03 Snow Fence

Ensure that the materials for snow fence conform to the following:

1. Wires. Use wires of a galvanized stay-cable type, with a diameter of not less than 12-1/2 gauge.
   
   
2. Wooden Pickets. Use unpainted, wooden pickets made from cedar, spruce, maple, or other satisfactory species of wood. Ensure that the pickets are free from knots with a diameter greater than one-half of the width of the picket.
   
   
3. Posts. Use posts as specified in 913.02.02.2.

Submit certifications of compliance, as specified in 106.07, for fence materials.

913.03 Bridge Railing  

913.03.01 Steel Railing

Fabricate steel railing from structural steel as specified in 906.01. Construct welds according to the requirements of AWS D1.1 Structural Welding Code. Use bolts and bolting materials as specified in 908.01. When specified, paint as specified in 906.06 or galvanize as specified in 912.02.01. Submit certifications of compliance, as specified in 106.07 and copies of mill certifications.

913.03.02 Aluminum Railing

Fabricate aluminum railing from aluminum components as specified in Table 913.03.02-1. Construct welds according to the requirements of ANSI/AWS D1.2 Structural Welding Code - Aluminum. Use bolts and bolting materials as specified in 908.01. When specified, paint as specified in 906.06. Submit certifications of compliance, as specified in 106.07, and copies of mill certifications.

Section 914 – Joint Materials

914.01 Preformed Joint Filler  

Use preformed joint fillers conforming to AASHTO M 33 or AASHTO M 213. For concrete pavement applications, punch holes in preformed joint filler to admit the dowels. Provide the filler for each joint in a single piece for the full depth and width required for the joint. If the RE approves the use of more than 1 piece for a joint, fasten the abutting ends securely, and hold to shape by stapling or other means of means of positive fastening.

Submit a certification of compliance, as specified in 106.07, for joint filler.

914.02 Joint Sealer  

For sealing joints and cracks in HMA and concrete pavements, use a hot-poured joint sealer that is listed on the QPL and conforms to ASTM D 6690. Use the following types in the listed applications:

1. For sealing cracks in HMA, use Type II sealer.
2. For sealing cracks and joints in concrete pavement and HMA saw and seal applications, use Type IV sealer.
3. In structural applications, use Type II sealer.

For concrete pavements, use cold-poured joint sealer that is listed on the QPL and conforms to ASTM D 5893, Type SL, except that ultimate elongation is required to be a minimum of 1200 percent.

In vertical applications, use cold-poured joint sealers that are listed on the QPL and conform to ASTM D 5893, Type NS, with a minimum ultimate elongation of 600 percent. If recommended by the manufacturer, apply primer before applying the sealer.

Use backer rod in conjunction with cold-poured joint sealer that conforms to ASTM D 5249, Type 1. Use backer rod with a width that is at least 25 percent greater than the width of the pavement joint or crack. Ensure that the backer rod is clean and dry at the time of installation.

Submit a certification of compliance, as specified in 106.07, for joint sealers and backer rods. Attach test results to the certification. The ME will randomly sample joint sealers at the source of manufacture or at the work site.

914.03 Polymerized Joint Adhesive  

For longitudinal cold joints in HMA paving, use polymerized joint adhesive that is a hot-applied asphaltic joint adhesive listed on the QPL and conforms to the requirements in Table 914.03-1:

Ensure that the polymerized joint adhesive has a viscosity at the recommended pour temperature to allow for proper application of the material. Obtain documentation of recommended pour temperature and safe heating temperature for the material from the manufacturer. Submit a certification of compliance, as specified in 106.07, for polymerized joint adhesive. Attach test results to the certification. The ME will randomly sample joint adhesive at the source of manufacture or at the work site.

914.04 Joint Assemblies  

914.04.01 Preformed Elastomeric (Compression Type)

1. Metal Components. Fabricate the structural steel components of the joint assembly as specified in 906.04 and as shown on the Plans and the approved working drawings. Ensure that the fabricator is AISC certified. The ME will inspect joint assemblies either at the fabrication shop or at the work site. Insert the elastomeric joint sealer according to the manufacturer’s recommendations.
   
   
2. Joint Sealer. Use preformed elastomeric joint sealers that are manufactured from vulcanized elastomeric compound using polychloroprene (neoprene) as the base polymer. Manufacture the joint sealer to conform to ASTM D 3542, with a minimum range of motion of at least 30 percent of the nominal size of the sealer. Ensure that the width to height ratio of the joint sealer is at least 90 percent.
   
   In new construction, do not field splice sealers. For reconstruction projects, the RE may allow field splices. If field splicing is allowed, splice using vulcanization or shop splicing methods. If shop splicing of sealer is unavoidable, splice using either factory vulcanization or cold-cured factory bonding using a high-strength, rapid-bonding adhesive. If splicing of a sealer is allowed, ensure that the sealer at the splice point has no significant misalignment at its sides or top and that misalignment at the bottom does not exceed half of the bottom wall thickness.
   
   Ensure that the manufacturer’s name or trademark and lot number are marked on the joint sealer to identify each shipment. Submit certifications of compliance, as specified in 106.07, for joint sealers. Attach a copy of the test results with the certification. Submit a sample of each size joint sealer to be used on the Project to the ME for quality assurance testing. Ensure that the sample is at least the minimum length specified in Table 914.04-1.
   



Table 914.04-1 Minimum Lengths of Samples for Testing
Sealer Size Width (w) in inches	Minimum Length (inches)
w < 2	84
2 ≤ w < 3	66
3 ≤ w < 4	50
w ≥ 4	42