INDIANA

DEPARTMENT
OF
TRANSPORTATION
____________

STANDARD
SPECIFICATIONS

2020
 ERIC HOLCOMB
GOVERNOR

INDIANA
DEPARTMENT OF TRANSPORTATION

Joe McGuinness
COMMISSIONER

STANDARDS COMMITTEE

CHAIRMAN
John Leckie, Construction and Materials Management Director

MEMBERS

Matt Beeson, Materials Management

Michael Beuchel, Contract Administration

David Boruff, Traffic Engineering

Kumar Dave, Pavement Engineering

Louis Feagans, Statewide Technical Services

Michael Koch, Fort Wayne District Construction

Mark Orton, Bridge Standards and Policy

Greg Pankow, State Construction Engineer

Kurt Pelz, Construction Technical Support

Elena Veksler, Highway Design and Technical Support

SECRETARY
Scott Trammell, Construction Specifications Engineer

Lana Podorvanova, Specifications Coordinator

 MEASUREMENTS

The first two paragraphs of 109.01, Measurement of Quantities reads as follows:

(a) General Requirements

All measurements of work completed under the contract will be according to the
English System unless otherwise specified.

The standard measures shown in this publication are primarily in the English
System of Units such as feet and inches, pounds, gallons, and acres. Any metric
equivalents, shown in parentheses, are intended only for those contracts in which
they are specified, or to maintain consistency with industry standards. No guarantee
is provided, explicit or implicit, that the units are accurate conversions.

The following table and general notes are provided to assist you in becoming
familiar with the metric system.

iii
 SI UNITS AND CONVERSION FACTORS
ENGLISH MULTIPLIER FOR CONVERSION
SI
MEASUREMENT ENGLISH UNIT UNIT FROM ENGLISH UNIT TO SI UNIT
SYMBOL
SYMBOL SI UNIT (*)
Acceleration foot per second squared ft/sec2 0.304 8 exactly meter per second squared m/s2
mile per hour squared mi/h2 1.060 93 kilometer per hour squared km/h2
Area square inch in2 645.16 exactly square millimeter mm2
square foot ft2 0.092 9 square meter m2
square yard yd2 0.836 1 square meter m2
acre ac 0.404 7 hectare ha
square mile mi2 2.59 square kilometer km2
Density pound per cubic foot lb/ft3 16.018 46 kilogram per cubic meter kg/m3
Energy foot·pound force ft lbf 1.355 8 joule J
kilowatt hour kW h 3 600 000. exactly joule J
Force/Weight pound force lbf 4.448 2 newton N
(Gravity of Force) kilopound force kip 4.448 2 kilonewton kN
ton t 8.896 4 kilonewton kN
Length inch in. 25.4 exactly millimeter mm
iv

foot ft 0.304 8 exactly meter m

yard yd 0.914 4 exactly meter m
mile mi 1.609 3 kilometer km
Mass ounce oz 28.349 5 gram g
pound mass lbm 0.453 6 kilogram kg
ton mass t 0.907 2 megagram Mg
Power horsepower (550 ft·lbf/s) hp 745.669 9 watt W
Pressure/Stress pound per square inch lb/in2 6.894 8 kilopascal kPa
pound per square foot lb/ft2 0.047 88 kilopascal kPa
kilopound per square inch kip/in2 6.894 8 megapascal MPa
Speed/Velocity foot per second ft/s 0.304 8 exactly meter per second m/s
mile per hour mi/h 1.609 3 kilometer per hour km/h
 Temperature degree Fahrenheit °F (°F -32)/1.8(**) exactly degree Celsius °C
Volume, Fluid cubic inch in3 16.387 1 milliliter mL
fluid ounce fl oz 29.573 4 milliliter mL
gallon gal. 3.785 4 liter L
1000 gallons kGAL. 3.785 4 kiloliter kL
Volume, Solid cubic inch in3 16.387.06 exactly cubic millimeter mm3
cubic foot ft3 0.028 32 cubic meter m3
bushel bu 0.035 24 cubic meter m3
3
cubic yard yd 0.764 6 cubic meter m3
1000 feet board measure MFBM 2.359 7 cubic meter m3
(*) Conversion from SI unit to English unit may be made by dividing the SI unit by the conversion factor shown in this column.
(**) This is a formula, and not a multiplier. The Fahrenheit temperature is substituted for °F in the formula to attain the Celsius temperature. Conversion from Celsius
temperature to Fahrenheit temperature may be made by substituting the Celsius temperature for °C in the formula (1.8 x °C) +32. This is an exact conversion.

Angles will continue to be measured in degrees, minutes, and seconds instead of radians.
v
 GENERAL NOTES

1. The SI unit of millimeter should be used to convert inches to millimeters.

2. The SI unit of Mass is the Kilogram (Kg) which should be used for smaller
masses expressed in pounds. The megagram (Mg) should be used for larger
masses expressed in tons.

3. All units peculiar to the various cgs systems (measurement systems constructed
by using the centimeter, gram and second as base units) are to be avoided.

4. In commercial and everyday use, the term weight nearly always means mass;
thus, when one speaks of a person’s weight, the quantity referred to is mass. In
Science and Technology, the term weight of a body has usually meant the force
that, if applied to the body, would give it an acceleration equal to the local
acceleration of free fall g (acceleration of gravity). When the term is used, it is
important to know whether mass or force is intended and to use SI Units
properly, by using Kilograms for Mass or Newtons for Force. The use of force
of gravity (mass times acceleration of gravity) instead of weight with this
meaning is recommended. Because of the dual use of the term weight as a
quantity, this term should be avoided in technical practice except under
circumstances in which its meaning is completely clear.

5. The term load means either mass or force, depending on its use. A load that
produces a vertically downward force because of the influence of gravity acting
on a mass may be expressed in mass units. Any other load is expressed in force
units.

6. A quantity stated as limits, such as “not more than” or “maximum”, must be

handled so that the stated limit is not violated.

7. Conversion of quantities should be handled with careful regard to the implied

correspondence between the accuracy of the data and the given number of digits.
In all conversions, the number of significant digits retained should be such that
accuracy is neither sacrificed nor exaggerated. For example, a length of 125 ft
converts exactly to 38.1 m. If however, the 125 ft length has been obtained by
rounding to the nearest 5 ft, the conversion should be given as 38 m. The proper
conversion procedure is to multiply a value by a conversion factor that is more
accurate than is required, the result is then rounded to the appropriate number of
significant digits.

8. For calculation of results, avoid rounding of intermediate quantities. For

reporting results, the rule for addition and subtraction is that the answer shall
contain no significant digits farther to the right than occur in the least precise
number. The rule for multiplication and division is that the product or quotient

vi
 shall contain no more significant digits than are contained in the number with
the fewest significant digits used in the multiplication.

9. When a figure is to be rounded to fewer digits than the total number available,
the standard “5” up procedures should be used as follows:

(a) When the first digit discarded is less than 5, the last digit retained
should not be changed. For example, 3.46325, if rounded to three
digits, would be 3.463; if rounded to two digits, would be 3.46.

(b) When the first digit discarded is 5 or greater, the last digit retained
should be increased by one unit. For example, 8.37652, if rounded to
three digits, would be 8.377; if rounded to two digits would be 8.38.

10. Refer to ASTM SI 10 American National Standard for Use of the International
System of Units (SI) for other conversion factors.

11. This specification book uses the word “shall” to describe the Contractor’s
responsibilities. The word “will” is used to describe the Department’s
responsibilities. The words “shall” and “will” are not required to be followed by
the words “by the Contractor” or “by the Department” to retain these meanings.

vii
 TABLE OF CONTENTS
Section Title Page

DIVISION 100 – GENERAL PROVISIONS

SECTION 101 – DEFINITIONS AND TERMS .................................................... 1

101.01 Abbreviations........................................................................................... 1
101.02 Above Normal Inclement Weather Days ................................................. 4
101.03 Blank........................................................................................................ 4
101.04 Bid Bond .................................................................................................. 4
101.05 Bidder ...................................................................................................... 4
101.06 Bridge ...................................................................................................... 4
(a) Length ..................................................................................................... 4
(b) Roadway Width ...................................................................................... 5
101.07 Business Day ........................................................................................... 5
101.08 Calendar Day ........................................................................................... 5
101.09 Change Order ........................................................................................... 5
101.10 Construction Limits ................................................................................. 5
101.11 Contract ................................................................................................... 5
101.12 Contract Information Book ...................................................................... 5
101.13 Contract Item (Pay Item) ......................................................................... 5
101.14 Contract Time .......................................................................................... 5
101.15 Contractor ................................................................................................ 6
101.16 Culvert ..................................................................................................... 6
101.17 Commissioner .......................................................................................... 6
101.18 Department .............................................................................................. 6
101.19 Embankment Foundation ......................................................................... 6
101.20 Engineer ................................................................................................... 6
101.21 Equipment ................................................................................................ 6
101.22 Extra Work .............................................................................................. 6
101.23 Failed Material ......................................................................................... 6
101.24 Force Account Work................................................................................ 6
101.25 Frequency Manual ................................................................................... 7
101.26 Holidays ................................................................................................... 7
101.27 Invitation for Bids .................................................................................... 7
101.28 Itemized Proposal .................................................................................... 7
101.29 Laboratory ............................................................................................... 7
101.30 Major and Minor Contract Items ............................................................. 7
101.31 Materials .................................................................................................. 8
101.32 Notice to Proceed..................................................................................... 8
101.33 Open to Unrestricted Traffic .................................................................... 8
101.34 Pavement Structure .................................................................................. 8
101.35 Performance Bond ................................................................................... 8
101.36 Plans ........................................................................................................ 8
101.37 Professional Engineer .............................................................................. 8

viii
 TABLE OF CONTENTS
Section Title Page

101.38 Profile Grade............................................................................................ 8

101.39 Project ...................................................................................................... 8
101.40 Proposal ................................................................................................... 9
101.41 Proposal Book.......................................................................................... 9
101.42 Quality Assurances Adjustments ............................................................. 9
101.43 Reasonably Close Conformance .............................................................. 9
101.44 Recurring Special Provisions ................................................................... 9
101.45 Right-of-Way ........................................................................................... 9
101.46 Road ......................................................................................................... 9
101.47 Roadbed ................................................................................................... 9
101.48 Roadside ................................................................................................ 10
101.49 Roadside Development .......................................................................... 10
101.50 Roadway ................................................................................................ 10
101.51 Schedule of Pay Items ........................................................................... 10
101.52 Shoulder ................................................................................................. 10
101.53 Sidewalk ................................................................................................ 10
101.54 Special Provisions.................................................................................. 10
101.55 Specifications......................................................................................... 10
101.56 Specified Completion Date .................................................................... 10
101.57 State ....................................................................................................... 10
101.58 Street ...................................................................................................... 10
101.59 Structures ............................................................................................... 11
101.60 Substantial Completion .......................................................................... 11
101.61 Subcontractor ......................................................................................... 11
101.62 Subgrade ................................................................................................ 11
101.63 Substructure ........................................................................................... 11
101.64 Superintendent ....................................................................................... 11
101.65 Superstructure ........................................................................................ 11
101.66 Surety ..................................................................................................... 11
101.67 Technician or Inspector ......................................................................... 11
101.68 Titles (Headings) ................................................................................... 12
101.69 Township, Town, City ........................................................................... 12
101.70 Traveled Way ........................................................................................ 12
101.71 Unique Special Provisions ..................................................................... 12
101.72 Work ...................................................................................................... 12
101.73 Work Day .............................................................................................. 12
101.74 Working Drawings................................................................................. 12
SECTION 102 – BIDDING REQUIREMENTS AND CONDITIONS .............. 13
102.01 Prequalification and Bidding ................................................................. 13
102.02 Certification Regarding Lobbying for Contracts, Grants,
Loans, and Cooperative Agreements ..................................................... 13

ix
 TABLE OF CONTENTS
Section Title Page

SECTION 103 – AWARD AND EXECUTION OF CONTRACT ..................... 13

103.01 Disadvantaged Business Enterprise Program ........................................ 13
(a) General Requirements ........................................................................... 13
(b) Definitions ............................................................................................ 14
(c) Goal ....................................................................................................... 15
(d) Affirmative Actions .............................................................................. 17
(e) Determination of Good Faith Efforts .................................................... 18
(f) Affirmative Action Certification ........................................................... 22
(g) Subcontracts .......................................................................................... 23
(h) Leases and Rentals ................................................................................ 23
(i) Records and Reports .............................................................................. 24
103.02 Specific Equal Employment Opportunity Responsibilities.................... 25
103.02.1 Record Keeping .................................................................................. 25
103.03 Blank...................................................................................................... 25
103.04 Insurance................................................................................................ 25
(a) Worker’s Compensation and Employer’s Liability............................... 26
(b) Commercial General Liability .............................................................. 26
(c) Business Automobile Liability .............................................................. 27
(d) Railroad’s Protective Liability .............................................................. 27
(e) Owner’s and Contractor’s Protective Liability Insurance
Coverage for Operations of Designated Contractor .............................. 27
(f) Basis of Payment ................................................................................... 28
103.05 Waiver of Damages ............................................................................... 28
103.06 Wage and Labor Requirements.............................................................. 28
(a) Non-discrimination of Employees ........................................................ 28
(b) Affidavits and Payrolls ......................................................................... 29
(c) Wage Stipulations ................................................................................. 29
103.07 Accident Prevention and Safety ............................................................. 30
SECTION 104 – SCOPE OF WORK.................................................................... 30
104.01 Intent of Contract ................................................................................... 30
104.02 Changed Conditions............................................................................... 31
(a) Differing Site Conditions ...................................................................... 31
(b) Suspensions of Work Ordered by the Engineer .................................... 32
(c) Significant Changes in the Character of Work...................................... 33
(d) Pre-established Remedies to Changed Conditions ................................ 33
104.03 Extra Work ............................................................................................ 36
104.04 Maintenance of Traffic .......................................................................... 36
(a) Special Detours ..................................................................................... 37
(b) Maintenance Directed by the Engineer ................................................. 37
(c) Blank ..................................................................................................... 38
(d) Traffic Control for Patching on a Two-Lane Roadway ........................ 38
104.05 Removal and Disposal of Structures and Obstructions .......................... 38
104.06 Removal and Disposal of Regulated Materials ...................................... 39

x
 TABLE OF CONTENTS
Section Title Page

(a) For Such Materials which are Identified in the Proposal

Book as Being Present on the Project Site ............................................ 40
(b) For Such Materials which are not Identified in the Proposal
Book as Being Present on the Project Site ............................................ 40
104.07 Rights in and Use of Materials Found in the Project Site ...................... 43
104.08 Final Clean-Up ...................................................................................... 43
SECTION 105 – CONTROL OF WORK ............................................................. 44
105.01 Authority of the Engineer ...................................................................... 44
105.02 Plans and Working Drawings ................................................................ 44
105.03 Conformance with Plans and Specifications.......................................... 45
105.04 Coordination of Plans, Standard Specifications, and Special
Provisions .............................................................................................. 46
105.05 Cooperation by Contractor .................................................................... 47
105.06 Cooperation with Utilities...................................................................... 47
105.07 Cooperation Between Contractors ......................................................... 48
105.08 Construction Stakes, Lines, and Grades ................................................ 48
(a) Construction Engineering by the State .................................................. 48
(b) Construction Engineering by the Contractor......................................... 49
(c) Production Staking by the Contractor ................................................... 52
105.09 Duties of Technician and Inspector ....................................................... 53
105.10 Inspection of Work ................................................................................ 53
105.11 Removal of Unacceptable and Unauthorized Work .............................. 54
105.12 Load Restrictions ................................................................................... 54
105.13 Maintenance During Construction ......................................................... 55
105.14 Failure to Maintain Roadway, Structures, Barricades, and
Construction Signs ................................................................................. 55
105.15 Acceptance and Final Inspection ........................................................... 56
(a) Partial Acceptance................................................................................. 56
(b) Final Acceptance................................................................................... 56
105.16 Notice of Changed Conditions and Claims ............................................ 57
(a) Contractual Notice of a Changed Condition ......................................... 57
(b) Claims ................................................................................................... 57
(c) Claim Resolution Process ..................................................................... 59
SECTION 106 – CONTROL OF MATERIAL .................................................... 62
106.01 Source of Supply and Quality Requirements ......................................... 62
(a) Approved or Prequalified Materials ...................................................... 62
(b) Material Records ................................................................................... 63
(c) Buy America Requirement .................................................................... 64
106.02 Samples, Tests, Cited Specifications ..................................................... 64
106.03 Plant Inspection ..................................................................................... 65
106.04 Blank...................................................................................................... 66
106.05 Storage of Materials............................................................................... 66

xi
 TABLE OF CONTENTS
Section Title Page

106.06 Handling of Materials ............................................................................ 66

106.07 Unacceptable Materials ......................................................................... 66
106.08 Hazard Communication Program .......................................................... 66
106.09 Department Furnished Materials ........................................................... 67
106.10 Proportioning Materials ......................................................................... 67
106.11 Sample Asbestos Exclusion Letter ........................................................ 67
SECTION 107 – LEGAL RELATIONS AND RESPONSIBILITY
TO PUBLIC ........................................................................................................... 67
107.01 Laws to be Observed ............................................................................. 67
107.02 Permits, Licenses, and Taxes ................................................................. 69
107.03 Patented Devices, Materials, and Processes .......................................... 69
107.04 Restoration of Surfaces Opened by Permit ............................................ 70
107.05 Federal Aid Provisions .......................................................................... 70
107.06 Equal Employment Opportunity Trainees ............................................. 70
107.07 Sanitary Conditions Requirements ........................................................ 72
107.08 Public Convenience and Safety ............................................................. 72
(a) Worker Safety ....................................................................................... 72
(b) Dust and Air Pollution .......................................................................... 73
(c) Protection to Traffic .............................................................................. 73
(d) Notice to Local Public Officials ........................................................... 73
(e) Convenience to Traffic and Property Owners ....................................... 74
107.09 Railroad-Highway Requirements .......................................................... 74
(a) Protection of Track Ballast.................................................................... 75
(b) Hold Harmless Clause .......................................................................... 75
107.10 Archaeological Artifacts ........................................................................ 75
107.11 Bridges over Navigable Waters ............................................................. 76
107.12 Traffic Control Devices ......................................................................... 76
107.13 Use of Explosives .................................................................................. 77
107.14 Protection and Restoration of Property and Landscape ......................... 78
107.15 Erosion Control Plan and Proof of Publication...................................... 79
107.16 Forest Protection .................................................................................... 79
107.17 Responsibility for Damage Claims ........................................................ 79
107.18 Opening Sections of Project to Traffic .................................................. 80
107.19 Contractor’s Responsibility for Work.................................................... 81
107.20 Contractor’s Responsibility for Utility Property and
Services ................................................................................................. 82
107.21 Furnishing Right-of-Way....................................................................... 83
107.22 Personal Liability of Public Officials .................................................... 83
107.23 Waiver of Legal Rights .......................................................................... 83
107.24 Governing Law ...................................................................................... 84
107.25 Severability ............................................................................................ 84

xii
 TABLE OF CONTENTS
Section Title Page

SECTION 108 – PROSECUTION AND PROGRESS ........................................ 84

108.01 Subletting of Contract ............................................................................ 84
108.02 Release of Retainage to Subcontractors ................................................. 85
108.03 Notice to Proceed................................................................................... 85
108.04 Prosecution of the Work ........................................................................ 85
108.05 Pre-phase Site Construction Meetings ................................................... 88
108.06 Limitation of Operations........................................................................ 88
108.07 Character of Workers, Methods, and Equipment ................................... 88
108.08 Determination and Extension of Contract Time .................................... 90
(a) Excusable, Non-Compensable Delays .................................................. 94
(b) Excusable, Compensable Delays .......................................................... 95
(c) Non-Excusable Delays .......................................................................... 96
(d) Concurrent Delays ................................................................................ 96
108.09 Failure to Complete on Time ................................................................. 96
108.10 Default and Termination of Contract ..................................................... 97
108.11 Termination of Contractor’s Responsibility .......................................... 98
108.12 Contract Documentation ........................................................................ 99
SECTION 109 – MEASUREMENT AND PAYMENT ....................................... 99
109.01 Measurement of Quantities .................................................................... 99
(a) General Requirements ........................................................................... 99
(b) Scales and Measurement by Weight (Mass) ........................................101
(c) Measurement by Volume .....................................................................102
(d) Measurement of Asphalt Materials ......................................................103
(e) Measurement of PCC ...........................................................................103
(f) Measurement of Aggregates .................................................................104
(g) Measurement of Timber or Lumber .....................................................105
(h) Rental of Equipment ............................................................................105
(i) Manufactured Materials ........................................................................105
109.02 Scope of Payment .................................................................................105
109.03 Compensation for Altered Quantities ...................................................106
109.04 Cost Reduction Incentive, CRI .............................................................106
(a) CRI Initial Requirements .....................................................................107
(b) CRI Formal Proposal Requirements ....................................................108
(c) Approval of Formal CRI Proposal .......................................................110
(d) Payment for Design of Formal Proposal, if Rejected...........................111
(e) Other Conditions ..................................................................................111
(f) Time Savings Proposals .......................................................................112
(g) Adjustments to Contract Time .............................................................112
(h) Method of Measurement ......................................................................112
(i) Basis of Payment ..................................................................................112
109.05 Payment for Extra Work .......................................................................114
(a) Agreed Price.........................................................................................114
(b) Force Account ......................................................................................114

xiii
 TABLE OF CONTENTS
Section Title Page

109.05.1 Quality Adjustments ..........................................................................117

(a) HMA ....................................................................................................117
(b) PCCP ...................................................................................................117
(c) Temporary Traffic Control Devices, TTCD.........................................117
(d) Failed Materials, FM............................................................................118
(e) Pavement Traffic Markings, PTM .......................................................118
(f) Stormwater Management ......................................................................118
109.05.2 Delay Costs ........................................................................................118
(a) Allowable Delay Costs.........................................................................118
(b) Blank ....................................................................................................120
109.05.3 PG Asphalt Binder Material Cost Adjustments .................................120
109.06 Eliminated Pay Items ............................................................................122
109.07 Partial Payments ...................................................................................122
109.08 Final Payment .......................................................................................123
SECTION 110 – MOBILIZATION AND DEMOBILIZATION ......................123
110.01 Description............................................................................................123
110.02 Limitations ............................................................................................123
110.03 Method of Measurement .......................................................................124
110.04 Basis of Payment ..................................................................................124
SECTION 111 – STOCKPILED MATERIALS .................................................124
111.01 Description............................................................................................124
111.02 General Requirements ..........................................................................124
111.03 Structural Steel and Concrete Structural Members ...............................125
(a) Delivered to the Job Site ......................................................................125
(b) Acceptably Stored at the Fabricator’s or Manufacturer’s
Storage Facilities ..................................................................................125
111.04 Dowel Bar Assemblies .........................................................................125
111.05 Granular Base, Subbase Materials, and Aggregates for
HMA and Concrete Pavements ............................................................125
111.06 Bridge Expansion Joints .......................................................................126
(a) Type SS ................................................................................................126
(b) Type M.................................................................................................126
111.07 Structural Supports for Signals, Signs, and Luminaires .......................126
111.08 Precast Concrete Median Barrier ..........................................................126
111.09 Concrete Face Panels and Ground Reinforcement for MSE
Walls .....................................................................................................126
111.10 Additional Requirements ......................................................................127
111.11 Method of Measurement .......................................................................127
111.12 Basis of Payment ..................................................................................127

xiv
 TABLE OF CONTENTS
Section Title Page

SECTION 112 – BLANK

SECTION 113 – PARTNERING OVERHEAD ..................................................128
113.01 Description............................................................................................128
113.02 Requirements ........................................................................................128
(a) Meeting Room .....................................................................................128
(b) Meeting Length ....................................................................................128
(c) Facilitator .............................................................................................128
113.03 Method of Measurement .......................................................................129
113.04 Basis of Payment ..................................................................................129

DIVISION 200 – EARTHWORK

SECTION 201 – CLEARING AND GRUBBING ...............................................131

201.01 Description............................................................................................131
201.02 General .................................................................................................131
201.03 Clearing and Grubbing .........................................................................131
201.04 Scalping ................................................................................................132
201.05 Hedge Removal ....................................................................................132
201.06 Method of Measurement .......................................................................132
(a) Area Basis ............................................................................................132
(b) Lump Sum Basis ..................................................................................132
(c) Individual Unit Basis ...........................................................................132
201.07 Basis of Payment ..................................................................................133
(a) Area Basis ............................................................................................133
(b) Lump Sum Basis ..................................................................................133
(c) Individual Unit Basis ...........................................................................133
(d) Clearing Right-of-Way ........................................................................134
(e) Exclusions ............................................................................................134
SECTION 202 – REMOVAL OF STRUCTURES AND
OBSTRUCTIONS.................................................................................................134
202.01 Description............................................................................................134
202.02 General Requirements ..........................................................................134
(a) Type Y Waste ......................................................................................136
(b) Type Z Waste .......................................................................................136
202.03 Removal of Bridges, Culverts, and Other Drainage
Structures ..............................................................................................136
(a) Complete ..............................................................................................136
(b) Portions ................................................................................................137
(c) Disposal of Concrete ............................................................................138
202.04 Removal of Pipe and Tile Drains ..........................................................138

xv
 TABLE OF CONTENTS
Section Title Page

202.05 Removal of PCCP, Sidewalks, Curbs, RCBA, and

Reinforced Concrete Moment Slabs .....................................................138
202.06 Removal of Houses and Buildings........................................................139
202.07 Inspection and Removal of Asbestos ....................................................140
202.08 Removal of Underground Storage Tanks Containing
Petroleum Products or Other Hazardous Chemicals .............................140
(a) Type A Waste ......................................................................................143
(b) Type B Waste ......................................................................................143
(c) Type C Waste .......................................................................................143
202.09 Remediation of Contaminated Soil and Groundwater ..........................143
202.10 Remediation of Other Regulated Materials ..........................................144
202.11 Transportation and Disposal of Regulated Materials ............................144
202.12 Blank.....................................................................................................145
202.13 Method of Measurement .......................................................................145
202.14 Basis of Payment ..................................................................................145
SECTION 203 – EXCAVATION AND EMBANKMENT .................................150
203.01 Description............................................................................................150
203.02 Common Excavation ............................................................................151
203.03 Rock Excavation ...................................................................................151
203.04 Unclassified Excavation .......................................................................151
203.05 Peat Excavation ....................................................................................151
203.06 Waterway Excavation ...........................................................................151
203.07 Class Y Excavation ...............................................................................151
203.08 Borrow or Disposal ...............................................................................152
(a) Borrow and Disposal Site Requirements .............................................152
(b) Additional Requirements .....................................................................156
203.08.1 Linear Grading ...................................................................................157
203.08.2 Coal Ash ............................................................................................157
203.09 General Requirements ..........................................................................158
203.10 Disposal of Excavated Material except Waterway and Peat
Excavation ............................................................................................160
203.11 Disposal of Waterway Excavation ........................................................161
203.12 Disposal of Peat ....................................................................................161
203.13 Slides ....................................................................................................161
203.14 Drainage................................................................................................161
203.15 Excavating Rock ...................................................................................162
203.16 Peat Deposit Treatment.........................................................................165
(a) Treatment of Existing Fills...................................................................165
(b) Treatment by Removal.........................................................................165
(c) Treatment by Displacement .................................................................166
203.17 Cased Test Holes ..................................................................................167
203.18 Embankment Construction ...................................................................167
203.19 Embankment Over and Around Structures ...........................................168

xvi
 TABLE OF CONTENTS
Section Title Page

203.20 Rock and Shale Embankment ...............................................................168

(a) Rock Embankment ...............................................................................168
(b) Shale, Shale and Soft Rock Mixtures, or Soft Rock ............................169
(c) Shale and Thinly Layered Limestone...................................................170
203.21 Embankment on Hillsides or Slopes .....................................................170
203.22 Embankment Over Existing Roadbeds .................................................171
203.23 Embankment other than Rock, with Strength or Density
Control ..................................................................................................172
203.23.1 Coal Ash Embankment ......................................................................174
203.24 Method of Making Strength, Stiffness and Density Tests ....................176
(a) Laboratory ............................................................................................176
(b) Field .....................................................................................................176
203.25 Embankment Without Stiffness Control ...............................................178
203.26 Proofrolling...........................................................................................179
203.27 Method of Measurement .......................................................................179
(a) Contract Quantity .................................................................................179
(b) Measured Quantities ............................................................................180
(c) Measurement on a Linear Basis ...........................................................180
(d) Measurement of Excavation Items on a Weight Basis .........................181
(e) Measurement of Embankments ............................................................181
(f) Measurement of Borrow .......................................................................181
(g) Measurement of Embankment Foundation Soils Treatment ................182
(h) Measurement of Water for Shale, Shale and Soft Rock
Mixtures, or Soft Rock .........................................................................182
(i) Lump Sum ............................................................................................182
(j) Measurement of Exploratory Cores ......................................................182
(k) Measurement of Coal Ash ...................................................................182
203.28 Basis of Payment ..................................................................................182
SECTION 204 – GEOTECHNICAL INSTRUMENTATION...........................186
204.01 Description............................................................................................186
204.02 Materials ...............................................................................................186
204.03 Settlement Plates...................................................................................187
(a) Installation Requirements.....................................................................187
(b) Instrument Readings and Settlement Period ........................................187
204.04 Standpipe Piezometers ..........................................................................188
(a) Installation Requirements.....................................................................188
(b) Readings and Maintenance of Piezometer ...........................................190
204.05 Method of Measurement .......................................................................190
204.06 Basis of Payment ..................................................................................190
SECTION 205 – STORMWATER MANAGEMENT ........................................191
205.01 Description............................................................................................191
205.02 Materials ...............................................................................................191

xvii
 TABLE OF CONTENTS
Section Title Page

205.03 General Requirements ..........................................................................191

(a) Stormwater Quality Control Plan Development ..................................192
(b) Stormwater Quality Manager ...............................................................193
(c) Stormwater Quality Control Plan Content ...........................................194
(d) Temporary Stormwater Management Features ....................................195
(e) Permanent Stormwater Management Features .....................................196
205.04 Temporary Surface Stabilization ..........................................................196
(a) Seed ......................................................................................................196
(b) Mulch ...................................................................................................197
(c) Manufactured Surface Protection Products ..........................................198
205.05 Concentrated Flow Protection ..............................................................199
(a) Check Dam...........................................................................................199
(b) Check Dam, Traversable......................................................................200
(c) Diversion Interceptors ..........................................................................200
(d) Sediment Traps ....................................................................................200
(e) Sediment Basins ...................................................................................200
(f) Slope Drains .........................................................................................200
(g) Vegetative Filter Strips ........................................................................200
(h) Splashpads ...........................................................................................200
(i) Inlet Protection .....................................................................................200
205.06 Perimeter Protection .............................................................................201
(a) Silt Fence .............................................................................................201
(b) Filter Berm ...........................................................................................201
205.07 Maintenance..........................................................................................201
(a) Silt Fence .............................................................................................201
(b) Sediment Basin ....................................................................................201
(c) Filter Berm ...........................................................................................201
(d) Inlet Protection.....................................................................................202
(e) Sediment Traps ....................................................................................202
(f) Concrete Washout ................................................................................202
(g) Check Dams .........................................................................................202
205.08 Quality Adjustments .............................................................................202
205.09 Removal ................................................................................................203
205.10 Method of Measurement .......................................................................203
205.11 Basis of Payment ..................................................................................204
SECTION 206 – STRUCTURE EXCAVATION ................................................208
206.01 Description............................................................................................208
206.02 Class X Excavation ...............................................................................208
(a) General Excavation ..............................................................................208
(b) Excavation for Foundation of Traffic Support Structures ....................209
206.03 Wet Excavation.....................................................................................209
206.04 Dry Excavation .....................................................................................209
206.05 Foundation Excavation, Unclassified ...................................................209

xviii
 TABLE OF CONTENTS
Section Title Page

206.06 General Requirements ..........................................................................210

206.07 Disposal of Excavated Material ............................................................210
206.08 Preparation of Foundation Surfaces ......................................................211
206.09 Cofferdams and Temporary Construction Dikes ..................................212
206.10 Method of Measurement .......................................................................213
206.11 Basis of Payment ..................................................................................213
(a) Culverts ................................................................................................216
(b) Bridges .................................................................................................216
(c) Traffic Structure Supports ....................................................................218
SECTION 207 – SUBGRADE ..............................................................................218
207.01 Description............................................................................................218
207.02 Materials ...............................................................................................218
207.03 Construction Requirements...................................................................219
(a) Subgrade Construction Methods ..........................................................219
(b) General Requirements..........................................................................219
207.04 Subgrade Treatment Types ...................................................................219
207.05 Method of Measurement .......................................................................221
207.06 Basis of Payment ..................................................................................221
SECTION 208 – FINISHING SHOULDERS, DITCHES,
AND SLOPES .......................................................................................................221
208.01 Description............................................................................................221
208.02 Finishing Shoulders ..............................................................................222
208.03 Finishing Ditches ..................................................................................222
208.04 Finishing Slopes ...................................................................................222
208.05 Blank.....................................................................................................222
208.06 Finishing at Contract Drainage Structures ............................................222
208.07 Method of Measurement .......................................................................223
208.08 Basis of Payment ..................................................................................223
SECTION 209 – FINISHING EARTH GRADED ROADS ...............................223
209.01 Description............................................................................................223
209.02 Construction Requirements...................................................................223
209.03 Method of Measurement .......................................................................223
209.04 Basis of Payment ..................................................................................223
SECTION 210 – FINAL TRIMMING AND CLEANING .................................223
210.01 Description............................................................................................223
210.02 Construction Requirements...................................................................224
210.03 Method of Measurement .......................................................................224
210.04 Basis of Payment ..................................................................................224
SECTION 211 – B BORROW AND STRUCTURE BACKFILL .....................225
211.01 Description............................................................................................225

xix
 TABLE OF CONTENTS
Section Title Page

211.02 Materials ...............................................................................................225

211.03 General Requirements ..........................................................................226
211.03.1 Structure Backfill Types ....................................................................226
(a) Type 1 ..................................................................................................227
(b) Type 2 ..................................................................................................227
(c) Type 3 ..................................................................................................227
(d) Type 4 ..................................................................................................228
(e) Type 5 ..................................................................................................228
211.04 Compaction...........................................................................................228
211.05 Embankment for Bridges ......................................................................228
211.06 B Borrow Around Bents .......................................................................229
211.07 Blank.....................................................................................................229
211.08 Spandrel Filling ....................................................................................229
211.09 Method of Measurement .......................................................................229
211.10 Basis of Payment ..................................................................................230
SECTION 212 – STOCKPILED SELECTED MATERIALS ...........................231
212.01 Description............................................................................................231
212.02 Materials ...............................................................................................231
212.03 Construction Requirements...................................................................231
212.04 Method of Measurement .......................................................................231
212.05 Basis of Payment ..................................................................................232
SECTION 213 – FLOWABLE BACKFILL ........................................................232
213.01 Description............................................................................................232
213.02 Materials ...............................................................................................232
213.03 Flowable Backfill Mix Design ..............................................................232
213.04 Flowable Backfill Mix Criteria .............................................................233
(a) Flow Consistency .................................................................................233
(b) Lightweight Dynamic Cone Penetration Blow Count
Number .................................................................................................233
(c) Removability Modulus .........................................................................233
213.05 Flowable Backfill Trial Batch...............................................................234
213.06 Mixing Equipment ................................................................................234
213.07 Placement .............................................................................................234
213.08 Method of Measurement .......................................................................235
213.09 Basis of Payment ..................................................................................235
SECTION 214 – GEOSYNTHETICS ..................................................................236
214.01 Description............................................................................................236
214.02 Materials ...............................................................................................236
214.03 Foundation Preparation .........................................................................236
(a) Geotextile as a Drainage Blanket .........................................................236
(b) Geotextile Placement for Pavement, Subgrade, or

xx
 TABLE OF CONTENTS
Section Title Page

Embankment ........................................................................................237
(c) Geogrid Placement in Embankment and Subgrade ..............................237
(d) Geocell Confining System ...................................................................238
214.04 Fill Placement .......................................................................................238
214.05 Method of Measurement .......................................................................238
214.06 Basis of Payment ..................................................................................239
SECTION 215 – CHEMICAL MODIFICATION OF SOILS ...........................239
215.01 Description............................................................................................239
215.02 Materials ...............................................................................................239
215.03 Testing and Mix Design........................................................................240
215.04 Storage and Handling ...........................................................................240
215.05 Weather Limitations .............................................................................240
215.06 Preparation of Soils...............................................................................241
215.07 Spreading of Chemical Modifiers .........................................................241
215.08 Mixing ..................................................................................................241
215.09 Compaction...........................................................................................241
215.10 Curing ...................................................................................................242
215.11 Method of Measurement .......................................................................242
215.12 Basis of Payment ..................................................................................242
SECTION 216 – CELLULAR CONCRETE FILL, CCF ..................................243
216.01 Description............................................................................................243
216.02 Materials ...............................................................................................243
216.03 Mix Design ...........................................................................................244
216.04 Properties and Tests ..............................................................................244
(a) CCF Cast Density.................................................................................244
(b) Foam Density .......................................................................................244
216.05 Storage and Handling ...........................................................................244
216.06 Weather Limitations .............................................................................245
216.07 Preparation of Subgrade .......................................................................245
216.08 Installation ............................................................................................245
216.09 Lots .......................................................................................................245
216.10 Testing ..................................................................................................245
216.11 Method of Measurement .......................................................................245
216.12 Basis of Payment ..................................................................................245
SECTION 217 – SOILS DRYING WITH CHEMICAL MODIFIERS ............246
217.01 Description............................................................................................246
217.02 Materials ...............................................................................................246
217.03 Testing and Mix Design........................................................................246
217.04 Storage and Handling ...........................................................................247
217.05 Weather Limitations .............................................................................247
217.06 Preparation of Soils...............................................................................247

xxi
 TABLE OF CONTENTS
Section Title Page

217.07 Spreading of Chemical Modifiers .........................................................247

217.08 Mixing ..................................................................................................247
217.09 Compaction...........................................................................................247
217.10 Method of Measurement .......................................................................248
217.11 Basis of Payment ..................................................................................248

DIVISION 300 – AGGREGATE PAVEMENT AND BASES

SECTION 301 – AGGREGATE BASE ...............................................................249

301.01 Description............................................................................................249
301.02 Materials ...............................................................................................249
301.03 Preparation of Subgrade .......................................................................249
301.04 Temperature Limitations ......................................................................249
301.05 Spreading ..............................................................................................249
301.06 Compacting...........................................................................................249
301.07 Checking and Correcting Base .............................................................250
301.08 Priming .................................................................................................250
301.09 Method of Measurement .......................................................................250
301.10 Basis of Payment ..................................................................................251
SECTION 302 – SUBBASE ..................................................................................251
302.01 Description............................................................................................251
302.02 Materials ...............................................................................................251
302.03 Preparation of Subgrade .......................................................................252
302.04 Temperature Limitations ......................................................................252
302.05 Spreading ..............................................................................................252
302.06 Compacting...........................................................................................252
(a) Aggregate Separation Layers and Dense Graded Subbase ...................252
(b) Aggregate Drainage Layers .................................................................252
302.07 Checking and Correcting Subbase ........................................................253
302.08 Method of Measurement .......................................................................253
302.09 Basis of Payment ..................................................................................253
SECTION 303 – AGGREGATE PAVEMENTS OR SHOULDERS ................253
303.01 Description............................................................................................253
303.02 Materials ...............................................................................................253
303.03 Preparation of Subgrade .......................................................................254
303.04 Temperature Limitations ......................................................................254
303.05 Spreading ..............................................................................................254
303.06 Compacting...........................................................................................254
303.07 Checking and Correcting Base and Surface..........................................254
303.08 Dust Palliative.......................................................................................254
303.09 Method of Measurement .......................................................................254

xxii
 TABLE OF CONTENTS
Section Title Page

303.10 Basis of Payment ..................................................................................254

SECTION 304 – ASPHALT BASES ....................................................................255
304.01 Description............................................................................................255
304.02 Materials ...............................................................................................255
304.03 Sealing Cracks and Joints .....................................................................255
304.04 Patching ................................................................................................255
304.05 Widening ..............................................................................................256
304.06 Method of Measurement .......................................................................256
304.07 Basis of Payment ..................................................................................257
SECTION 305 – CONCRETE BASES ................................................................257
305.01 Description............................................................................................257
305.02 Materials ...............................................................................................257
305.03 New PCC Base .....................................................................................258
305.04 Existing PCCP ......................................................................................258
(a) Patching................................................................................................258
(b) Surface Milling ....................................................................................258
(c) Retrofit Load Transfer .........................................................................258
(d) Rubblizing Existing PCCP ...................................................................258
305.05 Widening With PCC Base ....................................................................260
305.06 Method of Measurement .......................................................................260
305.07 Basis of Payment ..................................................................................261
SECTION 306 – MILLING ..................................................................................262
306.01 Description............................................................................................262
306.02 General .................................................................................................262
306.03 Equipment .............................................................................................262
(a) Roadway Milling Machine ...................................................................262
(b) Power Saw ...........................................................................................263
(c) Rotary Power Broom ...........................................................................263
(d) Straightedge .........................................................................................263
306.04 Asphalt or PCCP Scarification Milling.................................................263
306.05 Asphalt or PCCP Profile Milling to Correct Cross-Slope .....................264
306.06 Approach Milling .................................................................................265
306.07 Asphalt or PCCP Milling to a Specified Average Depth ......................265
306.08 Asphalt Overlay Removal.....................................................................266
306.09 Transition Milling .................................................................................266
306.10 Method of Measurement .......................................................................267
306.11 Basis of Payment ..................................................................................267
SECTION 307 – CEMENT STABILIZED FULL DEPTH
RECLAMATION, FDR .......................................................................................268
307.01 Description............................................................................................268
307.02 Just-in-Time Training, JITT .................................................................268

xxiii
 TABLE OF CONTENTS
Section Title Page

307.03 Quality Control .....................................................................................268

307.04 Materials ...............................................................................................269
307.05 Mix Design ...........................................................................................269
307.06 Roadway Preparation ............................................................................270
307.07 Equipment .............................................................................................270
(a) Spreaders and Distributors ...................................................................270
(b) Additive Slurry Storage and Supply Equipment ..................................271
(c) Mixing and Reclaiming Equipment .....................................................271
(d) Motor Grader .......................................................................................271
(e) Compaction Equipment........................................................................271
(f) Water Trucks ........................................................................................271
307.08 Weather Limitations .............................................................................272
307.09 Pulverization .........................................................................................272
307.10 Stabilization ..........................................................................................272
307.11 Control Strip and Compaction ..............................................................273
307.12 Opening to Traffic ................................................................................274
307.13 Maintenance..........................................................................................274
307.14 Curing ...................................................................................................275
307.15 Proofrolling...........................................................................................275
307.16 Milling ..................................................................................................275
307.17 Underdrain Installation .........................................................................275
307.18 RBC Overlay ........................................................................................275
307.19 Method of Measurement .......................................................................276
307.20 Basis of Payment ..................................................................................276
SECTION 308 – ASPHALT EMULSION STABILIZED FULL
DEPTH RECLAMATION, FDR.........................................................................277
308.01 Description............................................................................................277
308.02 Just in Time Training, JITT ..................................................................277
308.03 Quality Control .....................................................................................277
308.04 Materials ...............................................................................................278
308.05 Mix Design ...........................................................................................278
308.06 Roadway Preparation ............................................................................279
308.07 Equipment .............................................................................................279
(a) Spreaders and Distributors ...................................................................279
(b) Additive Slurry Storage and Supply Equipment ..................................280
(c) Mixing and Reclaiming Equipment .....................................................280
(d) Motor Grader .......................................................................................280
(e) Compaction Equipment........................................................................280
(f) Water Trucks ........................................................................................280
308.08 Weather Limitations .............................................................................281
308.09 Pulverization .........................................................................................281
308.10 Injection ................................................................................................281
308.11 Control Strip and Compaction ..............................................................282

xxiv
 TABLE OF CONTENTS
Section Title Page

308.12 Opening to Traffic ................................................................................283

308.13 Maintenance..........................................................................................284
308.14 Curing ...................................................................................................284
308.15 Proofrolling...........................................................................................284
308.16 Milling ..................................................................................................284
308.17 Underdrain Installation .........................................................................285
308.18 RBC Overlay ........................................................................................285
308.19 Method of Measurement .......................................................................285
308.20 Basis of Payment ..................................................................................285

DIVISION 400 – ASPHALT PAVEMENTS

SECTION 401 – QC/QA HMA PAVEMENT .....................................................287

401.01 Description............................................................................................287
401.02 Quality Control .....................................................................................287
401.03 Materials ...............................................................................................287
401.04 Design Mix Formula .............................................................................287
401.05 Volumetric Mix Design ........................................................................288
401.06 Recycled Materials ...............................................................................292
401.07 Lots and Sublots ...................................................................................293
401.08 Blank.....................................................................................................293
401.09 Acceptance of Mixtures ........................................................................294
401.10 General .................................................................................................296
401.11 Preparation of Surfaces to be Overlaid .................................................297
401.12 Process Control .....................................................................................297
401.13 Weather Limitations .............................................................................297
401.14 Spreading and Finishing .......................................................................297
401.15 Joints .....................................................................................................298
401.16 Density ..................................................................................................299
401.17 Pavement Corrugations .........................................................................301
401.18 Pavement Smoothness ..........................................................................301
(a) Profilograph .........................................................................................301
(b) 16 ft Straightedge and 10 ft Straightedge.............................................302
(c) Smoothness Correction ........................................................................303
401.19 Pay Factors ...........................................................................................304
(a) Dense Graded Mixture ≥ One Lot ........................................................304
(b) Dense Graded Mixture < One Lot and Open Graded
Mixture .................................................................................................305
(c) Smoothness ..........................................................................................308
401.20 Appeals .................................................................................................309
(a) MSG .....................................................................................................310
(b) BSG of the Gyratory Specimen ...........................................................310

xxv
 TABLE OF CONTENTS
Section Title Page

(c) Binder Content .....................................................................................310

(d) BSG of the Density Core .....................................................................310
401.21 Method of Measurement .......................................................................310
401.22 Basis of Payment ..................................................................................311
SECTION 402 –HMA PAVEMENT ....................................................................312
402.01 Description............................................................................................312
402.02 Quality Control .....................................................................................312
402.03 Materials ...............................................................................................312
402.04 Design Mix Formula .............................................................................313
402.05 Volumetric Mix Design ........................................................................313
402.06 Blank.....................................................................................................314
402.07 Mix Criteria ..........................................................................................314
(a) Composition Limits for HMA Transverse Rumble Strip
Mixtures ...............................................................................................314
(b) Composition Limits for HMA Wedge and Leveling
Mixtures ...............................................................................................314
(c) Composition Limits for Temporary HMA Mixtures ............................314
(d) Composition Limits for HMA Curbing Mixes.....................................314
402.08 Recycled Materials ...............................................................................315
402.09 Acceptance of Mixtures ........................................................................315
402.10 General .................................................................................................315
402.11 Preparation of Surfaces to be Overlaid .................................................315
402.12 Weather Limitations .............................................................................316
402.13 Spreading and Finishing .......................................................................316
402.14 Joints .....................................................................................................317
402.15 Compaction...........................................................................................318
402.16 Low Temperature Compaction Requirements ......................................319
402.17 Pavement Corrugations .........................................................................320
402.18 Pavement Smoothness ..........................................................................320
402.19 Method of Measurement .......................................................................320
402.20 Basis of Payment ..................................................................................320
SECTION 403 – CMA PAVEMENT ...................................................................321
403.01 Description............................................................................................321
403.02 Materials ...............................................................................................321
403.03 Weather Limitations .............................................................................322
403.04 Equipment .............................................................................................322
403.05 Preparation of Mixtures ........................................................................322
403.06 Preparation of Subgrade or Base ..........................................................322
403.07 Spreading Mixture ................................................................................323
403.08 Curing ...................................................................................................323
403.09 Compaction...........................................................................................323
403.10 Surface Tolerances................................................................................323

xxvi
 TABLE OF CONTENTS
Section Title Page

403.11 Method of Measurement .......................................................................323

403.12 Basis of Payment ..................................................................................323
SECTION 404 – SEAL COAT .............................................................................324
404.01 Description............................................................................................324
404.02 Quality Control .....................................................................................324
404.03 Asphalt Material ...................................................................................324
404.04 Cover Aggregate ...................................................................................324
404.05 Weather Limitations .............................................................................325
404.06 Equipment .............................................................................................325
404.07 Preparation of Surface ..........................................................................325
404.08 Applying Asphalt Material ...................................................................326
404.09 Application of Cover Aggregate ...........................................................326
404.10 Rolling Operation .................................................................................326
404.11 Sweeping Operation..............................................................................326
404.12 Protection of Surface ............................................................................326
404.13 Method of Measurement .......................................................................327
404.14 Basis of Payment ..................................................................................327
SECTION 405 – PRIME COAT...........................................................................327
405.01 Description............................................................................................327
405.02 Asphalt Materials ..................................................................................327
405.03 Cover Aggregate ...................................................................................327
405.04 Weather Limitations .............................................................................328
405.05 Equipment .............................................................................................328
405.06 Preparation of Surface ..........................................................................328
405.07 Application of Asphalt Material ...........................................................328
405.08 Cover Aggregate ...................................................................................328
405.09 Method of Measurement .......................................................................328
405.10 Basis of Payment ..................................................................................328
SECTION 406 – TACK COAT ............................................................................329
406.01 Description............................................................................................329
406.02 Materials ...............................................................................................329
406.03 Equipment .............................................................................................329
406.04 Preparation of Surface ..........................................................................329
406.05 Application of Asphalt Material ...........................................................329
406.06 Method of Measurement .......................................................................329
406.07 Basis of Payment ..................................................................................330
SECTION 407 – DUST PALLIATIVE ................................................................330
407.01 Description............................................................................................330
407.02 Asphalt Material ...................................................................................330
407.03 Weather Limitations .............................................................................330
407.04 Equipment .............................................................................................330

xxvii
 TABLE OF CONTENTS
Section Title Page

407.05 Preparation of Surface ..........................................................................330

407.06 Application of Asphalt Material ...........................................................330
407.07 Method of Measurement .......................................................................331
407.08 Basis of Payment ..................................................................................331
SECTION 408 – SEALING OR FILLING CRACKS AND JOINTS ...............331
408.01 Description............................................................................................331
408.02 Materials ...............................................................................................331
408.03 Equipment .............................................................................................331
408.04 Weather Limitations .............................................................................332
408.05 Routing and Sealing Cracks and Joints.................................................332
408.06 Filling Cracks .......................................................................................332
408.07 Method of Measurement .......................................................................332
408.08 Basis of Payment ..................................................................................332
SECTION 409 – EQUIPMENT ............................................................................333
409.01 Production, Transportation, and Laydown of Asphalt
Mixtures................................................................................................333
409.02 Mixing Plant .........................................................................................333
(a) Certified HMA Plant ............................................................................333
(b) CMA Mixing Plant ..............................................................................333
409.03 HMA Laydown Operations ..................................................................333
(a) Distributor ............................................................................................333
(b) Hauling Equipment ..............................................................................333
(c) Laydown Equipment ............................................................................334
(d) Compaction Equipment .......................................................................334
(e) Miscellaneous Equipment ....................................................................335
(f) Smoothness Equipment ........................................................................336
SECTION 410 – QC/QA HMA – SMA PAVEMENT ........................................336
410.01 Description............................................................................................336
410.02 Quality Control .....................................................................................336
410.03 Materials ...............................................................................................336
410.04 Design Mix Formula .............................................................................337
410.05 SMA Mix Design..................................................................................337
410.06 Recycled Materials ...............................................................................339
410.07 Lots and Sublots ...................................................................................339
410.08 Job Mix Formula ..................................................................................340
410.09 Acceptance of Mixtures ........................................................................340
410.10 General .................................................................................................342
410.11 Preparation of Surfaces to be Overlaid .................................................342
410.12 Process Control .....................................................................................343
410.13 Weather Limitations .............................................................................343
410.14 Spreading and Finishing .......................................................................343

xxviii
 TABLE OF CONTENTS
Section Title Page

410.15 Joints .....................................................................................................344

410.16 Density ..................................................................................................344
410.17 Pavement Corrugations .........................................................................345
410.18 Pavement Smoothness ..........................................................................346
410.19 Adjusted Points .....................................................................................346
(a) Mixture.................................................................................................346
(b) Density .................................................................................................348
410.20 Appeals .................................................................................................348
(a) MSG .....................................................................................................348
(b) Binder Content and Gradation .............................................................348
(c) BSG of the Density Core......................................................................348
410.21 Method of Measurement .......................................................................349
410.22 Basis of Payment ..................................................................................349
SECTION 411 – WARRANTED MICRO-SURFACING ..................................350
411.01 Description............................................................................................350
411.02 Materials ...............................................................................................350
411.03 Design Mix Formula .............................................................................351
411.04 Equipment .............................................................................................352
411.05 Pre-Paving Coordination ......................................................................352
411.06 Preparation of Surfaces .........................................................................352
411.07 Opening to Traffic ................................................................................353
411.08 Finished Pavement Properties...............................................................353
411.09 Warranty ...............................................................................................353
411.10 Conflict Resolution Team .....................................................................354
411.11 Warranty Work .....................................................................................354
411.12 Pavement Distress Indicators, Thresholds, and Remedial
Work .....................................................................................................355
411.13 Department Maintenance ......................................................................356
411.14 Method of Measurement .......................................................................356
411.15 Basis of Payment ..................................................................................356
411.16 Final Warranty Acceptance ..................................................................356
SECTION 412 – FOG SEAL ................................................................................357
412.01 Description............................................................................................357
412.02 Materials ...............................................................................................357
412.03 Equipment .............................................................................................357
412.04 Weather Limitations .............................................................................357
412.05 Preparation of Surface ..........................................................................357
412.06 Application of Asphalt Material ...........................................................357
412.07 Protection of Surface ............................................................................357
412.08 Application of Pavement Markings ......................................................358
412.09 Method of Measurement .......................................................................358
412.10 Basis of Payment ..................................................................................358

xxix
 TABLE OF CONTENTS
Section Title Page

SECTION 413 – BLANK

SECTION 414 - ULTRATHIN BONDED WEARING COURSE,
WARRANTED ......................................................................................................358
414.01 Description............................................................................................358
414.02 Materials ...............................................................................................358
(a) Blank ....................................................................................................359
(b) Asphalt Materials .................................................................................359
(c) Coarse Aggregates ...............................................................................359
414.03 Design Mix Formula .............................................................................359
414.04 Mix Design ...........................................................................................359
414.05 Use of Recycled Materials ....................................................................361
414.06 Quality Control .....................................................................................361
414.07 Equipment .............................................................................................361
414.08 Preparation of Surface ..........................................................................362
414.09 Asphalt Emulsion .................................................................................362
414.10 Pre-Paving Meeting ..............................................................................362
414.11 Mixture Placement ................................................................................363
414.12 Mixture Finishing .................................................................................363
414.13 Smoothness ...........................................................................................363
414.14 Warranty ...............................................................................................363
414.15 Conflict Resolution Team .....................................................................364
414.16 Warranty Work .....................................................................................364
414.17 Pavement Distress Indicators, Thresholds and Remedial
Action ...................................................................................................365
414.18 Department Maintenance ......................................................................366
414.19 Method of Measurement .......................................................................366
414.20 Basis of Payment ..................................................................................366
414.21 Final Warranty Acceptance ..................................................................366
SECTION 415 – BASE SEAL...............................................................................366
415.01 Description............................................................................................366
415.02 Materials ...............................................................................................366
415.03 Equipment .............................................................................................367
415.04 Weather Limitations .............................................................................367
415.05 Preparation of Surface ..........................................................................367
415.06 Application of Asphalt Material ...........................................................367
415.07 Protection of Surface ............................................................................367
415.08 Method of Measurement .......................................................................367
415.09 Basis of Payment ..................................................................................367
SECTION 416 - COLD IN-PLACE RECYCLING, CIR ...................................367
416.01 Description............................................................................................367
416.02 Just-in-Time Training, JITT .................................................................368

xxx
 TABLE OF CONTENTS
Section Title Page

416.03 Quality Control .....................................................................................368

416.04 Materials ...............................................................................................368
416.05 Mix Design ...........................................................................................369
416.06 Roadway Preparation ............................................................................369
416.07 Equipment .............................................................................................370
(a) Cold In-Place Recycler Equipment ......................................................370
(b) Spreaders for Dry Cement ...................................................................371
(c) Additive Slurry Storage and Supply Equipment ..................................371
(d) Spreading of Corrective Aggregate......................................................371
(e) Water Truck .........................................................................................372
(f) Laydown Equipment ............................................................................372
(g) Compaction Equipment .......................................................................372
416.08 Weather Limitations .............................................................................372
416.09 Processing and Mixing Operation.........................................................372
416.10 Control Strip and Compaction ..............................................................373
416.11 Opening to Traffic ................................................................................374
416.12 Maintenance..........................................................................................375
416.13 Curing ...................................................................................................375
416.14 Milling ..................................................................................................375
416.15 CIR Surface Course ..............................................................................375
416.16 Method of Measurement .......................................................................375
416.17 Basis of Payment ..................................................................................376
SECTION 417 - COLD CENTRAL PLANT RECYCLING, CCPR ................377
417.01 Description............................................................................................377
417.02 Just-in-Time Training, JITT .................................................................377
417.03 Quality Control .....................................................................................377
417.04 Materials ...............................................................................................378
417.05 Mix Design ...........................................................................................379
417.06 Roadway Preparation ............................................................................379
417.07 Pavement Removal ...............................................................................379
417.08 Equipment .............................................................................................380
(a) Milling Machine/Pavement Cold Planer ..............................................380
(b) Additive Slurry Storage and Supply Equipment ..................................380
(c) Sizing Equipment .................................................................................380
(d) Mixing and Proportioning Equipment .................................................380
(e) Hauling Equipment ..............................................................................381
(f) Laydown Equipment ............................................................................381
(g) Compaction Equipment .......................................................................381
417.09 Weather Limitations .............................................................................381
417.10 Material Sizing and Stockpiling ...........................................................381
417.11 Processing and Mixing Operation.........................................................382
417.12 Placement .............................................................................................382
417.13 Control Strip and Compaction ..............................................................382

xxxi
 TABLE OF CONTENTS
Section Title Page

417.14 Opening to Traffic ................................................................................383

417.15 Maintenance..........................................................................................384
417.16 Curing ...................................................................................................384
417.17 Milling and Pavement Smoothness.......................................................384
417.18 CCPR Surface Course...........................................................................384
417.19 Method of Measurement .......................................................................384
417.20 Basis of Payment ..................................................................................385

DIVISION 500 – CONCRETE PAVEMENT

SECTION 501 – QC/QA PORTLAND CEMENT CONCRETE

PAVEMENT, PCCP .............................................................................................387
501.01 Description............................................................................................387
501.02 Quality Control .....................................................................................387
501.03 Materials ...............................................................................................387
501.04 Concrete Mix Design ............................................................................387
(a) Change in Materials .............................................................................388
(b) Adjustments to Materials .....................................................................388
(c) Other Adjustments ...............................................................................389
501.05 Concrete Mix Criteria ...........................................................................389
501.06 Trial Batch ............................................................................................390
501.07 Lots and Sublots ...................................................................................391
501.08 Acceptance............................................................................................391
501.09 General .................................................................................................391
501.10 Preparation of Grade .............................................................................391
501.11 Preparation of Subbase .........................................................................392
501.12 Placement .............................................................................................392
501.13 Process Control .....................................................................................392
501.14 Concrete Mixing and Transportation ....................................................392
501.15 Weather Limitations .............................................................................393
501.16 Placing Concrete ...................................................................................393
501.17 Blank.....................................................................................................394
501.18 Joints .....................................................................................................394
501.19 Finishing ...............................................................................................394
501.20 Curing ...................................................................................................394
501.21 Form Removal ......................................................................................394
501.22 Pavement Inspection .............................................................................394
501.23 Opening to Traffic ................................................................................394
(a) Construction .........................................................................................394
(b) Non-Construction.................................................................................395
501.24 Pavement Corrugations .........................................................................395
501.25 Pavement Smoothness ..........................................................................395

xxxii
 TABLE OF CONTENTS
Section Title Page

(a) Profilograph .........................................................................................395

(b) 16 ft Straightedge and 10 ft Straightedge.............................................396
(c) Smoothness Correction ........................................................................397
501.26 Pavement Thickness .............................................................................397
501.27 Tolerance ..............................................................................................398
(a) Plastic Unit Weight ..............................................................................398
(b) Water to Cementitious Ratio ................................................................398
(c) Flexural Strength ..................................................................................398
(d) Air Content ..........................................................................................398
501.28 Pay Factors ...........................................................................................398
(a) Flexural Strength ..................................................................................399
(b) Air Content ..........................................................................................400
(c) Thickness .............................................................................................401
(d) Smoothness ..........................................................................................401
501.29 Appeals .................................................................................................402
(a) Flexural Strength ..................................................................................402
(b) Air Content ..........................................................................................403
501.30 Method of Measurement .......................................................................404
501.31 Basis of Payment ..................................................................................404
SECTION 502 – PORTLAND CEMENT CONCRETE
PAVEMENT, PCCP .............................................................................................405
502.01 Description............................................................................................405
502.02 Materials ...............................................................................................405
502.03 Concrete Mix Design ............................................................................405
502.04 Concrete Mix Criteria ...........................................................................406
(a) Portland Cement Concrete ...................................................................406
(b) High-Early Strength Concrete..............................................................407
502.05 Job Control ...........................................................................................407
502.06 General .................................................................................................408
502.07 Preparation of Grade .............................................................................408
502.08 Preparation of Subbase .........................................................................408
502.09 Placement .............................................................................................408
502.10 Concrete Mixing and Transportation ....................................................409
(a) Central Mixed Concrete .......................................................................410
(b) Shrink Mixed Concrete ........................................................................410
(c) Transit Mixed Concrete .......................................................................410
502.11 Weather Limitations .............................................................................410
502.12 Placing Concrete ...................................................................................411
502.13 Joints .....................................................................................................412
502.14 Finishing ...............................................................................................412
502.15 Curing ...................................................................................................412
502.16 Form Removal ......................................................................................412
502.17 Pavement Inspection .............................................................................412

xxxiii
 TABLE OF CONTENTS
Section Title Page

502.18 Opening to Traffic ................................................................................412

(a) Construction .........................................................................................412
(b) Non-Construction.................................................................................412
502.19 Pavement Corrugations .........................................................................412
502.20 Pavement Smoothness ..........................................................................413
502.21 Pavement Thickness .............................................................................413
(a) Sections ................................................................................................413
(b) Average PCCP Thickness ....................................................................414
(c) PCCP Adjusted Payment......................................................................414
(d) PCCP Non-Payment ............................................................................414
(e) PCCP Removal ....................................................................................414
502.22 Method of Measurement .......................................................................415
502.23 Basis of Payment ..................................................................................415
SECTION 503 – PCCP JOINTS ..........................................................................416
503.01 Description............................................................................................416
503.02 Materials ...............................................................................................416
503.03 Joints .....................................................................................................416
(a) Type D-1 Contraction Joint ..................................................................417
(b) Longitudinal Joint ................................................................................417
(c) Transverse Construction Joints ............................................................418
(d) Longitudinal Construction Joint ..........................................................418
(e) Terminal Joints.....................................................................................418
(f) Expansion Joints ...................................................................................419
(g) Retrofitted Tie Bars .............................................................................419
503.04 Dowel Bar Assemblies .........................................................................419
503.05 Sealing Cracks and Joints .....................................................................420
503.06 Random Crack Remediation .................................................................421
(a) Transverse ............................................................................................421
(b) Longitudinal .........................................................................................421
503.07 Method of Measurement .......................................................................421
503.08 Basis of Payment ..................................................................................421
SECTION 504 – PCCP FINISHING AND CURING .........................................422
504.01 Description............................................................................................422
504.02 Materials ...............................................................................................422
504.03 Finishing ...............................................................................................422
504.04 Curing ...................................................................................................423
(a) Liquid Membrane Forming Compounds ..............................................423
(b) Double Burlap ......................................................................................424
(c) Waterproof Covers ...............................................................................424
(d) Straw ....................................................................................................424
504.05 Method of Measurement .......................................................................424
504.06 Basis of Payment ..................................................................................424

xxxiv
 TABLE OF CONTENTS
Section Title Page

SECTION 505 – TESTS AND PROCEDURES ..................................................425

505.01 Test Methods and Procedures ...............................................................425
(a) Exceptions to AASHTO T 23 ..............................................................425
(b) Exceptions to AASHTO T 97 ..............................................................425
(c) Exceptions to AASHTO T 121 ............................................................426
(d) Exceptions to AASHTO R 60 ..............................................................426
(e) Exceptions to AASHTO T 152 ............................................................426
SECTION 506 – PCCP PATCHING ...................................................................426
506.01 Description............................................................................................426
506.02 Materials ...............................................................................................426
506.03 Concrete Mix Design ............................................................................427
(a) Change in Materials .............................................................................427
(b) Adjustments to Materials .....................................................................428
(c) Other Adjustments ...............................................................................428
506.04 Concrete Mix Criteria ...........................................................................429
506.05 Trial Batch ............................................................................................429
506.06 Job Control ...........................................................................................429
506.07 PCCP Removal .....................................................................................430
(a) Partial Depth Removal .........................................................................430
(b) Full Depth Removal .............................................................................430
506.08 Concrete Mixing and Transportation ....................................................431
(a) Central Mixed Concrete .......................................................................431
(b) Shrink Mixed Concrete ........................................................................431
(c) Transit Mixed Concrete .......................................................................431
506.09 Weather Limitations .............................................................................431
506.10 Placing Concrete ...................................................................................431
(a) Partial Depth ........................................................................................432
(b) Full Depth ............................................................................................432
506.11 Opening to Traffic ................................................................................432
506.12 Method of Measurement .......................................................................433
506.13 Basis of Payment ..................................................................................433
SECTION 507 – PCCP RESTORATION ...........................................................434
507.01 Description............................................................................................434
507.02 Materials ...............................................................................................434
507.03 Cracks ...................................................................................................434
(a) Routing, Cleaning and Sealing .............................................................435
(b) Cleaning and Filling.............................................................................435
507.04 Joints .....................................................................................................435
(a) Sawing, Cleaning and Sealing..............................................................435
(b) Cleaning and Filling.............................................................................436
507.05 PCCP Patching .....................................................................................436
(a) Full Depth Patching .............................................................................436

xxxv
 TABLE OF CONTENTS
Section Title Page

(b) Partial Depth Patching .........................................................................436

507.06 Profiling ................................................................................................437
507.07 Undersealing .........................................................................................437
507.08 Retrofit Load Transfer for PCCP ..........................................................437
507.09 Method of Measurement .......................................................................438
507.10 Basis of Payment ..................................................................................438
SECTION 508 – EQUIPMENT ............................................................................439
508.01 Production, Transportation, and Placement of PCC
Mixtures................................................................................................439
508.02 Mixing Plant .........................................................................................439
(a) Plant Inspection ....................................................................................439
(b) Proportioning System ..........................................................................439
(c) Material Storage ...................................................................................440
(d) Hoppers ................................................................................................440
(e) Mixing System .....................................................................................440
508.03 Transportation .......................................................................................441
(a) Truck Mixers and Truck Agitators .......................................................441
(b) Non-Agitator Trucks ............................................................................441
508.04 Placement Equipment ...........................................................................441
(a) Slipform ...............................................................................................441
(b) Form Riding Equipment ......................................................................442
(c) Hand Placement ...................................................................................442
508.05 Curing ...................................................................................................444
508.06 Texturing Equipment ............................................................................444
508.07 Sawing Equipment ................................................................................444
508.08 Miscellaneous Equipment .....................................................................444
(a) Hand Tools ...........................................................................................444
(b) Joint Sealing.........................................................................................444
(c) Grinding ...............................................................................................444
508.09 Testing Facility and Equipment ............................................................445
(a) Testing Facility ....................................................................................445
(b) Testing Equipment ...............................................................................445
(c) Profilograph .........................................................................................445
(d) Straightedge – 16 ft ..............................................................................445
(e) Straightedge – 10 ft ..............................................................................445

DIVISION 600 – INCIDENTAL CONSTRUCTION

SECTION 601 – GUARDRAIL ............................................................................447

601.01 Description............................................................................................447
601.02 Materials ...............................................................................................447
601.03 General Requirements ..........................................................................448

xxxvi
 TABLE OF CONTENTS
Section Title Page

601.04 Guardrail Erection ................................................................................449

601.05 Curved W-Beam Guardrail Systems .....................................................449
601.06 Guardrail Transitions ............................................................................449
601.07 Guardrail End Treatments.....................................................................450
601.08 Impact Attenuators................................................................................451
601.09 Extension of Existing Guardrail ...........................................................451
601.10 Removal of Existing Guardrail .............................................................452
601.11 Adjusting Existing Guardrail Height ....................................................452
601.12 Resetting Guardrail ...............................................................................452
601.13 Method of Measurement .......................................................................452
601.14 Basis of Payment ..................................................................................452
SECTION 602 – CONCRETE BARRIER...........................................................455
602.01 Description............................................................................................455
602.02 Materials ...............................................................................................455
602.03 Concrete Barrier and Concrete Glare Screen ........................................455
(a) Precast Concrete Barrier and Concrete Glare Screen ...........................456
(b) Cast-in-Place Concrete Barrier and Concrete Glare Screen.................456
(c) Finishing ..............................................................................................456
(d) Sealing .................................................................................................456
(e) Joints ....................................................................................................456
(f) Reflectorization ....................................................................................457
602.04 Blank.....................................................................................................457
602.05 Method of Measurement .......................................................................457
602.06 Basis of Payment ..................................................................................457
SECTION 603 – FENCES.....................................................................................458
603.01 Description............................................................................................458
603.02 Materials ...............................................................................................458
603.03 General Requirements ..........................................................................458
603.04 Setting Posts .........................................................................................459
603.05 Placing Barbed and Tension Wire and Fabric ......................................459
603.06 Resetting Fence.....................................................................................460
603.07 Method of Measurement .......................................................................460
603.08 Basis of Payment ..................................................................................460
SECTION 604 – SIDEWALKS, CURB RAMPS, STEPS,
AND HANDRAILS ...............................................................................................461
604.01 Description............................................................................................461
604.02 Materials ...............................................................................................461
604.03 Portland Cement Concrete Sidewalks and Curb Ramps .......................462
(a) General Requirements ..........................................................................462
(b) Excavation ...........................................................................................463
(c) Forms ...................................................................................................463

xxxvii
 TABLE OF CONTENTS
Section Title Page

(d) Placing Concrete ..................................................................................463

(e) Finishing ..............................................................................................463
(f) Joints.....................................................................................................464
(g) Detectable Warning Surfaces ...............................................................464
(h) Curing ..................................................................................................465
604.04 PCC Steps .............................................................................................465
604.05 Reconstructed PCC Sidewalk and Curb Ramp .....................................465
604.06 Re-Laid Sidewalk .................................................................................465
604.07 HMA Sidewalk .....................................................................................466
(a) Excavation and Forms ..........................................................................466
(b) Bed Course...........................................................................................466
(c) Placing HMA Sidewalk .......................................................................466
604.08 Backfilling and Finishing Shoulders and Slopes ..................................466
604.09 Hand Rails ............................................................................................466
604.10 Method of Measurement .......................................................................467
604.11 Basis of Payment ..................................................................................467
SECTION 605 – CURBING..................................................................................469
605.01 Description............................................................................................469
605.02 Materials ...............................................................................................469
605.03 Precast Cement Concrete Curbing ........................................................469
(a) Excavation............................................................................................469
(b) Installation ...........................................................................................469
(c) Joints ....................................................................................................470
(d) Backfilling ...........................................................................................470
605.04 Cast in Place Cement Concrete Curbing ...............................................470
(a) Excavation............................................................................................470
(b) Forms ...................................................................................................470
(c) Proportioning and Placing ....................................................................470
(d) Curb Turnouts and Combined Concrete Curb and Gutter
Turnouts ...............................................................................................471
(e) Joints ....................................................................................................471
(f) Curing ...................................................................................................471
(g) Backfilling ...........................................................................................471
(h) Curb Machine ......................................................................................471
605.05 Reflecting Cement Concrete Curbing ...................................................472
605.06 Concrete Center Curbing ......................................................................472
605.07 HMA Curbing .......................................................................................472
(a) Excavation............................................................................................472
(b) Preparation of Bed ...............................................................................473
(c) Mixture.................................................................................................473
(d) Placing .................................................................................................473
(e) Painting and Sealing.............................................................................473
605.08 Resetting Curbing .................................................................................474

xxxviii
 TABLE OF CONTENTS
Section Title Page

(a) Salvage of Curbing...............................................................................474

(b) Curb Removal ......................................................................................474
(c) Excavation............................................................................................474
(d) Resetting ..............................................................................................474
(e) Backfilling............................................................................................474
605.09 Method of Measurement .......................................................................474
605.10 Basis of Payment ..................................................................................475
SECTION 606 – PAVEMENT CORRUGATIONS ............................................475
606.01 Description............................................................................................475
606.02 Materials ...............................................................................................476
606.03 General Requirements ..........................................................................476
(a) Installation Tolerances .........................................................................477
(b) Maintenance of Traffic ........................................................................477
606.04 Method of Measurement .......................................................................477
606.05 Basis of Payment ..................................................................................477
SECTION 607 – PAVED SIDE DITCH OR CONCRETE GUTTER ..............478
607.01 Description............................................................................................478
607.02 Materials ...............................................................................................478
607.03 General Requirements ..........................................................................478
607.04 Cement Concrete Gutter and Turnout ...................................................478
607.05 Method of Measurement .......................................................................479
607.06 Basis of Payment ..................................................................................479
SECTION 608 – SHOULDER DRAINS ..............................................................479
608.01 Description............................................................................................479
608.02 Materials ...............................................................................................479
608.03 General Requirements ..........................................................................480
608.04 Method of Measurement .......................................................................480
608.05 Basis of Payment ..................................................................................480
SECTION 609 – REINFORCED CONCRETE BRIDGE
APPROACHES .....................................................................................................480
609.01 Description............................................................................................480
609.02 Materials ...............................................................................................480
609.03 General Requirements ..........................................................................481
609.04 Forms ....................................................................................................481
609.05 Joints .....................................................................................................481
609.06 Reinforcing Bars ...................................................................................481
609.07 Thickness ..............................................................................................481
609.08 Concrete Placement ..............................................................................482
609.09 Finishing ...............................................................................................482
609.10 Curing ...................................................................................................482
609.11 Smoothness ...........................................................................................483

xxxix
 TABLE OF CONTENTS
Section Title Page

609.12 Opening to Traffic ................................................................................483

609.13 Method of Measurement .......................................................................483
609.14 Basis of Payment ..................................................................................483
SECTION 610 – APPROACHES AND CROSSOVERS ...................................484
610.01 Description............................................................................................484
610.02 Materials ...............................................................................................484
610.03 General Requirements ..........................................................................484
610.04 Existing Approaches and Crossovers....................................................485
610.05 Method of Measurement .......................................................................485
610.06 Basis of Payment ..................................................................................485
SECTION 611 – MAILBOX INSTALLATIONS ...............................................486
611.01 Description............................................................................................486
611.02 Materials ...............................................................................................486
611.03 Mailbox Assembly ................................................................................486
611.04 Method of Measurement .......................................................................487
611.05 Basis of Payment ..................................................................................487
SECTION 612 – UNDERSEALING ....................................................................488
612.01 Description............................................................................................488
612.02 Materials ...............................................................................................488
612.03 Weather Limitations .............................................................................488
612.04 Shoulders ..............................................................................................488
612.05 Drilled Holes.........................................................................................488
612.06 Pumping ................................................................................................489
(a) Asphalt Material...................................................................................489
(b) Wood Plugs ..........................................................................................489
612.07 Method of Measurement .......................................................................490
612.08 Basis of Payment ..................................................................................490
SECTION 613 – SALVAGED ROAD MATERIALS.........................................490
613.01 Description............................................................................................490
613.02 Materials ...............................................................................................490
613.03 Construction Requirements...................................................................490
613.04 Method of Measurement .......................................................................491
613.05 Basis of Payment ..................................................................................491
SECTION 614 – CONCRETE HEADER ............................................................492
614.01 Description............................................................................................492
614.02 Materials ...............................................................................................492
614.03 PCC Header ..........................................................................................492
614.04 Reconstructed Cement Concrete Header ..............................................492
614.05 Method of Measurement .......................................................................492
614.06 Basis of Payment ..................................................................................493

xl
 TABLE OF CONTENTS
Section Title Page

SECTION 615 – MONUMENTS, MARKERS, AND PARKING

BARRIERS............................................................................................................493
615.01 Description............................................................................................493
615.02 Materials ...............................................................................................493
615.03 Reinforced Cement Concrete Right-of-Way Markers ..........................493
615.04 Monuments ...........................................................................................494
615.05 Bench Mark Posts .................................................................................494
615.06 Parking Barriers ....................................................................................494
(a) Concrete ...............................................................................................495
(b) Timber Post ..........................................................................................495
615.07 Setting Right-of-Way Markers .............................................................495
615.08 Resetting Right-of-Way Markers..........................................................495
615.09 Setting Monuments ...............................................................................495
615.10 Re-Established Monuments ..................................................................496
615.11 Setting Bench Mark Posts and Tablets .................................................496
615.12 Reset Bench Mark Posts .......................................................................496
615.13 Method of Measurement .......................................................................497
615.14 Basis of Payment ..................................................................................497
SECTION 616 – RIPRAP AND SLOPEWALL..................................................497
616.01 Description............................................................................................497
616.02 Materials ...............................................................................................498
616.03 Placing Dumped Riprap ........................................................................498
616.04 Placing Grouted Riprap ........................................................................498
616.05 Placing Revetment, Class 1, and Class 2 Riprap ..................................498
616.06 Placing Uniform Riprap ........................................................................498
616.07 Blank.....................................................................................................499
616.08 Placing Precast Cement Concrete Riprap .............................................499
616.09 Slopewall ..............................................................................................499
616.10 Undermined Paved Side Ditch ..............................................................499
616.11 Installation of Geotextile Under Riprap ................................................500
616.12 Method of Measurement .......................................................................501
616.13 Basis of Payment ..................................................................................501
SECTION 617 – BLANK
SECTION 618 – BLANK
SECTION 619 – PAINTING BRIDGE STEEL ..................................................502
619.01 Description............................................................................................502
619.02 Materials ...............................................................................................503
619.03 Quality Control and Quality Assurance ................................................503
(a) Test Methods and Procedures ..............................................................504
(b) Acceptance Testing ..............................................................................504
619.04 Prosecution of Work .............................................................................505

xli
 TABLE OF CONTENTS
Section Title Page

619.05 Inspection Access to Bridges ................................................................505

619.06 Maintaining Traffic...............................................................................505
619.07 Environmental and Safety Requirements..............................................505
(a) Pollution Control ..................................................................................506
(b) Waste Disposal ....................................................................................507
619.08 Surface Preparation...............................................................................509
(a) Pressure Washing .................................................................................510
(b) Solvent Cleaning ..................................................................................510
(c) Hand Tool Cleaning .............................................................................510
(d) Brush-Off Blast Cleaning ....................................................................510
(e) Commercial Blast Cleaning .................................................................510
(f) Near-White Blast Cleaning ...................................................................510
(g) White Metal Blast Cleaning .................................................................510
(h) Power Tool Cleaning ...........................................................................510
(i) Commercial Grade Power Tool Cleaning .............................................510
(j) Power Tool Cleaning to Bare Metal .....................................................511
619.09 Paint Systems ........................................................................................511
(a) Structural Steel Paint System ...............................................................511
(b) Partial Paint System .............................................................................511
619.10 Painting .................................................................................................511
(a) Weather Limitations .............................................................................512
(b) Storage .................................................................................................512
(c) Mixing ..................................................................................................512
(d) Thinning...............................................................................................513
(e) Application of Paint .............................................................................513
(f) Curing Time .........................................................................................514
(g) Stencil Identification ............................................................................514
619.11 Shop Prime Coating ..............................................................................514
(a) Non-Weathering Steel ..........................................................................515
(b) Weathering Steel ..................................................................................515
619.12 Field Painting New Steel Bridge ..........................................................515
619.13 Painting Existing Steel Bridges ............................................................515
619.14 Drain Castings Treatment .....................................................................516
619.15 Responsibility for Damage ...................................................................516
619.16 Blank.....................................................................................................516
619.17 Method of Measurement .......................................................................516
619.18 Basis of Payment ..................................................................................517
(a) Pre-Established Remedies for Changed Conditions .............................517
(b) Prices used in Pre-Established Remedies to Changed
Conditions ............................................................................................518

xlii
 TABLE OF CONTENTS
Section Title Page

SECTION 620 – BLANK

SECTION 621 – SEEDING AND SODDING .....................................................520
621.01 Description............................................................................................520
621.02 Materials ...............................................................................................520
621.03 Preparation of Ground Before Seeding .................................................520
621.04 Preparation of Ground Before Applying Erosion Control
Blankets ................................................................................................521
621.05 Applying Fertilizer, Seed, and Mulch ...................................................521
(a) Fertilizer ...............................................................................................521
(b) Seed .....................................................................................................521
(c) Mulch ...................................................................................................521
(d) Excelsior Blankets ...............................................................................523
(e) Paper Mat .............................................................................................523
(f) Straw Mat .............................................................................................524
(g) Wood Cellulose Fiber Mulch ...............................................................524
621.06 Seed Mixtures .......................................................................................525
(a) Seed Mixture R ....................................................................................525
(b) Seed Mixture U ....................................................................................525
(c) Seed Mixture P .....................................................................................525
(d) Blank ....................................................................................................525
(e) Seed Mixture D ....................................................................................525
(f) Blank ....................................................................................................526
(g) Seed Mixture Grass..............................................................................526
(h) Seed Mixture Legume ..........................................................................526
621.07 Mulched Seeding ..................................................................................527
621.08 Preparation of Ground Before Sodding ................................................527
621.09 Laying Sod ............................................................................................527
621.10 Watering Sod ........................................................................................528
621.11 Seeding or Sodding Disturbed Areas Outside Construction
Limits....................................................................................................528
621.12 Seasonal Limitations .............................................................................528
621.13 Method of Measurement .......................................................................528
621.14 Basis of Payment ..................................................................................529
(a) Warranty Bond .....................................................................................530
(b) Changed Fertilizer................................................................................531
(c) Mulching ..............................................................................................531
SECTION 622 – PLANTING TREES, SHRUBS, AND VINES ........................532
622.01 Description............................................................................................532
622.02 Materials ...............................................................................................532
622.03 Care and Handling of Plants .................................................................532
(a) Bare Rooted Plants ...............................................................................532
(b) Balled and Burlapped Plants and Container Grown Plants ..................533

xliii
 TABLE OF CONTENTS
Section Title Page

622.04 Collected Plants ....................................................................................533

622.05 Excavation for Plant Holes ...................................................................533
622.06 Planting Season.....................................................................................534
622.07 Pruning .................................................................................................534
622.08 Planting, Backfilling, and Watering......................................................535
(a) Plants with Bare Roots .........................................................................535
(b) Balled and Burlapped Plants ................................................................536
(c) Seedlings for Wildlife Habitat .............................................................536
622.09 Liquid Fertilizer Application ................................................................536
622.10 Mulching...............................................................................................536
622.11 Guying and Staking ..............................................................................536
622.12 Plant Protection.....................................................................................537
(a) Borer Control Coatings ........................................................................537
(b) Wrapping for Rodent Protection ..........................................................537
622.13 Retaining Walls and Tree Wells ...........................................................537
622.14 Tree Root Protection .............................................................................538
622.15 Pipe Underdrains ..................................................................................538
622.16 Damage to Plants ..................................................................................538
622.17 Grass and Weed Control .......................................................................538
622.18 Care, Inspection, and Replacement .......................................................539
(a) Care ......................................................................................................539
(b) Inspection and Replacement ................................................................539
622.19 Crown Vetch Plants and Seedlings .......................................................540
622.20 “Do Not Mow or Spray” Signs and “Do Not Disturb” Signs ...............540
622.21 Method of Measurement .......................................................................540
622.22 Basis of Payment ..................................................................................540
SECTION 623 – BLANK
SECTION 624 – BLANK
SECTION 625 – BLANK
SECTION 626 – BLANK
SECTION 627 – BLANK
SECTION 628 – FIELD OFFICE, FIELD LABORATORY, COMPUTER
SYSTEM, COMPUTER SYSTEM EQUIPMENT ............................................542
628.01 Description............................................................................................542
628.02 Field Office and Laboratory Requirements ..........................................542
(a) Field Office ..........................................................................................542
(b) Field Office Equipment and Supplies ..................................................544
(c) Computer System and Computer System Equipment ..........................546
(d) Field Office Internet Service ................................................................548
(e) Field Office Machines ..........................................................................548

xliv
 TABLE OF CONTENTS
Section Title Page

(f) Field Laboratory ...................................................................................549

628.03 Mobile Internet Service ........................................................................550
628.04 Cellular Telephones ..............................................................................551
(a) Type A .................................................................................................551
(b) Type B .................................................................................................551
628.05 Method of Measurement .......................................................................552
628.06 Basis of Payment ..................................................................................552

DIVISION 700 – STRUCTURES

SECTION 701 – DRIVEN PILING......................................................................555

701.01 Description............................................................................................555
701.02 Materials ...............................................................................................555
701.03 Handling of Epoxy Coated Piles ...........................................................556
701.04 Equipment for Driving Piles .................................................................556
(a) Approval of Pile Driving Equipment ...................................................556
(b) Pile Hammers.......................................................................................558
(c) Pile Driving Aids .................................................................................559
701.05 Nominal Driving Resistance of a Driven Pile .......................................562
(a) Dynamic Formula ................................................................................562
(b) Dynamic Pile Load Test.......................................................................563
(c) Static Load Test ...................................................................................565
701.06 Blank.....................................................................................................567
701.07 Piling Length ........................................................................................567
701.08 Nominal Driving Resistance of Production Piles .................................567
701.09 Preparation and Driving ........................................................................568
(a) Pilot Holes............................................................................................569
(b) Location and Alignment Tolerance......................................................570
(c) Heaved Piles.........................................................................................571
(d) Installation Sequence ...........................................................................571
(e) Inspection .............................................................................................571
(f) Pouring Concrete ..................................................................................571
701.10 Unsatisfactory Piles ..............................................................................571
701.11 Splicing Piles ........................................................................................572
(a) Steel Piles .............................................................................................572
(b) Timber Piles .........................................................................................572
(c) Concrete Piles ......................................................................................572
701.12 Blank.....................................................................................................572
701.13 Cut-Off Lengths ....................................................................................573
701.14 Method of Measurement .......................................................................573
701.15 Basis of Payment ..................................................................................573
SECTION 702 – STRUCTURAL CONCRETE .................................................576
702.01 Description............................................................................................576

xlv
 TABLE OF CONTENTS
Section Title Page

702.02 Classes of Concrete...............................................................................576

702.03 Materials ...............................................................................................577
702.04 Shipping and Storage ............................................................................577
702.05 Proportioning ........................................................................................577
702.06 Measuring and Batching .......................................................................579
(a) Portland Cement...................................................................................579
(b) Water ...................................................................................................580
(c) Aggregates ...........................................................................................580
(d) Bins and Scales ....................................................................................580
(e) Batching ...............................................................................................581
702.07 Mixing ..................................................................................................581
702.08 Mixing at Site of Work .........................................................................581
702.09 Ready-Mixed Concrete .........................................................................582
(a) General Requirements ..........................................................................582
(b) Mixers and Agitators ...........................................................................583
(c) Mixing and Delivery ............................................................................584
(d) Non-Agitating Equipment ....................................................................585
702.10 Pumping Concrete ................................................................................586
702.11 Cold Weather Concrete.........................................................................587
702.12 Consistency ...........................................................................................588
702.13 Forms ....................................................................................................588
(a) Construction .........................................................................................588
(b) Ties ......................................................................................................588
(c) Walls ....................................................................................................589
(d) Surface Treatment ................................................................................589
(e) Metal Forms .........................................................................................589
(f) Blank ....................................................................................................591
(g) Removal and Re-Use of Forms ............................................................591
(h) Test Beams...........................................................................................592
702.14 Falsework and Centering ......................................................................592
(a) Design and Construction ......................................................................593
(b) Removal ...............................................................................................594
702.15 Joints .....................................................................................................595
(a) Construction Joints ...............................................................................595
(b) Expansion Joints ..................................................................................596
(c) Folded Metal Joints ..............................................................................596
(d) Sliding Joints .......................................................................................596
(e) Polychloroprene Joint Membrane ........................................................597
702.16 Drainage Pipes Through Concrete Masonry .........................................597
702.17 Incased Pipes and Conduits ..................................................................597
702.18 Roadway Surface Drainage ..................................................................597
702.19 Pouring Bent Caps ................................................................................597
702.20 Placing Concrete ...................................................................................597
(a) General Requirements ..........................................................................597
xlvi
 TABLE OF CONTENTS
Section Title Page

(b) Chutes and Troughs .............................................................................598

(c) Vibrating ..............................................................................................599
(d) Depositing Concrete Under Water .......................................................599
(e) Placing Footing Concrete .....................................................................600
(f) Concrete Foundation Seal .....................................................................600
702.21 Finishing Concrete Surfaces .................................................................601
702.22 Curing Concrete ....................................................................................601
(a) Protective Covering Curing Methods ...................................................602
(b) Curing-Sealing Materials .....................................................................603
702.23 Waterproofing .......................................................................................604
702.24 Application of Loads to and Acceptance of New Concrete ..................604
702.25 Field Drilled Holes in Concrete ............................................................605
702.26 Artificial Lighting .................................................................................606
702.27 Method of Measurement .......................................................................606
702.28 Basis of Payment ..................................................................................606
SECTION 703 – REINFORCING BARS ............................................................608
703.01 Description............................................................................................608
703.02 Materials ...............................................................................................608
703.03 Bar List .................................................................................................608
703.04 Protection of Materials .........................................................................608
703.05 Bending.................................................................................................609
703.06 Placing and Fastening ...........................................................................609
703.07 Method of Measurement .......................................................................610
703.08 Basis of Payment ..................................................................................611
SECTION 704 – CONCRETE FLOOR SLABS .................................................612
704.01 Description............................................................................................612
704.02 Materials ...............................................................................................612
704.03 Forms ....................................................................................................612
704.04 Placing Reinforcement and Concrete....................................................612
704.05 Finishing Concrete ................................................................................613
704.06 Curing ...................................................................................................615
704.07 Method of Measurement .......................................................................615
704.08 Basis of Payment ..................................................................................615
SECTION 705 – SIDEWALKS ON STRUCTURES ..........................................616
705.01 Description............................................................................................616
705.02 Materials ...............................................................................................616
705.03 Construction Requirements...................................................................616
705.04 Method of Measurement .......................................................................616
705.05 Basis of Payment ..................................................................................616
SECTION 706 – BRIDGE RAILINGS ................................................................617
706.01 Description............................................................................................617

xlvii
 TABLE OF CONTENTS
Section Title Page

706.02 Materials ...............................................................................................617

706.03 Concrete Railing ...................................................................................617
706.04 Concrete Railing With Reinforced Concrete Moment Slab ..................618
706.05 Steel Railings ........................................................................................619
706.06 Bridge Railing Pedestrian Fence...........................................................619
706.07 Method of Measurement .......................................................................619
706.08 Basis of Payment ..................................................................................620
SECTION 707 – PRECAST AND PRECAST PRESTRESSED
CONCRETE STRUCTURAL MEMBERS ........................................................621
707.01 Description............................................................................................621
707.02 Materials ...............................................................................................621
707.03 General Requirements ..........................................................................622
707.04 Steel and Concrete Requirements .........................................................623
(a) Reinforcing Bars ..................................................................................623
(b) Prestressing Strands .............................................................................623
(c) Concrete ...............................................................................................624
(d) Other Requirements .............................................................................626
707.05 Forms ....................................................................................................626
707.06 Placing and Finishing Concrete ............................................................627
707.07 Removal of Forms and Curing..............................................................628
(a) Wet Curing without Supplemental Heat ..............................................628
(b) Accelerated Curing ..............................................................................628
707.08 Handling and Shipping .........................................................................630
707.09 Placing Structural Members..................................................................630
707.10 Blank.....................................................................................................631
707.11 Method of Measurement .......................................................................631
707.12 Basis of Payment ..................................................................................632
SECTION 708 – PNEUMATICALLY PLACED MORTAR ............................633
708.01 Description............................................................................................633
708.02 Materials ...............................................................................................633
708.03 Preparing Surface..................................................................................633
708.04 Reinforcement ......................................................................................633
708.05 Proportioning and Mixing.....................................................................634
708.06 Placing Mortar ......................................................................................634
708.07 Finishing ...............................................................................................634
708.08 Method of Measurement .......................................................................635
708.09 Basis of Payment ..................................................................................635
SECTION 709 – PORTLAND CEMENT CONCRETE SEALERS .................635
709.01 Description............................................................................................635
709.02 Materials ...............................................................................................636
709.03 General Requirements ..........................................................................636

xlviii
 TABLE OF CONTENTS
Section Title Page

709.04 Surface Preparation...............................................................................636

709.05 Sealer Application ................................................................................636
(a) Non-Epoxy PCC Sealers ......................................................................637
(b) Clear Sealers ........................................................................................637
(c) Alternate to Concrete Sealers ...............................................................637
709.06 Safety Precautions ................................................................................637
709.07 Method of Measurement .......................................................................638
709.08 Basis of Payment ..................................................................................638
SECTION 710 – PATCHING CONCRETE STRUCTURES
AND REPOINTING MASONRY IN STRUCTURES ......................................638
710.01 Description............................................................................................638
710.02 Materials ...............................................................................................638
710.03 Patching Concrete Structures ................................................................639
(a) Concrete Removal ................................................................................639
(b) Replacement of Reinforcement............................................................640
(c) Patching................................................................................................640
(d) Curing ..................................................................................................640
710.04 Repointing Rubble Masonry .................................................................640
710.05 Repointing Dressed Stone and Brick Masonry .....................................641
710.06 Method of Measurement .......................................................................641
710.07 Basis of Payment ..................................................................................641
SECTION 711 – STEEL STRUCTURES ............................................................642
711.01 Description............................................................................................642
711.02 Materials ...............................................................................................642
711.03 General Requirements ..........................................................................642
711.04 Certification of Fabricators ...................................................................643
(a) General Information .............................................................................643
(b) Certification Categories .......................................................................643
711.05 Working Drawings................................................................................645
711.06 Storage of Materials..............................................................................645
711.07 Mill Orders and Shipping Statements ...................................................645
711.08 Mill Test Reports ..................................................................................645
711.09 Notice of Beginning Work....................................................................646
711.10 Facilities for Inspection ........................................................................646
711.11 Straightening Material ..........................................................................646
711.12 Finish ....................................................................................................646
711.13 Flame Cutting .......................................................................................647
711.14 Edge Planing .........................................................................................647
711.15 Abutting Joints ......................................................................................648
711.16 End Connection Angles ........................................................................648
711.17 Blank.....................................................................................................648
711.18 Blank.....................................................................................................648

xlix
 TABLE OF CONTENTS
Section Title Page

711.19 Bent Plates ............................................................................................648

711.20 Fit of Stiffeners .....................................................................................649
711.21 Bolt Holes .............................................................................................649
(a) High Tensile Strength Bolts, and Unfinished Bolts .............................649
(b) Ribbed Bolts, Turned Bolts, or other Approved Bearing-
Type Bolts ............................................................................................650
711.22 Punched Holes ......................................................................................650
711.23 Reamed or Drilled Holes ......................................................................650
711.24 Subpunching and Reaming of Field Connections .................................651
711.25 Accuracy of Punched or Subdrilled Holes ............................................651
711.26 Accuracy of Reamed Holes and Holes Drilled Full Size ......................651
711.27 Fitting for Bolting .................................................................................651
711.28 Filler Plates ...........................................................................................651
711.29 Toothed Expansion Plates.....................................................................652
711.30 Blank.....................................................................................................652
711.31 Peening Welds by Means of Ultrasonic Impact Treatment,
UIT .......................................................................................................652
711.32 Welds ....................................................................................................652
(a) AWS Requirements..............................................................................652
(b) Welding of High Performance Steel ....................................................653
(c) Field Welding.......................................................................................654
711.33 Stud Shear Connectors ..........................................................................655
711.34 Annealing and Stress Relieving ............................................................655
711.35 Eyebars .................................................................................................655
711.36 Facing of Bearing Surfaces ...................................................................655
711.37 Pins and Rollers ....................................................................................656
711.38 Boring Pin Holes ..................................................................................656
711.39 Pin Clearances ......................................................................................656
711.40 Threads for Bolts and Pins ....................................................................656
711.41 Pilot and Driving Nuts ..........................................................................657
711.42 Finishing Cast Steel ..............................................................................657
711.43 Finished Members ................................................................................657
711.44 Shop Assembling ..................................................................................657
(a) Full Truss or Girder Assembly .............................................................657
(b) Progressive Beam or Girder Assembly ................................................658
(c) Full Chord Assembly ...........................................................................658
(d) Progressive Chord Assembly ...............................................................658
(e) Special Complete Structure Assembly .................................................659
711.45 Drifting of Holes ...................................................................................659
711.46 Match Marking .....................................................................................659
711.47 Shop Cleaning and Painting..................................................................659
711.48 Shop Cleaning and Storage of Weathering Steel ..................................659
(a) Hot Rolled Products .............................................................................659
(b) Welded Area ........................................................................................659
l
 TABLE OF CONTENTS
Section Title Page

711.49 Furnishing Bolts ...................................................................................659

711.50 Weighing of Members ..........................................................................660
711.51 Full Size Tests ......................................................................................660
711.52 Acceptance............................................................................................660
711.53 Shipping ................................................................................................660
711.54 General Requirements ..........................................................................660
711.55 Delivery of Materials ............................................................................661
711.56 Handling and Storing ............................................................................661
711.57 Falsework..............................................................................................661
711.58 Bearings and Anchorages .....................................................................661
711.59 Field Straightening Material .................................................................662
711.60 Field Assembly of Steel ........................................................................662
711.61 Misfits ...................................................................................................662
711.62 Pin Connections ....................................................................................663
711.63 Blank.....................................................................................................663
711.64 Diaphragm Connections .......................................................................663
711.65 Bolted Connections Using High Strength Bolts ...................................663
(a) General .................................................................................................663
(b) Bolts, Nuts, and Washers .....................................................................663
(c) Bolted Parts ..........................................................................................663
(d) Installation ...........................................................................................664
(e) Inspection .............................................................................................666
711.66 Bolted Connections Using Other Than High Strength Bolts ................667
711.67 Final Clean-Up .....................................................................................667
711.68 Structural Steel Cutting, Rivet and Bolt Removal, and
Drilled Bolt Holes in Repair Projects ...................................................667
711.69 Jacking and Supporting Beams .............................................................667
711.70 Field Cleaning and Storage of Weathering Steel ..................................667
711.71 Painting .................................................................................................668
711.72 Method of Measurement .......................................................................668
711.73 Basis of Payment ..................................................................................668
(a) Lump Sum Basis ..................................................................................669
(b) Unit Weight Basis ................................................................................670
SECTION 712 – TIMBER STRUCTURES.........................................................671
712.01 Description............................................................................................671
712.02 Materials ...............................................................................................671
712.03 General Requirements ..........................................................................672
712.04 Caps ......................................................................................................673
712.05 Stringers ................................................................................................673
712.06 Bents .....................................................................................................674
712.07 Wheel Guards and Railings ..................................................................674
712.08 Painting .................................................................................................674
712.09 Single-Ply Plank Floors ........................................................................675

li
 TABLE OF CONTENTS
Section Title Page

712.10 Two-Ply Plank Floors ...........................................................................675

712.11 Method of Measurement .......................................................................675
712.12 Basis of Payment ..................................................................................675
SECTION 713 – TEMPORARY BRIDGES AND APPROACHES..................676
713.01 Description............................................................................................676
713.02 Materials ...............................................................................................676
713.03 General Requirements ..........................................................................676
713.04 Temporary Bridge.................................................................................676
713.05 Temporary Pipe ....................................................................................676
(a) Corrugated Steel Circular Pipe.............................................................677
(b) Corrugated Steel Pipe-Arch, 3 in. by 1 in. Corrugations .....................677
(c) Structural Plate Pipe-Arch 6 in. by 2 in. Corrugations .........................677
713.06 Temporary Approaches ........................................................................677
713.07 Maintenance..........................................................................................677
713.08 Removal ................................................................................................678
713.09 Method of Measurement .......................................................................678
713.10 Basis of Payment ..................................................................................678
SECTION 714 – REINFORCED CONCRETE BOX STRUCTURES .............679
714.01 Description............................................................................................679
714.02 Materials ...............................................................................................679
714.03 General Requirements ..........................................................................681
714.04 Design Requirements ............................................................................681
(a) Box Structure .......................................................................................681
(b) Concrete Headwalls, Wingwalls, and Footings ...................................681
(c) Working Drawings ...............................................................................682
714.05 Erection Requirements..........................................................................683
714.06 Precast Concrete Headwalls, Wingwalls, and Footings ........................684
(a) Headwall Reinforcement Placement Relative to Top of
Structure ...............................................................................................684
(b) Wingwall Placement ............................................................................684
714.07 Rejection ...............................................................................................685
714.08 Repairs ..................................................................................................685
714.09 Extension of Existing Structure ............................................................685
(a) Precast Reinforced Concrete Box Structure Extension ........................686
(b) Cast-In-Place Concrete Structure Extension ........................................686
714.10 Precast Reinforced-Concrete Box Structure Section Joints ..................686
714.11 Method of Measurement .......................................................................687
714.12 Basis of Payment ..................................................................................687
SECTION 715 – PIPE CULVERTS, AND STORM AND
SANITARY SEWERS ..........................................................................................689
715.01 Description............................................................................................689

lii
 TABLE OF CONTENTS
Section Title Page

715.02 Materials ...............................................................................................689

(a) Type 1 Pipe ..........................................................................................690
(b) Type 2 Pipe ..........................................................................................690
(c) Type 3 Pipe ..........................................................................................691
(d) Type 4 Pipe ..........................................................................................691
(e) Type 5 Pipe ..........................................................................................691
(f) Slotted Drain Pipe.................................................................................691
(g) Slotted Vane Drain Pipe.......................................................................692
(h) End Bent Drain Pipe ............................................................................692
(i) Underdrain Outlet Pipe .........................................................................692
(j) Grated Box End Sections ......................................................................692
(k) Pipe End Sections ................................................................................692
(l) Roadway Drain Casting Extensions......................................................692
(m) Drainage Pipe through Concrete Masonry ..........................................692
(n) Bridge Deck Drain System ..................................................................693
715.03 General Requirements ..........................................................................693
715.04 Excavation ............................................................................................693
715.05 Laying Pipe ...........................................................................................694
715.06 Joining Pipe ..........................................................................................695
715.07 Tee and Stub-Tee Connections .............................................................695
715.08 Blank.....................................................................................................696
715.09 Backfilling ............................................................................................696
715.10 Pipe End Sections, Anchors, Grated Box End Sections, and
Safety Metal End Sections ....................................................................698
715.11 Re-Laid Pipe .........................................................................................699
715.12 Pavement Replacement .........................................................................699
715.13 Method of Measurement .......................................................................699
715.14 Basis of Payment ..................................................................................701
SECTION 716 – TRENCHLESS PIPE INSTALLATION ................................704
716.01 Description............................................................................................704
(a) Auger Boring .......................................................................................704
(b) Carrier Pipe ..........................................................................................704
(c) Casing Pipe ..........................................................................................704
(d) Drive Shaft ...........................................................................................704
(e) Guided Boring ......................................................................................704
(f) Horizontal Directional Drilling ............................................................704
(g) Microtunneling ....................................................................................705
(h) Pipe Jacking .........................................................................................705
(i) Pipe Ramming ......................................................................................705
(j) Reception Shaft.....................................................................................705
(k) Response Levels ..................................................................................705
(l) Spoils ....................................................................................................705
716.02 Materials ...............................................................................................705

liii
 TABLE OF CONTENTS
Section Title Page

716.03 General Requirements ..........................................................................706

716.04 Method of Measurement .......................................................................708
716.05 Basis of Payment ..................................................................................708
SECTION 717 – STRUCTURAL PLATE PIPE, PIPE-ARCHES,
AND ARCHES ......................................................................................................708
717.01 Description............................................................................................708
717.02 Materials ...............................................................................................708
717.03 General Requirements ..........................................................................709
717.04 Backfill .................................................................................................710
717.05 Relaid Pipe and Pipe-Arch....................................................................710
717.06 Blank.....................................................................................................711
717.07 Concrete Paved Inverts .........................................................................711
717.08 Method of Measurement .......................................................................711
717.09 Basis of Payment ..................................................................................711
SECTION 718 – UNDERDRAINS .......................................................................712
718.01 Description............................................................................................712
718.02 Materials ...............................................................................................712
718.03 Pipe Installation ....................................................................................713
(a) Locations Outside MSE Wall Ground Reinforcement
Limits ...................................................................................................713
(b) Underdrains Within MSE Wall Ground Reinforcement
Limits ...................................................................................................713
718.04 Geotextile..............................................................................................713
718.05 Underdrain Outlets................................................................................713
718.06 Underdrain Outlet Protectors ................................................................714
718.07 Video Inspection ...................................................................................714
718.08 Patching Underdrains............................................................................714
718.09 Method of Measurement .......................................................................715
718.10 Basis of Payment ..................................................................................715
SECTION 719 – TILE DRAINS...........................................................................716
719.01 Description............................................................................................716
719.02 Materials ...............................................................................................716
719.03 Trench Excavation ................................................................................717
719.04 Laying Tile ...........................................................................................717
719.05 Backfilling ............................................................................................718
719.06 Blank.....................................................................................................718
719.07 Method of Measurement .......................................................................718
719.08 Basis of Payment ..................................................................................718
SECTION 720 – MANHOLES, INLETS, AND CATCH BASINS ...................719
720.01 Description............................................................................................719
720.02 Materials ...............................................................................................719

liv
 TABLE OF CONTENTS
Section Title Page

720.03 General Requirements ..........................................................................720

720.04 Grade Adjustment of Existing Structures .............................................722
720.05 Capping Existing Structures .................................................................723
720.06 Method of Measurement .......................................................................723
720.07 Basis of Payment ..................................................................................724
SECTION 721 – AUTOMATIC DRAINAGE GATES ......................................725
721.01 Description............................................................................................725
721.02 Materials ...............................................................................................725
721.03 Construction Requirements...................................................................725
721.04 Method of Measurement .......................................................................725
721.05 Basis of Payment ..................................................................................725
SECTION 722 – CONCRETE BRIDGE DECK OVERLAYS ..........................726
722.01 Description............................................................................................726
722.02 Quality Control .....................................................................................726
722.03 Materials ...............................................................................................726
722.04 Storage and Handling of Materials .......................................................727
722.05 Proportioning ........................................................................................727
(a) Latex Modified Concrete .....................................................................727
(b) Latex Modified Concrete, Very Early Strength ...................................728
(c) Silica Fume Modified Concrete ...........................................................728
722.06 Preparation of the Bridge Floor ............................................................730
(a) Removal of Existing Concrete Overlay ...............................................730
(b) Surface Preparation of Existing Concrete Deck...................................730
(c) Cleaning ...............................................................................................733
722.07 Patching of the Bridge Floor .................................................................733
(a) Full Depth Patching .............................................................................733
(b) Partial Depth Patching .........................................................................734
722.08 Overlay Dam.........................................................................................734
722.09 Mixing ..................................................................................................735
(a) Latex Modified Concrete and Latex Modified Concrete,
Very Early Strength ..............................................................................735
(b) Silica Fume Modified Concrete ...........................................................736
722.10 Placing and Finishing ...........................................................................736
722.11 Texturing ..............................................................................................738
722.12 Curing ...................................................................................................739
722.13 Calibration of Continuous Mixers ........................................................740
(a) Frequency .............................................................................................740
(b) Equipment ............................................................................................741
(c) Pre-calibration ......................................................................................741
(d) Calibration ...........................................................................................741
722.14 Patching an Existing Bridge Deck Overlay ..........................................743
(a) Materials ..............................................................................................743

lv
 TABLE OF CONTENTS
Section Title Page

(b) Storage and Handling of Materials ......................................................743

(c) Proportioning .......................................................................................743
(d) Preparation of the Bridge Floor ...........................................................743
(e) Patching................................................................................................743
(f) Mixing ..................................................................................................743
(g) Placing and Finishing...........................................................................743
(h) Texturing..............................................................................................743
(i) Curing ...................................................................................................744
(j) Calibration of Continuous Mixers ........................................................744
722.15 Method of Measurement .......................................................................744
722.16 Basis of Payment ..................................................................................745
SECTION 723 – REINFORCED CONCRETE THREE-SIDED
STRUCTURES .....................................................................................................748
723.01 Description............................................................................................748
723.02 Materials ...............................................................................................748
723.03 General Requirements ..........................................................................750
723.04 Design Requirements ............................................................................750
(a) Placement of Reinforcement ................................................................751
(b) Splicing and Spacing of Reinforcement...............................................751
(c) Working Drawings ...............................................................................751
723.05 Manufacture ..........................................................................................753
723.06 Rejection ...............................................................................................753
723.07 Repairs ..................................................................................................753
723.08 Trench Compaction ..............................................................................754
723.09 Footings ................................................................................................754
723.10 Pedestals ...............................................................................................754
723.11 Placement of Structure Sections and Wingwalls ..................................754
723.12 Extension of Existing Structure ............................................................755
(a) Precast Reinforced Concrete Three-Sided Structure
Extension ..............................................................................................756
(b) Cast-In-Place Concrete Three-Sided Structure Extension ...................756
723.13 Blank.....................................................................................................756
723.14 Joints .....................................................................................................757
723.15 Backfilling ............................................................................................757
723.16 Scour Protection ...................................................................................757
723.17 Method of Measurement .......................................................................758
723.18 Basis of Payment ..................................................................................758
SECTION 724 – STRUCTURAL EXPANSION JOINTS .................................760
724.01 Description............................................................................................760
(a) Structural Expansion Joint ...................................................................760
(b) Replacement of Existing Structural Expansion Joint ...........................760
(c) Replacement of Existing Structural Expansion Joint Seal ...................760

lvi
 TABLE OF CONTENTS
Section Title Page

724.02 Materials ...............................................................................................760

(a) Expansion Joint SS...............................................................................760
(b) Expansion Joint M ...............................................................................761
724.03 General Requirements ..........................................................................761
(a) Replacement of Existing Structural Expansion Joint ...........................761
(b) Replacement of Existing Structural Expansion Joint Seal ...................761
724.04 Method of Measurement .......................................................................761
724.05 Basis of Payment ..................................................................................761
SECTION 725 – SLIP LINING OF EXISTING PIPE .......................................762
725.01 Description............................................................................................762
725.02 Materials ...............................................................................................762
725.03 Right-of-Entry Areas ............................................................................764
725.04 Quality Control .....................................................................................764
725.05 Filling of Cavities Outside of the Existing Pipe ...................................764
725.06 Joining Liner Pipe .................................................................................764
(a) Welder, Butt Fuser, or Joiner Joint Testing..........................................764
(b) Solid Wall HDPE Liner Pipe ...............................................................765
(c) Profile Wall HDPE Liner Pipe .............................................................765
725.07 Cellular Concrete Grout ........................................................................765
725.08 Liner Pipe Installation...........................................................................766
725.09 Method of Measurement .......................................................................767
725.10 Basis of Payment ..................................................................................768
SECTION 726 – BEARING ASSEMBLIES .......................................................769
726.01 Description............................................................................................769
726.02 Materials ...............................................................................................769
726.03 Construction Requirements...................................................................770
726.04 Method of Measurement .......................................................................770
726.05 Basis of Payment ..................................................................................770
SECTION 727 – STRUCTURAL CONCRETE REPAIR BY EPOXY
INJECTION ..........................................................................................................771
727.01 Description............................................................................................771
727.02 Materials ...............................................................................................771
727.03 Approvals..............................................................................................771
727.04 Construction Requirements...................................................................771
727.05 Method of Measurement .......................................................................772
727.06 Basis of Payment ..................................................................................772
SECTION 728 – BLANK
SECTION 729 – BLANK
SECTION 730 – BLANK

lvii
 TABLE OF CONTENTS
Section Title Page

SECTION 731 – MECHANICALLY STABILIZED EARTH

RETAINING WALLS ..........................................................................................772
731.01 Description............................................................................................772
731.02 General Design Requirements ..............................................................772
731.03 Design Criteria ......................................................................................773
(a) Geotechnical Considerations ................................................................774
(b) Height of Wall .....................................................................................775
(c) Ground Reinforcement .........................................................................775
(d) Other Criteria .......................................................................................776
731.04 Submittals .............................................................................................777
731.05 Materials ...............................................................................................779
731.06 General Requirements ..........................................................................780
731.07 Foundation Preparation .........................................................................780
731.08 Retaining Wall Excavation ...................................................................781
731.09 Wall Erection ........................................................................................782
731.10 Joint Spacers and Joint Covering for Wall Panels ................................783
731.11 Backfill Placement ................................................................................783
731.12 Method of Measurement .......................................................................784
731.13 Basis of Payment ..................................................................................784
SECTION 732 – MODULAR CONCRETE BLOCK RETAINING WALL....786
732.01 Description............................................................................................786
732.02 General Design Requirements ..............................................................786
732.03 Design Criteria ......................................................................................786
(a) Geotechnical Considerations ................................................................787
(b) Height of Wall for Internal Stability ....................................................787
(c) Ground Reinforcement .........................................................................788
732.04 Submittals .............................................................................................789
732.05 Materials ...............................................................................................790
(a) Concrete Modular Block Wall Units....................................................791
(b) Blank ....................................................................................................792
732.06 General Requirements ..........................................................................792
732.07 Foundation Preparation .........................................................................793
732.08 Retaining Wall Excavation ...................................................................793
732.09 Wall Erection ........................................................................................793
732.10 Backfill Placement ................................................................................793
732.11 Method of Measurement .......................................................................794
732.12 Stockpiled Modular Block Units ..........................................................794
732.13 Basis of Payment ..................................................................................794
SECTION 733 – STEEL BIN-TYPE RETAINING WALL...............................795
733.01 Description............................................................................................795
733.02 Materials ...............................................................................................795
733.03 General .................................................................................................795

lviii
 TABLE OF CONTENTS
Section Title Page

733.04 Foundation Preparation .........................................................................796

733.05 Retaining Wall Excavation ...................................................................796
733.06 Backfill Placement ................................................................................796
733.07 Method of Measurement .......................................................................797
733.08 Basis of Payment ..................................................................................797
SECTION 734 – PERMANENT EARTH RETENTION SYSTEM
FOR CUT-WALL APPLICATION ....................................................................797
734.01 Description............................................................................................797
734.02 Contractor Design Requirements ..........................................................797
(a) Design Calculations .............................................................................798
(b) Working Drawings ...............................................................................799
(c) Submittals ............................................................................................801
734.03 Materials ...............................................................................................801
734.04 General Requirements ..........................................................................802
734.05 Performance Monitoring During Construction .....................................802
734.06 Performance Monitoring After Construction ........................................802
734.07 Method of Measurement .......................................................................803
734.08 Basis of Payment ..................................................................................803
SECTION 735 – TEMPORARY WIRE-FACED MECHANICALLY
STABILIZED EARTH RETAINING WALLS .................................................803
735.01 Description............................................................................................803
735.02 General Design Requirements ..............................................................803
735.03 Design Criteria ......................................................................................804
735.04 Submittals .............................................................................................804
735.05 Materials ...............................................................................................804
735.06 General Requirements ..........................................................................805
735.07 Wall Erection ........................................................................................805
735.08 Method of Measurement .......................................................................806
735.09 Basis of Payment ..................................................................................806
SECTION 736 – BLANK
SECTION 737 – WELDED WIRE REINFORCEMENT, WWR .....................807
737.01 Description............................................................................................807
737.02 Materials ...............................................................................................807
737.03 Design Requirements ............................................................................808
737.04 Working Drawings................................................................................808
737.05 Fabrication ............................................................................................808
737.06 Handling and Storage ...........................................................................808
737.07 Placing and Securing ............................................................................809
737.08 Repair of Coated WWR ........................................................................809
(a) Epoxy-Coated ......................................................................................809
(b) Galvanized ...........................................................................................810

lix
 TABLE OF CONTENTS
Section Title Page

737.09 Final Inspection ....................................................................................810

737.10 Method of Measurement .......................................................................810
737.11 Basis of Payment ..................................................................................810

DIVISION 800 – TRAFFIC CONTROL DEVICES AND LIGHTING

SECTION 801 – TRAFFIC CONTROLS FOR CONSTRUCTION

AND MAINTENANCE OPERATIONS .............................................................811
801.01 Description............................................................................................811
801.02 Materials ...............................................................................................811
801.03 General Requirements ..........................................................................812
801.04 Construction Signs ................................................................................814
(a) Type A .................................................................................................815
(b) Type B .................................................................................................815
(c) Type C..................................................................................................815
(d) Type D .................................................................................................815
(e) Temporary Panel Sign ..........................................................................815
801.05 Detour Route Marker Assembly ...........................................................815
801.06 Road Closure Sign Assembly ...............................................................816
801.07 Barricades .............................................................................................816
(a) Type III-A Barricade ............................................................................816
(b) Type III-B Barricade ............................................................................816
(c) Permanent Type III Barricade ..............................................................816
801.08 Cones and Tubular Markers..................................................................816
801.09 Drums ...................................................................................................817
801.10 Temporary Traffic Barriers...................................................................818
(a) Placement .............................................................................................819
(b) Connection ...........................................................................................819
(c) Anchorage ............................................................................................820
(d) Delineation ...........................................................................................820
(e) End Treatment ......................................................................................821
(f) Storage ..................................................................................................821
801.10.1 Construction Zone Energy Absorbing Terminal, CZ.........................821
801.11 Temporary Crossovers ..........................................................................822
801.12 Temporary Pavement Marking .............................................................823
(a) Temporary Pavement Marking Methods..............................................823
(b) Quality Assurance Unit ........................................................................825
801.13 Temporary Illumination ........................................................................825
801.14 Construction Warning Lights................................................................825
(a) Type A .................................................................................................825
(b) Type B .................................................................................................825
(c) Type C..................................................................................................825

lx
 TABLE OF CONTENTS
Section Title Page

(d) Vehicle Warning Lights .......................................................................826

801.15 Electronic Devices ................................................................................826
(a) Flashing Arrow Sign ............................................................................826
(b) Portable Changeable Message Signs, PCMS .......................................826
(c) Temporary Worksite Speed Limit Sign Assembly...............................826
(d) Temporary Traffic Signals ...................................................................827
(e) Automated Flagger Assistance Devices ...............................................828
801.16 Temporary Traffic Control Zone ..........................................................829
(a) Temporary Mounted Construction Signs .............................................829
(b) Maintenance of Traffic for Mobile Operations ....................................830
(c) Traffic Control for Temporary Traffic Stoppage .................................830
801.17 Method of Measurement .......................................................................830
801.18 Basis of Payment ..................................................................................832
SECTION 802 – SIGNS ........................................................................................837
802.01 Description............................................................................................837
802.02 Materials ...............................................................................................838
802.03 Location of Signs and Sign Structures ..................................................838
802.04 Working Drawings................................................................................838
802.05 Excavation and Backfill ........................................................................839
802.06 Placing Concrete ...................................................................................839
802.07 Installing Supports ................................................................................839
(a) Posts .....................................................................................................839
(b) Overhead Sign Structures ....................................................................840
802.08 Installing Signs .....................................................................................841
(a) Sheet Signs ...........................................................................................842
(b) Panel Signs...........................................................................................842
802.09 Removal or Relocation of Signs or Support Assemblies ......................842
802.10 Roadway and Bridge Reference Signs ..................................................843
802.11 Method of Measurement .......................................................................843
802.12 Basis of Payment ..................................................................................844
SECTION 803 – WELDING ALUMINUM ALLOYS .......................................847
803.01 Description............................................................................................847
803.02 Materials ...............................................................................................847
803.03 Welding Processes ................................................................................847
(a) Preparation of Materials .......................................................................847
(b) Welding Procedure ..............................................................................848
(c) Weld Quality ........................................................................................849
(d) Inspection.............................................................................................849
(e) Corrections ...........................................................................................849
803.04 Qualification of Procedures, Welders, and Welding
Operators ..............................................................................................850

lxi
 TABLE OF CONTENTS
Section Title Page

SECTION 804 – DELINEATORS .......................................................................850

804.01 Description............................................................................................850
804.02 Materials ...............................................................................................850
804.03 Delineator Visibility .............................................................................851
804.04 Posts ......................................................................................................851
804.05 Flexible Delineator Posts ......................................................................851
804.06 Method of Measurement .......................................................................851
804.07 Basis of Payment ..................................................................................851
SECTION 805 – TRAFFIC SIGNALS ................................................................852
805.01 Description............................................................................................852
805.02 Materials ...............................................................................................852
805.03 General Requirements ..........................................................................853
805.04 Pole Installation ....................................................................................855
805.05 Placing Signal Heads ............................................................................856
805.06 Grounding .............................................................................................857
805.07 Wire and Cable Installations .................................................................857
805.08 Controller Cabinet, Signal Service, and Detector Housing
Installation ............................................................................................858
805.09 Loop Wire Detector Installation ...........................................................859
(a) Layout ..................................................................................................859
(b) Installation ...........................................................................................859
(c) Splices ..................................................................................................860
(d) Testing and Acceptance .......................................................................860
805.10 Other Vehicle Detection Systems .........................................................863
805.11 Steel Conduit ........................................................................................863
805.12 PVC, HDPE, and Fiberglass Conduit ...................................................864
805.13 Foundations ..........................................................................................864
805.14 Final Clean-Up .....................................................................................864
805.15 Method of Measurement .......................................................................865
805.16 Basis of Payment ..................................................................................865
SECTION 806 – BLANK
SECTION 807 – HIGHWAY ILLUMINATION ................................................870
807.01 Description............................................................................................870
807.02 Materials ...............................................................................................870
807.03 Working Drawings................................................................................871
807.04 Excavation ............................................................................................872
(a) Trench Excavation ...............................................................................872
(b) Foundation Excavation ........................................................................873
(c) Landscape Replacement .......................................................................873
807.05 Backfilling ............................................................................................873
807.06 Placing Conduit ....................................................................................873

lxii
 TABLE OF CONTENTS
Section Title Page

807.07 Connections in Base of Lighting Standards ..........................................874

807.08 Placing Wire and Cable ........................................................................876
(a) Underground Through Cable-duct .......................................................876
(b) Underground Through Conduit............................................................876
(c) In Conduit Risers .................................................................................877
(d) Through Conduit in Bridge Coping .....................................................877
(e) Aerial Cable .........................................................................................877
807.09 Lighting Handholes ..............................................................................877
807.10 Concrete Foundations For Lighting Standards .....................................878
(a) Cast-in-Place Foundations ...................................................................878
(b) Precast Foundations .............................................................................879
(c) Grading of Foundations .......................................................................879
807.11 Placing Lighting Standards ...................................................................879
(a) Lighting Standards Under 80 ft in Height ............................................879
(b) High Mast Lighting Standards of 80 ft Height and Over .....................880
807.12 Grounding .............................................................................................880
807.13 Luminaires ............................................................................................881
(a) Installation............................................................................................881
(b) Warranty ..............................................................................................883
807.14 Sign, Underpass, Roadway, High Mast Lighting Location,
and Luminaire Identification ................................................................883
807.15 Service Point Power Entry ....................................................................884
(a) Types of Service Points........................................................................884
(b) Sign and Underpass Circuits ................................................................885
(c) Multiple Relay Switches ......................................................................885
807.16 Testing of Highway Lighting System ...................................................885
(a) Testing Lighting Circuitry....................................................................885
(b) Testing and Inspecting Luminaires ......................................................886
807.17 Pay Item and Installation Summary Sheets...........................................886
807.18 Method of Measurement .......................................................................887
807.19 Basis of Payment ..................................................................................887
SECTION 808 – PAVEMENT TRAFFIC MARKINGS ....................................890
808.01 Description............................................................................................890
808.02 Materials ...............................................................................................890
808.03 General Requirements ..........................................................................890
808.04 Longitudinal Markings and Milled Corrugations .................................891
(a) Center Lines .........................................................................................891
(b) Lane Lines ...........................................................................................892
(c) Edge Lines ...........................................................................................892
(d) Barrier Lines ........................................................................................892
(e) Markings in Retrofitted Corrugations ..................................................892
808.05 Transverse Markings and Pavement Message Markings ......................893
(a) Transverse Markings ............................................................................893

lxiii
 TABLE OF CONTENTS
Section Title Page

(b) Pavement Message Markings ..............................................................893

808.06 Curb Markings ......................................................................................893
808.07 Pavement Marking Material Application, Equipment, and
Performance Requirements ...................................................................893
(a) Traffic Paint .........................................................................................895
(b) Durable Pavement Marking Material ...................................................896
808.08 Marking Protection and Maintenance of Traffic...................................899
(a) Vehicle Signs .......................................................................................899
(b) Vehicle Warning Lights .......................................................................899
(c) Cones ...................................................................................................899
(d) Front Escort Vehicles...........................................................................900
(e) Marking Application Vehicles .............................................................900
(f) Rear Escort Vehicles ............................................................................900
808.09 Warranty for Durable Pavement Marking Material ..............................900
(a) Surface Applied Durable Pavement Marking Warranty ......................901
(b) Grooved Durable Pavement Marking Warranty ..................................901
808.10 Removal of Pavement Markings...........................................................901
808.11 Snowplowable Raised Pavement Markers ............................................902
(a) Surface Preparation ..............................................................................902
(b) Location ...............................................................................................902
(c) Reflector Color.....................................................................................902
(d) Installation ...........................................................................................902
(e) Removal of Markers.............................................................................903
(f) Replacement of Prismatic Reflectors....................................................903
808.12 Method of Measurement .......................................................................903
808.13 Basis of Payment ..................................................................................904
SECTION 809 – ITS CONTROLLER CABINETS AND
FOUNDATIONS ...................................................................................................906
809.01 Description............................................................................................906
809.02 Materials ...............................................................................................906
809.03 General .................................................................................................906
809.04 Grounding .............................................................................................906
809.05 Cabinet Wiring .....................................................................................907
809.06 Field Testing .........................................................................................907
809.07 Clean-Up...............................................................................................907
809.08 Method of Measurement .......................................................................908
809.09 Basis of Payment ..................................................................................908

DIVISION 900 – MATERIALS DETAILS

SECTION 901 – PCC MATERIALS ...................................................................909

901.01 Hydraulic Cement .................................................................................909

lxiv
 TABLE OF CONTENTS
Section Title Page

(a) General .................................................................................................909

(b) Portland Cement ..................................................................................909
(c) Masonry Cement ..................................................................................912
901.02 Fly Ash Used as a Pozzolan..................................................................912
(a) General .................................................................................................912
(b) Acceptance Criteria..............................................................................913
901.03 Ground Granulated Blast Furnace Slag Used As a Pozzolan................914
(a) General .................................................................................................914
(b) Acceptance Criteria..............................................................................915
901.04 Silica Fume Used As a Pozzolanic Mineral Admixture........................917
(a) General .................................................................................................917
(b) Acceptance Criteria..............................................................................917
901.05 Chemical Anchor System .....................................................................919
(a) Requirements .......................................................................................919
(b) Laboratory Testing ...............................................................................920
901.06 PCC Sealer/Healers ..............................................................................920
(a) Requirements .......................................................................................920
(b) Laboratory Testing ...............................................................................920
901.07 Rapid Setting Patch Materials...............................................................920
(a) Normal Weather Mixes ........................................................................920
(b) Hot Weather Mixes ..............................................................................920
(c) Requirements .......................................................................................920
(d) Test Report...........................................................................................922
901.08 Packaged, Dry, Combined Materials for Mortar and
Concrete................................................................................................922
901.09 Air-Cooled Blast Furnace Slag for Retaining Walls .............................922
901.10 Components of MSE Retaining Walls ..................................................923
(a) PCC Components .................................................................................923
(b) Joint Spacers and Joint Covering .........................................................926
SECTION 902 – ASPHALT MATERIALS.........................................................926
902.01 Asphalt ..................................................................................................926
(a) Performance Graded Asphalt Binders ..................................................926
(b) Asphalt Emulsions ...............................................................................928
(c) Cutback Asphalts .................................................................................932
(d) Utility Asphalt .....................................................................................933
(e) Asphalt for Coating Corrugated Metal Pipe .........................................934
902.02 Sampling and Testing Asphalt Materials ..............................................934
902.03 Application Temperatures ....................................................................939
SECTION 903 – CLASSIFICATION OF SOILS ...............................................940
903.01 Definitions ............................................................................................940
903.02 Soils Having 0% to 19% Retained on No. 10 (2.00 mm)
Sieve .....................................................................................................940

lxv
 TABLE OF CONTENTS
Section Title Page

903.03 Soils Having 20% or More Retained on No 10 (2.00 mm)

Sieve and More Than 20% Passing No. 200 (75 µm) Sieve .................941
903.04 Soils Having 20% or More Retained on No. 10 (2.00 mm)
Sieve and Less Than 20% Passing No. 200 (75 µm) Sieve ..................941
903.05 Organic Soils ........................................................................................941
903.06 Marly Soils ...........................................................................................941
SECTION 904 – AGGREGATES ........................................................................942
904.01 Aggregates ............................................................................................942
904.02 Fine Aggregates ....................................................................................944
(a) For Portland Cement Concrete .............................................................944
(b) For HMA Mixtures ..............................................................................944
(c) For SMA Mixtures ...............................................................................945
(d) For Pneumatically Placed Mortar ........................................................945
(e) Mortar Sand .........................................................................................945
(f) Mineral Filler for SMA ........................................................................945
(g) Snow and Ice Abrasives .......................................................................946
(h) Sizes of Fine Aggregates .....................................................................946
(i) Sampling and Testing ...........................................................................946
904.03 Coarse Aggregates ................................................................................947
(a) Classification of Aggregates ................................................................948
(b) Coarse Aggregate Angularity for HMA and SMA ..............................950
(c) Flat and Elongated ...............................................................................950
(d) Surface Aggregate Requirements.........................................................950
(e) Sizes of Coarse Aggregates ..................................................................952
(f) Sampling and Testing ...........................................................................953
904.04 Riprap ...................................................................................................953
(a) Dumped Riprap ....................................................................................953
(b) Grouted Riprap ....................................................................................953
(c) Revetment, Class 1, and Class 2 Riprap...............................................953
(d) Uniform Riprap ....................................................................................954
(e) Precast Concrete Riprap .......................................................................954
(f) Sizes of Riprap .....................................................................................954
904.05 Structure Backfill ..................................................................................954
904.06 Exceptions to AASHTO Standard Methods .........................................955
(a) Exceptions to AASHTO T 2 ................................................................955
(b) Exceptions to AASHTO T 11, T 27, and T 37.....................................955
(c) Exceptions to AASHTO T 27 for Coarse Aggregates..........................955
(d) Exceptions to AASHTO T 85 ..............................................................956
(e) Exceptions to AASHTO T 103 and 104...............................................956
SECTION 905 – MASONRY UNITS ...................................................................956
905.01 Clay or Shale Brick...............................................................................956
(a) Sewer Brick ..........................................................................................956

lxvi
 TABLE OF CONTENTS
Section Title Page

(b) Manhole Brick .....................................................................................956

(c) Building Brick ......................................................................................957
905.02 Concrete Brick ......................................................................................957
905.03 Concrete Masonry Blocks.....................................................................957
905.04 Precast Concrete Curbing .....................................................................957
905.05 Detectable Warning Surfaces................................................................957
905.06 Precast Concrete Units Not Otherwise Covered ...................................958
SECTION 906 – JOINT MATERIALS ...............................................................959
906.01 Joint Fillers ...........................................................................................959
906.02 Joint Sealing Materials .........................................................................959
(a) Joint Sealers .........................................................................................959
(b) Backer Rod ..........................................................................................961
906.03 Blank.....................................................................................................962
906.04 Blank.....................................................................................................962
906.05 Blank.....................................................................................................962
906.06 Blank.....................................................................................................962
906.07 Bridge Expansion Joints .......................................................................962
(a) Type SS ................................................................................................962
(b) Type M.................................................................................................963
906.08 High Density Bearing Strip...................................................................965
SECTION 907 – CONCRETE, CLAY, AND PLASTIC
DRAINAGE COMPONENTS .............................................................................965
907.01 Non-Reinforced Concrete Pipe .............................................................965
907.02 Reinforced Concrete Pipe .....................................................................965
907.03 Reinforced Concrete Horizontal Elliptical Pipe....................................966
907.04 Precast Concrete Manholes, Inlets, and Catch Basins ..........................966
907.05 Precast Reinforced Concrete Structure Sections ...................................967
(a) Box .......................................................................................................967
(b) Three-Sided..........................................................................................967
907.06 Precast Reinforced Concrete Headwalls, Wingwalls,
Footings and Spandrel Walls ................................................................967
907.07 Joint Membrane System for Precast Reinforced Concrete
Box Structure Sections .........................................................................968
907.08 Clay Pipe...............................................................................................968
907.09 Perforated Clay Pipe .............................................................................969
907.10 Drain Tile..............................................................................................969
907.11 Pipe Joint Sealant..................................................................................969
(a) Preformed Flexible Joint Sealants ........................................................969
(b) Bituminous Mastic Sealant ..................................................................969
907.12 Joint Mortar ..........................................................................................970
907.13 Rubber Type Gaskets ............................................................................970
907.14 Blank.....................................................................................................971

lxvii
 TABLE OF CONTENTS
Section Title Page

907.15 Blank.....................................................................................................971
907.16 Thermoplastic Pipe Requirements ........................................................971
907.17 Corrugated Polyethylene Drainage Tubing and Pipe ............................971
(a) Corrugated Polyethylene Tubing .........................................................971
(b) Corrugated Polyethylene Pipe..............................................................972
907.18 Perforated PVC Semicircular Pipe .......................................................972
907.19 Corrugated Polypropylene Pipe ............................................................972
907.20 Profile Wall Polyethylene Pipe .............................................................972
907.21 Smooth Wall Polyethylene Pipe ...........................................................972
907.22 Profile Wall PVC Pipe ..........................................................................972
907.23 Smooth Wall PVC Pipe ........................................................................973
907.24 Smooth Wall Pipe for Outlets ...............................................................973
(a) Type PSM PVC Pipe and Fittings ........................................................973
(b) Schedule 40 PVC Pipe .........................................................................973
907.25 Thermoplastic Liner Pipe .....................................................................973
(a) Solid Wall HDPE Liner Pipe ...............................................................973
(b) Profile Wall HDPE Liner Pipe .............................................................973
(c) Profile Wall PVC Liner Pipe................................................................974
907.26 Solvent Cements for PVC Pipe and Pipe Fittings .................................974
907.27 Elastomeric Seals ..................................................................................974
907.28 Reinforced Thermosetting Resin Pipe and Pipe Fittings ......................974
SECTION 908 – METAL PIPE ............................................................................975
908.01 Blank.....................................................................................................975
908.02 Corrugated Steel Pipe and Pipe-Arches ................................................975
908.03 Blank.....................................................................................................976
908.04 Corrugated Aluminum Alloy Pipe and Pipe-Arches.............................976
908.05 Blank.....................................................................................................976
908.06 Metal End Sections ...............................................................................976
908.07 Fully Bituminous Coated Corrugated and Lined Steel Pipe
and Pipe-Arches....................................................................................977
908.08 Polymer Precoated Galvanized Corrugated Steel Culvert
Pipe and Pipe-Arches............................................................................978
908.09 Structural Plate Pipe, Pipe-Arches, and Arches ....................................978
(a) Steel .....................................................................................................978
(b) Aluminum Alloy ..................................................................................978
908.10 Cast Iron Soil Pipe ................................................................................979
908.11 Steel Pipe ..............................................................................................979
908.12 Straps, Hook Bolts and Nuts Used in Anchors .....................................979
908.13 Blank.....................................................................................................979
908.14 Slotted Drain or Slotted Vane Drain Pipe .............................................979
SECTION 909 – PAINT AND LIQUID EPOXY ................................................980
909.01 General Requirements ..........................................................................980

lxviii
 TABLE OF CONTENTS
Section Title Page

909.02 For Metal ..............................................................................................980

(a) Zinc Primers .........................................................................................980
(b) Epoxy Intermediate Paint .....................................................................982
(c) Polyurethane Finish Coat .....................................................................982
(d) Waterborne Finish Paint ......................................................................983
(e) Finish Coat for Weathering Steel .........................................................984
909.03 Structural Steel Coating System ...........................................................985
(a) Toxicity ................................................................................................985
(b) Resistance ............................................................................................985
(c) Approval of Structural Steel Coating System ......................................985
909.04 Field Paint for Wood or Metal ..............................................................985
909.05 White and Yellow Waterborne Traffic Paint ........................................986
909.06 Blank.....................................................................................................988
909.07 Blank.....................................................................................................988
909.08 Blank.....................................................................................................988
909.09 Blank.....................................................................................................989
909.10 Non-Epoxy PCC Sealers.......................................................................989
(a) Properties .............................................................................................989
(b) Test Report...........................................................................................989
909.11 Epoxy-Resin-Base System for Bonding Plastic Concrete to
Hardened Concrete ...............................................................................989
909.12 Epoxy Resin Additives for Injection into Concrete ..............................989
SECTION 910 – METAL MATERIALS .............................................................990
910.01 Reinforcing Bars, Dowel Bars and WWR ............................................990
(a) General .................................................................................................990
(b) Specific Requirements .........................................................................990
(c) Inspection, Sampling, and Testing .......................................................993
910.02 Structural Steel .....................................................................................993
(a) Structural Steel .....................................................................................993
(b) Weathering Steel ..................................................................................994
(c) High Strength Structural Steel .............................................................994
(d) High Performance Steel .......................................................................994
(e) Charpy V-Notch Toughness Tests .......................................................994
(f) Mill Test Reports ..................................................................................995
(g) High Strength Bolts, Nuts, and Washers..............................................995
(h) Bolts other than High Strength Bolts ...................................................996
910.03 Permanent Metal Forms ........................................................................997
910.04 Steel Forgings and Steel Shafting .........................................................998
(a) Carbon Steel Forgings ..........................................................................998
(b) Cold Finished Carbon Steel Shafting ...................................................998
(c) Alloy Steel Forgings ............................................................................998
(d) Certification .........................................................................................998
910.05 Castings ................................................................................................998

lxix
 TABLE OF CONTENTS
Section Title Page

(a) Steel Castings .......................................................................................999

(b) Iron Castings ........................................................................................999
(c) Ductile Iron Castings ...........................................................................999
(d) Malleable Castings ...............................................................................999
(e) Carbon Steel Castings ..........................................................................999
910.06 Bronze and Copper Alloy ...................................................................1000
(a) Bronze Castings .................................................................................1000
(b) Copper Alloy Plates ...........................................................................1000
910.07 Steel Components of MSE Retaining Walls .......................................1000
(a) Backing Mats, Clevis Connector, Connector Bar, and
Wire-Facing........................................................................................1000
(b) Ground Reinforcement ......................................................................1001
(c) Fasteners ............................................................................................1002
(d) Alignment Pins ..................................................................................1002
910.08 Steel Bin-Type Retaining Wall Units .................................................1002
910.09 Guardrail .............................................................................................1002
910.10 Guardrail Posts ...................................................................................1003
(a) Steel Guardrail Posts ..........................................................................1003
(b) Timber Guardrail Posts ......................................................................1004
910.11 Guardrail Accessories, Fittings, and Hardware ..................................1004
(a) For Steel Beam Guardrail...................................................................1004
(b) For Steel Tube Guardrail ...................................................................1006
910.12 Blank...................................................................................................1007
910.13 Steel Fence Posts ................................................................................1007
(a) Line Posts ...........................................................................................1007
(b) Tubular Steel Fence Posts ..................................................................1007
(c) Fence Fastenings ................................................................................1008
910.14 Sign Posts ...........................................................................................1008
(a) Steel, Flanged, Channel Posts ............................................................1008
(b) Wide Flange Posts .............................................................................1010
(c) Structural Steel Posts .........................................................................1010
(d) Structural Aluminum Posts ................................................................1011
(e) Square Steel Posts ..............................................................................1011
(f) Portable Construction Sign Trailer .....................................................1012
910.15 Delineator Posts ..................................................................................1012
910.16 Copper Flashing ..................................................................................1013
910.17 Bronze or Copper Alloy Plates ...........................................................1013
910.18 Fence, Fittings, and Gates ...................................................................1014
(a) Farm Field or Woven Wire Fence ......................................................1014
(b) Steel Fabric Chain Link Fence ...........................................................1014
(c) Aluminum Fabric Chain Link Fence ..................................................1016
(d) Gates ..................................................................................................1017
910.19 Overhead Sign Structures ...................................................................1018
(a) Aluminum Trusses for Overhead Sign Structures, Box
lxx
 TABLE OF CONTENTS
Section Title Page

Truss and Dynamic Message Sign Structure Truss ............................1018

(b) Steel Overhead Sign Structures, Cantilever, Monotube,
Tri-Chord, Bridge Attached, and End-Supports for Box
Truss and Dynamic Message Sign Structure ......................................1019
910.20 Steel Bridge Railing Components.......................................................1022
910.21 Steel Sheet Piling ................................................................................1023
910.22 Grating for Grated Box End Sections .................................................1023
(a) Type I Grated Box End Sections ........................................................1023
(b) Type II Grated Box End Sections ......................................................1023
SECTION 911 – WOOD MATERIALS ............................................................1024
911.01 Untreated Lumber ...............................................................................1024
(a) General ...............................................................................................1024
(b) Species and Grade ..............................................................................1025
(c) Inspection ...........................................................................................1025
(d) Tolerances ..........................................................................................1025
(e) Untreated Piling .................................................................................1025
911.02 Treated Lumber ..................................................................................1026
(a) General ...............................................................................................1026
(b) Bridge Lumber ...................................................................................1026
(c) Piling ..................................................................................................1027
(d) Blank ..................................................................................................1027
(e) Sign Posts ...........................................................................................1027
(f) Sawn Timber Posts and Blockouts .....................................................1027
(g) Recreational Applications ..................................................................1031
(h) Preservatives ......................................................................................1031
SECTION 912 – CONCRETE CURING MATERIALS AND
ADMIXTURES ...................................................................................................1032
912.01 Curing Materials .................................................................................1032
(a) Burlap Cloth made from Jute or Kenaf ..............................................1032
(b) Waterproof Paper Blankets ................................................................1032
(c) White Polyethylene Sheeting, Film....................................................1032
(d) White Burlap Polyethylene Sheet ......................................................1032
(e) Liquid Membrane Forming Compounds ............................................1032
(f) Polyethylene Film...............................................................................1032
912.02 Curing-Sealing Materials ....................................................................1032
912.03 Admixtures for Use in Concrete .........................................................1033
(a) Air Entraining Admixtures .................................................................1033
(b) Chemical Admixtures for Concrete ...................................................1033
(c) Test Report .........................................................................................1034
912.04 Latex Modifiers ..................................................................................1035
912.05 Foaming Agent ...................................................................................1035

lxxi
 TABLE OF CONTENTS
Section Title Page

SECTION 913 – SOIL TREATMENT MATERIALS .....................................1036

913.01 Water ..................................................................................................1036
913.02 Calcium Chloride ................................................................................1036
913.03 Sodium Chloride .................................................................................1036
913.04 Lime ....................................................................................................1036
(a) Hydrated Lime for Masonry...............................................................1036
(b) Lime for Soil Modification ................................................................1036
913.05 Blank...................................................................................................1037
913.06 Bentonite Grout ..................................................................................1037
SECTION 914 – ROADSIDE DEVELOPMENT MATERIALS ....................1037
914.01 Special Topsoil for Roadside Development .......................................1037
914.02 Temporary Seed ..................................................................................1038
914.03 Fertilizer..............................................................................................1038
914.04 Grass and Legume Seed......................................................................1038
914.05 Mulch ..................................................................................................1042
(a) Mulch for Seeding ..............................................................................1042
(b) Mulch for Plants.................................................................................1043
914.06 Leguminous Inoculants .......................................................................1044
914.07 Sod ......................................................................................................1044
914.08 Plant Materials ....................................................................................1044
(a) Quality of Plant Material....................................................................1045
(b) Plant Names .......................................................................................1045
(c) Substitutions .......................................................................................1045
(d) Grading Standards..............................................................................1045
(e) Nursery Inspection and Plant Quarantine...........................................1045
(f) Balled and Burlapped Plants...............................................................1045
(g) Container Grown Plants .....................................................................1046
(h) Bare Rooted Plants.............................................................................1046
(i) Collected Plants ..................................................................................1046
(j) Forms, Shapes, and Condition of Plants .............................................1046
(k) Inspection...........................................................................................1047
(l) Shipment .............................................................................................1047
(m) Certification ......................................................................................1047
914.09 Miscellaneous Material .......................................................................1047
(a) Water ..................................................................................................1047
(b) Stakes for Bracing and Anchoring .....................................................1048
(c) Tree Wound Dressing ........................................................................1048
(d) Porous Material ..................................................................................1048
(e) Pipe ....................................................................................................1048
(f) Staples ................................................................................................1048
(g) Plastic Net ..........................................................................................1048
(h) Filter Sock..........................................................................................1049

lxxii
 TABLE OF CONTENTS
Section Title Page

SECTION 915 – BRIDGE PILES AND BEARINGS .......................................1049

915.01 Steel Pipe Piles and Epoxy Coated Steel Pipe Piles ...........................1049
(a) General Requirements ........................................................................1049
(b) Fluted Steel Pipe Piles .......................................................................1050
(c) Rounded Steel Pipe Piles ...................................................................1050
(d) Epoxy Coating for Piles .....................................................................1050
915.02 Steel H Piles and Epoxy Coated Steel H Piles ....................................1053
915.03 Pile Shoes ...........................................................................................1053
915.04 Elastomeric Bearings ..........................................................................1054
(a) Description .........................................................................................1054
(b) Materials ............................................................................................1054
(c) Manufacturing Requirements .............................................................1057
(d) Appearance and Dimensions..............................................................1058
(e) Quality Assurance ..............................................................................1058
(f) Certification ........................................................................................1058
915.05 Bearing Assemblies with Polytetrafluoroethylene, PTFE,
Sliding Surfaces ..................................................................................1059
SECTION 916 – MATERIALS CERTIFICATIONS .......................................1060
916.01 General ...............................................................................................1060
916.02 Types of Certifications .......................................................................1060
(a) Type A ...............................................................................................1060
(b) Type B ...............................................................................................1060
(c) Type C................................................................................................1060
(d) Type D ...............................................................................................1061
(e) Other Types ........................................................................................1061
(f) Requirements for Small Quantities of Materials ................................1061
(g) Buy America Requirement ................................................................1061
916.03 Sample Forms .....................................................................................1061
(a) For Buy America Requirement ..........................................................1061
(b) Sample Type A Certification Form....................................................1062
(c) Sample Type B Certification Form ....................................................1063
(d) Sample Type C Certification Form ....................................................1064
(e) Sample Type D Certification Form ....................................................1065
(f) Sample Asbestos Exclusion Letter .....................................................1066
SECTION 917 – QUALITY ASSURANCE AGGREGATE
CERTIFICATION ..............................................................................................1067
917.01 General Requirements ........................................................................1067
917.02 Quality Control Plan ...........................................................................1067
917.03 Source Approval Requirements ..........................................................1067
(a) Step 1 .................................................................................................1068
(b) Step 2 .................................................................................................1068
(c) Step 3 .................................................................................................1068

lxxiii
 TABLE OF CONTENTS
Section Title Page

917.04 Removal from Certified Producer Status ............................................1068

917.05 Appeals ...............................................................................................1069
SECTION 918 – GEOSYNTHETIC MATERIALS .........................................1069
918.01 General Requirements ........................................................................1069
918.02 Geotextile............................................................................................1069
(a) Geotextile Properties for Riprap and Revetment
Applications .......................................................................................1070
(b) Geotextile Properties for Underdrains and Drainage
Applications .......................................................................................1071
(c) Geotextile Properties for Pavement or Subgrade
Stabilizations ......................................................................................1072
(d) Geotextile Properties for Silt Fence ...................................................1073
918.03 Geomembrane .....................................................................................1074
918.04 Geocell Confinement System .............................................................1074
918.05 Geogrid ...............................................................................................1075
918.06 Fabric for Waterproofing ....................................................................1077
SECTION 919 – TRAFFIC SIGNS ....................................................................1077
919.01 Traffic Signs .......................................................................................1077
(a) Backing Material ................................................................................1078
(b) Sheeting Material ...............................................................................1079
(c) Letters, Numbers, Symbols, and Accessories ....................................1080
(d) Fasteners ............................................................................................1080
(e) Basis for Use ......................................................................................1080
SECTION 920 – HIGHWAY ILLUMINATION MATERIALS .....................1081
920.01 Highway Illumination Materials .........................................................1081
(a) Lighting Standards and Mast Arms, under 80 ft ................................1081
(b) High Mast Standards of 80 ft and Over .............................................1085
(c) Wire and Cable ..................................................................................1090
(d) Luminaires .........................................................................................1092
(e) Circuit Breakers and Enclosure ..........................................................1094
(f) Multiple Relay Switches with Photocell Receptacles.........................1095
(g) Materials Certification .......................................................................1095
(h) Junction Box ......................................................................................1095
SECTION 921 – PAVEMENT MARKING MATERIALS..............................1096
921.01 Blank...................................................................................................1096
921.02 Durable Marking Material ..................................................................1096
(a) Thermoplastic ....................................................................................1096
(b) Preformed Plastic ...............................................................................1096
(c) Multi-Component ...............................................................................1097
(d) Snowplowable Raised Pavement Marker and Cast Metal
Base ....................................................................................................1097

lxxiv
 TABLE OF CONTENTS
Section Title Page

(e) Pavement Marking Beads ..................................................................1098

SECTION 922 – TRAFFIC SIGNAL MATERIALS
AND EQUIPMENT ............................................................................................1099
922.01 Description..........................................................................................1099
922.02 Traffic Signal Control Equipment ......................................................1099
(a) Model Approval .................................................................................1099
(b) Controller Assemblies or Major Units Furnished and
Installed by the Contractor .................................................................1100
(c) Warranty ............................................................................................1101
(d) Certification of NEMA TS2 Traffic Control Equipment ...................1101
(e) NEMA TS2 Fully Actuated Solid State Controller Unit,
CU ......................................................................................................1102
(f) NEMA TS2 Cabinet, Auxiliary Equipment, and Terminal
and Facilities, TF, Requirements ........................................................1104
(g) Cabinets .............................................................................................1110
922.03 Signal Head Components ...................................................................1113
(a) General ...............................................................................................1113
(b) Housing, Door, and Visor ..................................................................1113
(c) Signal Indications...............................................................................1113
(d) Wiring ................................................................................................1114
(e) Section Coupling ................................................................................1114
(f) Terminal Block ...................................................................................1114
(g) Material Requirements .......................................................................1114
(h) Signal Backplates...............................................................................1115
(i) Certification ........................................................................................1115
922.04 Pedestrian Signal Components ...........................................................1115
(a) Pedestrian Signal Head ......................................................................1115
(b) Pedestrian Push-Button ......................................................................1116
922.05 Blank...................................................................................................1118
922.06 Disconnect Hanger Junction Box .......................................................1118
922.07 Signal Support Assemblies .................................................................1119
(a) Clearance............................................................................................1119
(b) Balance Adjuster ................................................................................1119
(c) Span Hanger .......................................................................................1119
(d) Tether Bracket ...................................................................................1119
(e) Pipe Arm Assemblies .........................................................................1120
922.08 Signal Cantilever Mount Signal Bracket ............................................1120
922.09 Pedestal Poles and Cast Aluminum Pedestal Bases ............................1121
(a) Cast Aluminum Pedestal Base ...........................................................1121
(b) Pedestal Pole ......................................................................................1122
(c) Pole Cap .............................................................................................1122
922.10 Signal Supports ...................................................................................1122
(a) Steel Strain Pole .................................................................................1123

lxxv
 TABLE OF CONTENTS
Section Title Page

(b) Timber Strain Pole .............................................................................1124

(c) Signal Cantilever Structures ...............................................................1124
(d) Downguys, Anchors, Rods, and Guards ............................................1125
(e) Support Cable.....................................................................................1126
922.11 Signal Cable ........................................................................................1127
(a) Hook-up Wire ....................................................................................1127
(b) Signal Control Cable ..........................................................................1127
(c) Service Cable .....................................................................................1127
922.12 Signal Interconnect .............................................................................1128
(a) Integral Messenger Interconnect Cable ..............................................1128
(b) 6 Pair/19 Telemetry Cable .................................................................1128
(c) Fiber Optic Interconnect Cable ..........................................................1128
(d) Radio Interconnect Using Spread Spectrum Radio Modems .............1128
922.13 Detection Components........................................................................1129
(a) Loop Detector Lead-in Cable .............................................................1129
(b) Roadway Loop Wire ..........................................................................1129
(c) Other Vehicle Detection Systems ......................................................1129
922.14 Ground Wire .......................................................................................1129
922.15 Splicing Kit .........................................................................................1129
922.16 Ground Rod and Connections .............................................................1129
922.17 Handholes ...........................................................................................1130
(a) Type I (Concrete Handhole)...............................................................1130
(b) Type II (Polymer Concrete Handhole)...............................................1130
922.18 Entrance Switch ..................................................................................1130
922.19 Conduit and Fittings ...........................................................................1131
(a) Steel Conduit ......................................................................................1131
(b) PVC Schedule 40 or 80 Conduit ........................................................1131
(c) Fiberglass Conduit .............................................................................1131
(d) HDPE Schedule 40 or 80 Conduit .....................................................1131
922.20 Detector Housing ................................................................................1132
922.21 Certification ........................................................................................1132
SECTION 923 – TEMPORARY TRAFFIC CONTROL DEVICES ..............1132
923.01 Temporary Pavement Marking Tape ..................................................1132
923.02 Temporary Raised Pavement Marker .................................................1132
923.03 Construction Warning Lights..............................................................1132
(a) Flash Requirements ............................................................................1133
(b) Optical Requirements ........................................................................1133
(c) Lens Requirements .............................................................................1134
(d) Head and Case ...................................................................................1135
(e) Photoelectric Controls ........................................................................1135
923.04 Flashing Arrow Sign ...........................................................................1135
(a) Solar Powered ....................................................................................1136
(b) Diesel Powered ..................................................................................1136

lxxvi
 TABLE OF CONTENTS
Section Title Page

(c) AC Powered .......................................................................................1136

923.05 Portable Changeable Message Sign ....................................................1138
923.06 Temporary Worksite Speed Limit Sign Assembly .............................1138
923.07 Tubular Marker ...................................................................................1138
923.08 Automated Flagger Assistance Device ...............................................1138
(a) Signs...................................................................................................1138
(b) Signals ...............................................................................................1139
(c) Supplemental Conspicuity Devices....................................................1139
(d) Gate Arm ...........................................................................................1139
(e) Cabinets and Controller .....................................................................1139
(f) Remote Control Device ......................................................................1139
(g) Batteries and Charging System ..........................................................1139
(h) Trailer ................................................................................................1139
923.09 Acceptance of Temporary Traffic Control Devices ............................1140
SECTION 924 – WELDING SUPPLIES ...........................................................1140
924.01 Welding Supplies ................................................................................1140
(a) Aluminum Alloy Base Metals ............................................................1140
(b) Blank ..................................................................................................1141
SECTION 925 – ITS CONTROLLER CABINET ............................................1141
925.01 General Requirements ........................................................................1141
925.02 Model Approval ..................................................................................1143
925.03 Warranty .............................................................................................1143
925.04 Cabinet Accessories ............................................................................1144
(a) Rack Frame Assembly .......................................................................1144
(b) Equipment Shelves ............................................................................1144
(c) Sunshield ............................................................................................1144
(d) Side Panels .........................................................................................1144
(e) Data Pocket ........................................................................................1144
(f) Equipment Labels ...............................................................................1144
(g) Primary Power Terminal Block .........................................................1144
(h) Ground Lug ........................................................................................1145
(i) Ground Bus .........................................................................................1145
(j) Transient Voltage Surge Suppression .................................................1145
(k) Load Center Main Breaker.................................................................1145
(l) Load Center Panelboard .....................................................................1146
(m) GFI Duplex Receptacle.....................................................................1146
(n) Duplex Receptacle .............................................................................1146
(o) Terminal Strip Surge Protector ..........................................................1146
(p) Door Open Switches ..........................................................................1146
(q) Light Switch.......................................................................................1146
(r) Lamp Holders .....................................................................................1146
(s) Lamps .................................................................................................1146

lxxvii
 TABLE OF CONTENTS
Section Title Page

(t) Circulating Fans ..................................................................................1147

(u) Enclosure Heaters ..............................................................................1147
(v) Heater Relays .....................................................................................1147
(w) Thermostats .......................................................................................1147
(x) Detector Card DIN Rail Terminal Blocks..........................................1147
(y) I/O Module.........................................................................................1147
(z) Detector Card Rack ............................................................................1148
(aa) Padlocks ...........................................................................................1148
(bb) Other Cabinet Equipment ................................................................1148
925.05 Cabinet Wiring ...................................................................................1148
925.06 Drawings.............................................................................................1149
SECTION 926 – MISCELLANEOUS MATERIALS ......................................1149
926.01 Flexible Delineator Posts ....................................................................1149
(a) Type I. Ground Mounted Flexible Delineator Post ............................1149
(b) Type II. Surface Mounted Flexible Delineator Post ..........................1149
926.02 Delineators ..........................................................................................1150
(a) Acrylic Plastic Delineators .................................................................1150
(b) Reflective Sheeting Delineators .........................................................1150
(c) Barrier Delineators .............................................................................1151
(d) Temporary Barrier Delineator............................................................1151
926.03 Alternate Material Guardrail Blockouts..............................................1151

INDEX OF PAY ITEMS .....................................................................................1153

lxxviii
 101.01

DIVISION 100 – GENERAL PROVISIONS

SECTION 101 – DEFINITIONS AND TERMS

Wherever in these specifications or in other contract documents the following

terms or pronouns in place of them are used, the intent and meaning shall be interpreted
as follows.

101.01 Abbreviations
Wherever the following abbreviations are used in these specifications, the
Proposal book, or on the plans, they are to be construed the same as the respective
10 expressions represented.

AAR Association of American Railroads

AASHTO American Association of State Highway and
Transportation Officials
ACBF air-cooled blast furnace slag
AE asphalt emulsion
AIA American Institute of Architects
AMRL AASHTO Materials Reference Laboratory
AMS Aerospace Material Specifications
20 ANSI American National Standards Institute
AP class A aggregate for concrete slabs
APS accessible pedestrian signal
ARA American Railway Association
AREA American Railway Engineering Association
ARS asphalt roofing shingles
ASCE American Society of Civil Engineers
ASLA American Society of Landscape Architects
ASNS American Standards for Nursery Stock
ASTM American Society for Testing and Materials
30 ATSSA American Traffic Safety Services Association
AWPA American Wood Protection Association
AWS American Welding Society
AWWA American Water Works Association
BBR bending beam rheometer
BF blast furnace slag
BMP best management practice
CAPWAP Case Pile Wave Analysis Program
CCPR Cold Central Plant Recycling
CCRL Cement and Concrete Reference Laboratory of the
40 National Institute of Standards and Technology
CESSWI Certified Erosion Sediment and Stormwater Inspector
CFR Code of Federal Regulations
CIR Cold In-Place Recycling

1
 101.01

CISEC Certified Inspector of Sediment and Erosion Control

CPESC Certified Professional in Erosion and Sediment Control
CMA cold mix asphalt
CMD concrete mix design
COE Corps of Engineers (US Army)
CWI Certified Welding Inspector
50 DBE disadvantaged business enterprise
DCP Dynamic Cone Penetrometer
DMF design mix formula
DSR dynamic shear rheometer
DTE District Testing Engineer
EPA Environmental Protection Agency
ESAL equivalent single-axle loads
FDR Full Depth Reclamation
FHWA Federal Highway Administration, Department of
Transportation
60 FSS Federal Specifications and Standards, General Services
Administration
GBF granulated blast furnace slag
GGBFS ground granulated blast furnace slag
HDB hydrostatic design basis
HDPE high density polyethylene
HFRS high float seal coat asphalt emulsion
HMA hot mix asphalt
HRWR high range water reducing
HRWRR high range water reducing and retarding
70 IAC Indiana Administrative Code
IC Indiana Code
IDEM Indiana Department of Environmental Management
IDNR Indiana Department of Natural Resources
IEEE Institute of Electrical and Electronics Engineers
IMSA International Municipal Signal Association
IOSHA Indiana Occupational Safety and Health Administration
INDOT Indiana Department of Transportation
ISO International Organization for Standardization
ITM Indiana Test Method or Procedure
80 JITT Just-in-Time Training
JMF job mix formula
LRFD Load and Resistance Factor Design
LWD Light Weight Deflectometer
MAF mixture adjustment factor
MC medium curing asphalt
MCA medium curing asphalt with additive
MSE mechanically stabilized earth
MSG maximum specific gravity
MUTCD Manual on Uniform Traffic Control Devices

2
 101.01

90 NCHRP National Cooperative Highway Research Program

NEMA National Electrical Manufacturers Association
NEPCOAT North East Protective Coating Committee
NHS National Highway System
NIST National Institute of Standards and Technology
NOI Notice of Intend
NOS Notice of Sufficiency
NOT Notice of Termination
NPDES National Pollutant Discharge Elimination System
NTPEP National Transportation Product Evaluation Program
100 OG open graded
OSHA U.S. Occupational Safety and Health Administration
PAV pressurized aging vessel
PCC portland cement concrete
PCCP portland cement concrete pavement
PDA pile driving analysis
PG performance grade asphalt
POTW Publicly Owned Treatment Works
PVC polyvinyl chloride
QC quality control
110 QC/QA quality control/quality assurance
QCP quality control plan
RAP recycled asphalt pavement
RBC reclaimed base course
RCBA reinforced concrete bridge approaches
RCRA Resource Conservation and Recovery Act
RECP rolled erosion control product
RS seal coat asphalt emulsion
RTFO rolling thin film oven
SAE Society of Automotive Engineers
120 SC slow curing asphalt
SCA slow curing asphalt with additive
SF steel furnace slag
SHRP Strategic Highway Research Program
SMA stone matrix asphalt
SSD saturated surface dry
SSPC the Society for Protective Coatings
SWPPP Stormwater Pollution Prevention Plan
SWQCP Stormwater Quality Control Plan
SWQM Stormwater Quality Manager
130 TCLP Toxicity Characteristic Leaching Procedure
TSR tensile strength ratio
UA utility asphalt
UL Underwriter Laboratory
UST underground storage tank
VFA voids filled with asphalt

3
 101.02

VMA voids in mineral aggregate

VOC volatile organic compounds
WWR welded wire reinforcement

140 101.02 Above Normal Inclement Weather Days

The specific yearly number of days over and above the normal inclement weather
days shown below which work on the controlling operation is delayed by rain or other
inclement weather. The above normal days include the days following a weather event
on which the controlling operation is still delayed.

The following table shows the estimated number of normal inclement weather
days in each month, the Department considers when setting completion dates.

ESTIMATED NUMBER OF DAYS

Month
R, RS, and M Contracts T and B Contracts
April 18 8
May 8 5
June 5 3
July 5 3
August 4 3
September 5 3
October 6 4
November 12 5

150 101.03 Blank

101.04 Bid Bond

The approved form of security furnished with a bid to guarantee that the bidder
will enter into the contract if the bidder is awarded the contract.

101.05 Bidder
An individual, partnership, firm, corporation, or combination of same submitting
a bid for the advertised work.

160 101.06 Bridge

A structure, including supports, erected over a depression or an obstruction such
as water, highway, or a railway having a track or passageway for carrying traffic or
other moving loads, and having a length measured along the center of the roadway of
more than 20 ft between undercopings of abutments or extreme ends of openings for
multiple boxes.

(a) Length
The length of a bridge structure is the overall length measured along the line of
survey stationing back to back of backwalls of abutments, if present, otherwise end to
170 end of the bridge floor, but in no case less than the total clear opening of the structure.

4
 101.14

(b) Roadway Width

The clear width measured at right angles to the longitudinal centerline of the
bridge between the bottom of curbs or guard timbers or, in the case of multiple height
of curbs, between the bottoms of the lower risers.

101.07 Business Day

Monday through Friday except for holidays in accordance with 101.26.

180 101.08 Calendar Day

Every day shown on the calendar.

101.09 Change Order

A written order issued to the Contractor covering changes in the contract and
establishing payment for the work affected by the changes.

101.10 Construction Limits

The line shown on the plans beyond which no work is intended to be performed
and that which no disturbance of existing terrain will be allowed unless otherwise
190 authorized by the Engineer.

101.11 Contract
The written agreement between the Department and the Contractor setting forth
the obligations of the parties thereto including, but not limited to, the performance of
the work, the furnishing of labor and materials, and the basis of payment.

The contract may include, but is not limited to, the Proposal book, Schedule of
Pay Items, contract form, bid bond, performance bond, specifications, special
provisions, information to bidders, instructions to bidders, general and detailed plans,
200 notice to proceed, and any change orders and agreements that are required to complete
the construction of the work in an acceptable manner, including authorized extensions
thereof, all of which constitute one instrument.

101.12 Contract Information Book

A document which includes a contract information sheet, an estimate of
quantities, special provisions, and additional contract requirements. Such document
may include the plans.

101.13 Contract Item (Pay Item)

210 A specifically described unit of work for which a price is provided in the contract.

101.14 Contract Time

The number of work days or calendar days allowed for completion of the contract
or phase of the contract, including authorized time extensions.

If a calendar date of contract completion or contract phase completion is shown

in the Proposal book in lieu of the number of work or calendar days, the contract shall

5
 101.15

be completed by that date.

220 101.15 Contractor

The individual, partnership, firm, corporation, or combination of same contracting
with or desiring to contract with the Department for performance of prescribed work.

101.16 Culvert
A structure not classified as a bridge which provides an opening under the
roadway.

101.17 Commissioner
The chief executive and chief administrative officer of the Department who is
230 responsible for administering the Department.

101.18 Department
The Indiana Department of Transportation as constituted under the laws of
Indiana for the administration of highway work.

101.19 Embankment Foundation

The existing materials upon which an embankment is to be constructed.

101.20 Engineer
240 The Chief Engineer of the Department acting directly or through the duly
authorized representatives.

101.21 Equipment
All machinery and equipment together with the necessary supplies for upkeep and
maintenance, and all tools and apparatus necessary for the proper construction and
acceptable completion of the work.

101.22 Extra Work

An item of work not provided for in the contract as awarded but found essential
250 to the satisfactory completion of the contract.

101.23 Failed Material

Material or a finished product determined not to be in accordance with applicable
specifications or tolerances and that has been adjudicated by the Department’s Failed
Materials Committee or other Department representatives in accordance with 105.03.

101.24 Force Account Work

Extra work in the contract for which the Contractor and the Department cannot
reach agreement on the unit price or lump sum price prior to performing the work.
260 Settlement will be made upon receipt and approval of documents substantiating and
truly representing the allowable costs incurred by the Contractor for performing such
extra work.

6
 101.30

101.25 Frequency Manual

A document issued by the Department which is titled Manual for Frequency of
Sampling and Testing and Basis for Use of Materials. The number of samples and
tests, the basis for approval, the basis for use, and similar requirements for furnished
materials are specified in the document.

270 101.26 Holidays

Holidays are considered to be:

All Sundays
New Year’s Day
Martin Luther King Day
Lincoln’s Birthday
Washington’s Birthday
Good Friday
Primary Election Day
280 Memorial Day
Independence Day
Labor Day
Columbus Day
Election Day
Veteran’s Day
Thanksgiving Day
Friday after Thanksgiving Day
Christmas Day

290 If a holiday listed above, except Sunday, falls on a Sunday, the following Monday
shall be considered a holiday. If a holiday listed above falls on a Saturday, the
preceding Friday shall be considered a holiday.

101.27 Invitation for Bids

The advertisement for proposals for all work or materials on which bids are
required. Such advertisement will indicate with reasonable accuracy the quantity and
location of the work to be done or the character and quantity of the material to be
furnished and the time and place of the opening of proposals.

300 101.28 Itemized Proposal

The Schedule of Pay Items shown in the Proposal book.

101.29 Laboratory
The testing laboratory of the Department or any other testing laboratory which
may be designated by the Engineer.

101.30 Major and Minor Contract Items

All contract items having an original contract value in excess of 5% of the original
contract amount shall be considered as major items. Minor contract items shall be all

7
 101.31

310 items shown in the Schedule of Pay Items which constitutes 5% or less of the original
contract amount.

101.31 Materials
All substances specified for use in the construction of the project and its
appurtenances.

101.32 Notice to Proceed

Written notice to the Contractor to proceed with the contract work including,
when applicable, the date of beginning of contract time.
320
101.33 Open to Unrestricted Traffic
The condition that exists when all pavement work is completed, including surface
courses, and shoulders. All safety features including guardrail and signs are in place,
and pavement markings are in the final marking pattern.

101.34 Pavement Structure

The combination of subbase, base course, and surface course placed on a subgrade
to support the traffic load and distribute it to the roadbed.

330 101.35 Performance Bond

The approved form of security, furnished and executed by the bidder and its surety
or sureties, guaranteeing complete execution of the contract, as defined herein, and for
the payment of all legal debts pertaining to the construction of the project. The
performance bond will be in effect after both parties have signed the contract and the
contract has been approved by the Attorney General of the State.

101.36 Plans
The approved plans, profiles, typical cross sections, standard drawings, working
drawings, and supplemental drawings or exact reproductions thereof which show the
340 location, character, dimensions, and details of the work to be done.

101.37 Professional Engineer

A person who is duly licensed by the Indiana Professional Licensing Agency to
practice engineering in the State.

101.38 Profile Grade

The trace of a vertical plane intersecting the top surface of the proposed wearing
surface, usually along the longitudinal centerline of the roadbed. Profile grade means
either elevation or gradient of such trace according to the context.
350
101.39 Project
The specific section of the highway where work is to be performed under the
contract.

8
 101.47

101.40 Proposal
The Schedule of Pay Items shown in the Proposal book.

101.41 Proposal Book

A document which includes the Proposal Sheet, Schedule of Pay Items, and
360 contract forms which shall be completed or signed by the bidder.

101.42 Quality Assurances Adjustments

Monetary credits either to the Contractor or to the Department for material used
that are outside specified tolerances but within allowable tolerances as indicated for
QC/QA pay items or others that may apply.

101.43 Reasonably Close Conformance

Reasonably close conformance means conformance with reasonable and
customary manufacturing and construction tolerances where working tolerances are
370 not specified. Where working tolerances are specified, reasonably close conformance
means conformance with such working tolerances. Without detracting from the
complete and absolute discretion of the Engineer to insist on such tolerances as
establishing reasonably close conformance, variations beyond such tolerances may be
accepted as reasonably close conformance where they will not materially affect the
value or utility of the work and the interest of the State.

Reasonably close conformance also means, for materials manufactured according

to the English system of measures, that the materials are about the same size as nearly
equivalent metric-sized materials. For materials manufactured according to the metric
380 system of measures, reasonably close conformance means the materials are about the
same size as nearly equivalent English-sized materials. Nearly equivalent sized
materials will be accepted unless the nearly equivalent material is outside specified
working tolerances in the contract documents.

101.44 Recurring Special Provisions

Approved additions or revisions to the Standard Specifications with the intent to
be used on multiple contracts.

101.45 Right-of-Way
390 A general term denoting land, property, or interest therein, usually in a strip,
acquired for or devoted to a highway.

101.46 Road
A general term denoting a public way for purposes of vehicular travel, including
the entire area within the right-of-way.

101.47 Roadbed
The graded portion of a highway within top and side slopes, prepared as a
foundation for the pavement structure and shoulders.
400

9
 101.48

101.48 Roadside
A general term denoting the area adjoining the outer edge of the roadway.
Extensive areas between the roadways of a divided highway may also be considered
roadside.

101.49 Roadside Development

That work necessary to the complete highway which provides for the preservation
of landscape materials and features; the rehabilitation and protection against erosion
of all areas disturbed by construction through seeding, sodding, mulching, and the
410 placing of other ground covers; and such suitable planting and other improvements as
may increase the effectiveness and enhance the appearance of the highway.

101.50 Roadway
The portion of a highway within limits of construction.

101.51 Schedule of Pay Items

A part of the Proposal book which shows pay items, quantities, and pay units for
the contract. The bidder shall complete the document by filling in the unit prices and
the bid amounts.
420
101.52 Shoulder
The portion of the roadway contiguous with the traveled way for accommodation
of stopped vehicles, for emergency use, and for lateral support of base and surface
courses.

101.53 Sidewalk
The portion of the roadway primarily constructed for the use of pedestrians.

101.54 Special Provisions

430 Additions or revisions to the Standard Specifications that describe conditions and
requirements for special situations on a specific project.

101.55 Specifications
A general term applied to all directions, provisions, and requirements pertaining
to performance of the work.

101.56 Specified Completion Date

The date on which the contract work is specified to be complete.

440 101.57 State

The State of Indiana acting through its authorized representative.

101.58 Street
A general term denoting a public way for purposes of vehicular travel, including
the entire area within the right-of-way.

10
 101.67

101.59 Structures
Bridges, culverts, catch basins, drop inlets, retaining walls, cribbing, manholes,
end walls, buildings, sewers, service pipes, underdrains, foundation drains, and other
450 features which may be encountered in the work and not otherwise classified herein.

101.60 Substantial Completion

The date, as determined by the Department, when the construction of a project is
sufficiently completed in accordance with the plans and specifications, as modified by
any approved change orders, so that it can be used for its intended purpose. In order
for a project to be used for its intended purpose, all lanes shall be, or have the ability
to be, opened to traffic without further need for them to be restricted for any purpose
except for the placement or maintenance of permanent erosion and sediment control
or the maintenance or removal of temporary erosion and sediment control. As a
460 minimum, all of the following criteria shall be met: All lanes of the road or bridge
shall be completed through its final roadway surface, including shoulders, with all the
sidewalks, curbs, drainage features, markings, permanent safety appurtenances,
lighting, traffic signals, and signing as shown in the contract documents.

101.61 Subcontractor
An individual, partnership, firm, corporation, or combination of same to whom
the Contractor sublets part of the contract.

101.62 Subgrade
470 The upper portion of a roadbed upon which the pavement structure and shoulders
are constructed.

101.63 Substructure
All of that part of the structure below the bearings of simple and continuous spans,
skewbacks or arches, and tops of footings of rigid frames together with backwalls,
wingwalls, and wing protection railings.

101.64 Superintendent
The authorized representative of the Contractor in responsible charge of the work.
480
101.65 Superstructure
The entire structure except the substructure.

101.66 Surety
The corporate body bound with and for the Contractor for the full and complete
performance of the contract and for the payment of all debts pertaining to the work.
When applied to the Bid Bond, it refers to the corporate body which engages to be
responsible in the execution of the contract by the bidder, within the specified time.

490 101.67 Technician or Inspector

The authorized representative of the Engineer assigned to make detailed
inspections of contract performances.

11
 101.68

101.68 Titles (Headings)

The titles or headings of the sections and subsections herein are intended for
convenience of reference and shall not be considered as having any bearing on their
interpretation.

101.69 Township, Town, City

500 A subdivision of a county used to designate or identify the location of the
proposed work.

101.70 Traveled Way

The portion of the roadway for the movement of vehicles, exclusive of shoulders
and auxiliary lanes.

101.71 Unique Special Provisions

Additions or revisions to the Standard Specifications that pertain only to a specific
situation on a contract that is not covered by an existing Recurring Special Provision
510 or other standard contract document, and is intended only for a single use in a specific
contract.

101.72 Work
The furnishing of labor, materials, equipment, and incidentals necessary or
convenient to the successful completion of the project and the carrying out of the duties
and obligations imposed by the contract.

101.73 Work Day

A calendar day, exclusive of Saturdays and State recognized holidays, on which
520 weather and other conditions not under the control of the Contractor will enable work
on the controlling operations for at least 50% of the day with the normal working force.
However, if weather is unsuitable for work on the controlling operation at the normal
starting time, and remains unsuitable for 2 h, a work day will not be charged if the
Contractor does not work. No work days will be charged during the months of
December, January, February, or March, unless otherwise specified.

101.74 Working Drawings

Supplementary bridge plans, stress sheets, shop drawings, erection plans,
falsework plans, framework plans, cofferdam plans, bending diagrams for
530 reinforcement, or any other supplementary plans, detailed drawings, design drawings,
or similar data which the Contractor is required to submit for approval.

12
 103.01

SECTION 102 – BIDDING REQUIREMENTS AND CONDITIONS

102.01 Prequalification and Bidding

The bidder will be required to prequalify and follow the bidding procedures as set
out in the rules for Prequalification of Contractors and Bidding, 105 IAC 11, now on
file with the Indiana Secretary of State, copies of which are available upon request in
the Contract Administration Division.

If apparent errors, discrepancies, or unclear statements are found in the contract

10 documents prior to letting, the District Construction Engineer for the district shown on
the Proposal sheet shall be contacted by telephone or fax.

102.02 Certification Regarding Lobbying for Contracts, Grants, Loans, and

Cooperative Agreements
This requirement will apply only to a federal aid contract. The bidder certifies to
the best of its knowledge and belief, that it has complied with the requirements of
FHWA-1273 Part XI, included in the Contract Information book.

If required, the bidder shall complete and submit Standard Form-LLL, Disclosure
20 Form to Report Lobbying, in accordance with its instructions. Such form and its
instructions are available from the Department.

SECTION 103 – AWARD AND EXECUTION OF CONTRACT

103.01 Disadvantaged Business Enterprise Program

This requirement will apply only to a federal aid contract.

(a) General Requirements

Failure to carry out the requirements set forth in 49 CFR Part 26, as outlined in
the Department's DBE Program Manual, shall constitute a breach of contract and, after
notification, may result in such contract sanctions as the Department or the Federal
10 Highway Administration may determine to be appropriate, including, but not limited
to: (a) withholding of payments to the Contractor under the contract until the
Contractor complies, and/or (b) cancellation, termination or suspension of the contract,
in whole or in part.

The above referenced CFR section requires the following policy and
disadvantaged business enterprise obligation to be included in all subsequent
agreements between the Contractor and all subcontractors as follows:

1. It will be the policy of the Department to create a level

20 playing field on which DBE’s can compete fairly for
federally funded contracts. Consequently, the
disadvantaged business enterprise requirements of 49 CFR
Part 26, as outlined in the Department’s DBE Program
Manual, apply to this contract.
13
 103.01

2. The Contractor shall not discriminate on the basis of race,

color, national origin, religion, sex, sexual orientation or
gender identity in the award and performance of this
contract. The Contractor shall carry out the applicable DBE
30 requirements in the award and administration of federally
funded contracts. Failure by the Contractor to carry out
these requirements is a material breach of this contract
which may result in the termination of this contract or such
other remedy as the Department deems appropriate, which
may include, but is not limited to: withholding progress
payments; assessing sanctions; liquidated damages; and/or
disqualifying the Contractor from future bidding as non-
responsible. The Contractor shall include language
prohibiting discrimination on the basis of race, color,
40 national origin, religion, sex, sexual orientation or gender
identity in the performance of this contract and all
subcontracts.

(b) Definitions
The following definitions will apply.

1. DBE
A small business concern which is at least 51% owned by one or more socially
and economically disadvantaged individuals, or, in the case of a publicly owned
50 business, at least 51% of the stock of which is owned by one or more socially and
economically disadvantaged individuals; and whose managements and daily business
operations are controlled by one or more of the socially and economically
disadvantaged individuals who own it.

2. Small Business Concern

A small business as defined pursuant to Section 3 of the Small Business Act and
relevant regulations promulgated pursuant thereto, except that a small business
concern shall not include a concern or group of concerns controlled by the same
socially and economically disadvantaged individual or individuals which has annual
60 average gross receipts in excess of $16.6 million over the previous three fiscal years.

3. Socially and Economically Disadvantaged Individuals

Those individuals who are citizens of the United States or lawfully admitted
permanent residents and who are women, black Americans, Hispanic Americans,
Native Americans, Asian-Pacific Americans, Asian-Indian Americans, or other
minorities or individuals found to be disadvantaged by the Small Business
Administration pursuant to Section 8(a) of the Small Business Act.

14
 103.01

4. Certified DBE
70 A business enterprise which has completed and filed a request for certification
with the Department, and that the business enterprise has been reviewed and
determined to comply with the guidelines established in 49 CFR Part 26. Business
enterprises which are determined to be eligible will be certified as DBEs to perform
specific types of work.

(c) Goal
A contract provision DBE goal may be shown on the Proposal sheet. Such goal,
if required, has been established as the desired minimum amount to be contracted to
DBEs. The Contractor shall meet or exceed the goal, or demonstrate that it could not
80 be met despite good faith efforts. Achievement of the goal does not relieve the
Contractor of the requirement for affirmative action on subsequent subcontracting on
this contract. Only work with listed DBEs that are certified prior to the date of the
letting will count toward the goal. Credit towards contract goals will be given only for
work performed by certified DBEs in the work areas for which they have been
certified. The same requirements with respect to obtaining the goal apply for a
Contractor that is certified as a DBE. A DBE Contractor shall either achieve the goal
utilizing other DBE firms or demonstrate that the goal could not be met despite good
faith efforts.

90 Contracting may be in the form of a subcontract, lease agreement, or material

supply agreement. Prime contractors will receive 100% credit for work done by the
DBE under subcontracts and lease agreements. Credit for utilization of a DBE material
supplier depends on whether the supplier is a manufacturer, regular dealer or broker.
Full credit will be given for suppliers who manufacture the items and are certified as
Supplier Manufacturer in the DBE repository. Credit will be limited to 60% of the
expenditure for suppliers acting as a regular dealer and are certified as Supplier
Regular Dealer in the DBE repository. Credit will be limited to fees and commissions
for suppliers acting as a broker and are certified as Supplier Broker in the DBE
repository. Suppliers shall also perform a commercially useful function in order for
100 credit to be received.

The Contractor shall not terminate or reduce a commitment to a DBE, or an

approved substitute DBE firm, that was listed on the Affirmative Action Certification
without the prior written consent of the Department. This includes, but is not limited
to, instances in which the Contractor seeks to perform work originally designated for
a DBE subcontractor with its own forces or those of an affiliate, a non-DBE firm, or
with another DBE firm. Unless the Department provides written consent, the
Contractor shall not be entitled to any payment for work or materials unless it is
performed or supplied by the listed DBE.
110
Written consent will only be provided by the Department if the Contractor has
good cause to terminate or reduce its commitment to the DBE firm. Good cause shall
consist of any of the following circumstances:

15
 103.01

1. The listed DBE subcontractor fails or refuses to execute a

written contract.

2. The listed DBE subcontractor fails or refuses to perform

the work of its subcontract in a manner consistent with
120 normal industry standards, unless such failure or refusal of
the DBE subcontractor to perform its work on the
subcontract results from the bad faith or discriminatory
action of the Contractor.

3. The listed DBE subcontractor fails or refuses to meet the

Contractor's reasonable, nondiscriminatory bond
requirements.

4. The listed DBE subcontractor becomes bankrupt,

130 insolvent, or exhibits credit unworthiness.

5. The listed DBE subcontractor is ineligible to work on

public works projects because of suspension and
debarment proceedings pursuant to 2 CFR Parts 180, 215
and 1200 or applicable state law.

6. The Department has determined that the listed DBE

subcontractor is not a responsible contractor.

140 7. The listed DBE subcontractor voluntarily withdraws from

the project and provides the Department written notice of
its withdrawal.

8. The listed DBE is ineligible to receive DBE credit for the

type of work required.

9. A DBE owner dies or becomes disabled with the result that

the listed DBE contractor is unable to complete its work on
the contract.
150
10. Other documented good causes, that the Department will
determine, which compels the termination of the DBE
subcontractor. Good cause does not exist, however, if the
Contractor seeks to terminate a DBE it relied upon to
obtain the contract so that it can self-perform the work for
which the DBE contractor was engaged or so that the
Contractor can substitute another DBE or non-DBE
contractor after the contract has been awarded.

16
 103.01

160 Before transmitting to the Department its request to terminate or reduce a

commitment made to a listed DBE, the Contractor shall give written notice to the
affected DBE, with a copy to the Department, of its intent to request termination or
reduction and the reasons for the request. The DBE shall be given five days to respond
to the Contractor and the Department of the reasons, if any, why it objects to the
proposed termination or reduction, and why the Department should not approve the
Contractor’s action. If required in a particular case, as a matter of public necessity and
safety, the Department may specify a response period shorter than five days.

When a DBE subcontractor is terminated as specified herein or fails to complete

170 its work on the contract for any reason, the Department will require the Contractor to
make good faith efforts to find another DBE subcontractor to substitute for the original
DBE. These good faith efforts shall be directed at finding another DBE to perform at
least the same amount of work under the contract as the DBE that was terminated, to
the extent needed to meet the contract goal the Department established for the contract.

In order to receive DBE credit for commitments made as part of the prime contract
award process, a DBE firm shall be certified before the due date for bids on the prime
contract. There may be situations after the award of the prime contract in which it is
appropriate to count DBE credit for the use of a DBE firm. To be eligible to obtain
180 DBE credit in these situations, the DBE firm shall be certified prior to participation on
the contract.

If a non-DBE contractor joint ventures with a DBE contractor, the portion of the
joint venture which is performed by a DBE may be utilized to achieve the DBE goal.
Two types of DBE joint ventures are allowed and are defined as follows:

1. DBE Joint Venture Type A

A DBE contractor and a non-DBE contractor bidding on specific pay items to be
performed by each company.
190
2. DBE Joint Venture Type B
A DBE contractor and a non-DBE contractor combining resources and agreeing
upon a percentage of the total work to be performed by each contractor.

DBE joint ventures type A do not require DBE joint venture certification. DBE
joint venture type B do require DBE joint venture certification. A request for DBE
joint ventures type B certification shall be submitted no later than 9:00 a.m. local time
the last business day before the letting and shall be approved prior to bidding in order
to receive credit toward the DBE goal. The DBE shall be certified with the Department
200 prior to requesting DBE joint venture certification. The work for the DBE shall be
identified, performed, managed, and supervised by its forces.

(d) Affirmative Actions

The Contractor shall develop an affirmative action plan for a Disadvantaged
Business Enterprise Program which shall include the minimum requirements as
follows:
17
 103.01

1. Appointment of a representative with authority to

administer the Contractor’s Disadvantaged Business
210 Enterprise Program.

2. Documents of affirmative action methods and procedures

intended to be used in seeking out and considering certified
DBEs as subcontractors or suppliers.

3. A list of certified DBEs to be contacted prior to the

selection of a potential subcontractor for the particular pay
items within the capabilities of the DBEs. This list shall
include but shall not be limited to the requirements as
220 follows:

a. The name of each subcontractor or supplier and a

notation as to their DBE certification status.

b. The potential type of work or services to be

performed by each subcontractor or supplier.

(e) Determination of Good Faith Efforts

Appendix A of 49 CFR Part 26 has been used for guidance in preparing the
230 Department’s procedures to determine the adequacy of good faith efforts. Additional
factors consistent with 49 CFR Part 26, and the Department’s policies and procedures
have also been utilized.

1. Good Faith Efforts Prior to Award

The following factors will be considered in determining good faith efforts prior
to award of a contract. The Contractor, including DBE Contractors, shall submit
evidence on each of the factors.

a. The Contractor shall make reasonable effort to

240 contact all ready, willing, and able DBEs who
express a desire to work on any of the pay items of
the contract.

b. To effectively participate, the DBE shall have the

opportunity to analyze the contract and submit
quotations prior to letting. Information provided by
the Contractor to the DBEs shall include, at a
minimum, the contract number, pay items,
quantities for those pay items to be subcontracted,
250 and the date the subcontract bid is desired.

18
 103.01

c. The Contractor shall select the portions of the work

to be performed by DBEs in order to increase the
likelihood of DBE participation. This shall
include, where appropriate, an attempt to break
down the contract into economically feasible units
to facilitate DBE participation.

d. The Contractor shall provide the interested DBEs

260 with complete information about the plans,
specifications, and requirements of the contract.
Attempts shall be made to have plans available or
to notify the DBE of the location of available plans.
The Contractor shall notify the DBE of revisions
to the contract.

e. It will be considered unacceptable to avoid

subcontracting to DBEs if such subcontracting to
DBEs results in the need to further subdivide
270 remaining work items.

f. The Contractor shall negotiate in good faith with

interested DBEs and not reject such DBEs as
unqualified without sound reasons based on
thorough investigation of their capabilities.
Confirmed documentation that a DBE has not been
able to perform previous work through no fault of
others will be considered to be sound reason.
Unacceptable criteria include, but are not limited
280 to, unsubstantiated oral statements and unsigned
documentation.

g. The Contractor shall make efforts to assist

interested DBEs in obtaining bonding, lines of
credit, or insurance required by the State.
However, the Contractor shall affirmatively
consider waiving requirements it may have in
order to assist the DBE.

290 h. Only firms certified as DBEs prior to the letting

date can be used to meet the contract goal for the
Department’s DBE program.

The Contractor will be considered to have made good faith efforts if it either:

a. Documents that it has obtained enough DBE

participation to meet the goal, or

19
 103.01

b. Documents that it made adequate good faith efforts

300 in accordance with the factors set out above to
meet the goal even though it did not succeed in
obtaining enough DBE participation to do so.

If a DBE goal has been established for the contract, the Contractor shall take good
faith efforts to achieve the established goal prior to the bid opening. The Affirmative
Action Certification shall be completed and submitted with the Proposal Book to
indicate both race/gender conscious and race/gender neutral proposed DBE utilization.

The award of the contract will be made to the lowest and best bidder when all
310 other requirements have been met and good faith efforts have been taken toward
meeting the DBE goal, if required, in accordance with these requirements.

If the apparent low bidder has not achieved the contract DBE goal, the bidder shall
respond by email or in writing within five business days after notification by the
Department of the failure to meet the DBE goal. The response shall provide evidence
identifying the bidder’s good faith efforts and all affirmative actions taken prior to
letting to achieve the required DBE goal. Failure to respond within the five business
day period will result in rejection of the bid, and may result in forfeiture of the bid
bond, and the referral of the bidder to the Prequalification Committee.
320
Responses shall be sent to the Department’s Division of Contract Administration.
The Department will review the bidder’s good faith efforts for compliance with these
requirements.

If the Department determines that adequate good faith efforts have been made,
and the bidder has met all other bidding requirements, the contract will be awarded.

If the Department determines that good faith efforts were inadequate, the
Department will notify the bidder of the determination by email. The determination
330 will outline the reasons for determination of non-compliance with good faith effort
requirements.

The bidder may request a review of a determination of non-compliance by email

or written submittal within five business days of the bidder’s receipt of notification of
non-compliance from the Department. The request for review shall include evidence
disputing the Department’s reasons for issuing a determination of non-compliance.
The request shall be sent to the Department’s Division of Contract Administration.

Upon receipt of a request, the Department will contact the bidder to schedule a
340 review. The review will be held by the Department’s Deputy Commissioner and Chief
Legal Counsel, or a designee who did not participate in the original determination of
non-compliance. The review will be conducted in accordance with the Department’s

20
 103.01

policy for review of good faith efforts requirements. A copy of the policy is available
on the Department’s website or through the Division of Contract Administration.

If the Deputy Commissioner’s finding determines that the bidder’s good faith
efforts were adequate, and the bidder has met all other bidding requirements, the
contract will be awarded and the Department will adjust the contract time by the
number of calendar days from the date of the original determination of non-compliance
350 to and including the date of the Deputy Commissioner’s findings.

If the Deputy Commissioner’s finding determines that the bidder’s good faith
efforts were inadequate, the finding will be forwarded to the Commissioner. The
Commissioner will review the Deputy Commissioner’s finding and issue a written
Contract Award Determination.

If the Commissioner’s Contract Award Determination finds that the bidder’s good
faith efforts were adequate, and the bidder has met all other bidding requirements, the
contract will be awarded and the Department will adjust the contract time by the
360 number of calendar days from the start of the original determination of non-
compliance to and including the date of the Commissioner’s determination.

If the Commissioner’s Contract Award Determination finds that the bidder’s good
faith efforts were inadequate, at the Commissioner’s sole option and without further
proceedings, either all bids will be rejected or the contract will be awarded to the next
lowest and qualified bidder. An apparent low bidder who has not met the DBE goal
and requirements for good faith efforts may be requested not to rebid on this contract
during subsequent lettings.

370 The Commissioner’s Contract Award Determination will be the final decision of
the Department.

2. Good Faith Efforts for Extra Work

When extra work in accordance with 104.03 is added to a contract with a DBE
goal, the Contractor shall hire or make good faith efforts to hire a DBE subcontractor
to perform significant extra work.

For purposes of DBE good faith efforts, significant extra work is defined as new
pay items added to a Contract that result in a new contracting opportunity not
380 reasonably related to existing pay items being performed by the Contractor or a
subcontractor.

When significant extra work related to existing pay items being performed by a
DBE subcontractor is added to a contract with a DBE goal, the Contractor shall offer
that same DBE subcontractor the opportunity to perform the extra work whether or
not the existing pay items are counted toward the DBE goal. The Contractor shall
consider other DBE subcontractors if the extra work would result in the original DBE
subcontractor exceeding its prequalification limits. The Department may consider an

21
 103.01

exception to a DBE subcontractor’s prequalification limit. If the DBE subcontractor is

390 unable to perform the extra work, the Contractor shall hire or make good faith efforts
to hire an alternate DBE subcontractor to perform the work.

When significant extra work related to existing pay items being performed by a
non-DBE subcontractor is added to a contract with a DBE goal, the non-DBE
subcontractor may perform the extra work. If the non-DBE subcontractor is unable to
perform the extra work, the Contractor may self-perform the extra work. If the
Contractor chooses not to self-perform the extra work, the Contractor shall hire or
make good faith efforts to hire a DBE firm to perform the work.

400 When significant extra work related to existing pay items being performed by the
Contractor is added to a contract with a DBE goal, the Contractor may self-perform
the extra work. If the Contractor chooses not to self-perform the extra work, the
Contractor shall hire or make good faith efforts to hire a DBE firm to perform the
work.

The Contractor shall forward documentation of good faith efforts to hire a DBE
subcontractor to perform extra work to the District Equal Employment Opportunity
Officer (EEO Officer) for review. The EEO Officer will determine if good faith efforts
have been met in accordance with 103.01(e)1.
410
If the EEO Officer determines that the Contractor failed to make good faith efforts
to hire a DBE firm when required as a result of significant extra work, written notice
will be sent to the Contractor. The Contractor may appeal the determination in
accordance with 103.01(e)1.

(f) Affirmative Action Certification

The Affirmative Action Certification, included in the Proposal book, shall be
completed when the Proposal book is submitted to the Department. The certification
shall list all DBE firms the Contractor plans to utilize, either race/gender consciously
420 or race/gender neutrally. Blank certifications shall cause the bid to be rejected. If a
portion of a pay item is to be performed by a DBE, an explanation shall be included
stating exactly what the DBE is performing or supplying. Failure to do so may affect
the award of the contract. The Contractor shall ensure that DBE firms listed on the
Affirmative Action Certification are certified DBE firms as listed in the Department’s
DBE directory at the time of letting. In addition to the listing of DBE firms that will
be used race/gender consciously to meet the goal, the Contractor shall also provide a
total for the amount of work that it anticipates will be performed by other DBE firms
used race/gender neutrally on the contract beyond the goal requirements.

430 Race/gender neutral awards involve the utilization of a DBE firm because the
DBE firm is the best firm to perform the work. Race/gender conscious awards involve
the utilization of a DBE firm primarily to achieve the contract DBE goal.

22
 103.01

(g) Subcontracts
If the Contractor intends to subcontract a portion of the work, affirmative action
shall be taken to seek out and consider DBEs as potential subcontractors prior to the
subcontractual commitment.

The contacts made with potential DBE subcontractors and the results thereof shall
440 be documented and made available to the Department and the FHWA upon request.

If the Contractor originally did not intend to subcontract a portion of the work and
later circumstances dictate subcontracting a portion of the work, the affirmative action
contacts described herein shall be performed.

Upon receipt of notification from the Department, a Disadvantaged Business

Enterprise Utilization Affidavit, Form DBE-3, shall be completed by the Contractor
and returned to the Department. The Contractor and the subcontractor/lessor/supplier
shall certify on Form DBE-3 that specific amounts have been paid and received. A
450 DBE-3 Form certification shall be completed and submitted for every DBE utilized on
the contract, whether or not there was a DBE contract goal.

(h) Leases and Rentals

Hauling leases made with DBEs shall be submitted to the Department for approval
before beginning work. Leases for hauling, when used, shall be submitted when
borrow, subbase, compacted aggregate, HMA mix, cement concrete mix, or a
combination of the above is to be hauled by a DBE. The lease shall show the dollar
amount of anticipated work before the work is started. The actual dollar amount shall
be reported to the Department after the work has been completed.
460
In order to perform a commercially useful function on a contract, the dollar
volume of hauling by a DBE trucking firm that is counted toward the DBE goal is
limited to the total value of transportation services provided by the DBE's own trucks;
the total value of transportation services a DBE lessee provides with its own trucks;
and the total value of transportation services a non-DBE lessee provides with its own
trucks, not to exceed the value of transportation services provided by DBE-owned
trucks. In addition, DBE credit will also be given for any fee or commission the non-
DBE lessee receives as a result of the lease arrangement for any additional non-DBE
trucks.
470
In order to count leased trucks toward the goal, the lease must indicate that the
DBE has exclusive use of and control over the truck. This does not preclude the leased
truck from being used by others during the term of the lease with the consent of the
DBE, so long as the lease gives the DBE absolute priority for use of the leased truck.
Leased trucks must display the name and identification number of the DBE. The DBE
must be responsible for the management and supervision of the entire trucking
operation for which it is responsible on a particular contract, and there cannot be a
contrived arrangement for the purpose of meeting the DBE goals.

23
 103.01

480 The Contractor shall provide the Engineer copies of any lease agreements between
DBE trucking subcontractors and any DBE or non-DBE trucking firms or
owner/operators that will be used to supplement the DBE trucking subcontractor’s
trucks for the purpose of meeting the DBE goal. Copies of these lease agreements shall
be provided by the time of use of any supplemental trucks on the Contract.

In addition to delivery ticket information required by Section 106, the name of

trucking firm shall be included on each ticket for material delivered to the job site by
a DBE trucking subcontractor or lessee.

490 The Contractor shall notify the Department when purchases or rental of
equipment, other than leases for hauling, are made with DBEs. The information
submitted shall include the name of the business, the dollar amount of the transaction,
and the type of purchase made or type of equipment rented.

If a subcontract agreement between the Contractor and a majority subcontractor

requires that the majority subcontractor sublease a portion of its hauling to a DBE, the
Contractor may receive credit toward the contract goal. The Contractor shall notify the
Department when sublease agreements exist, the name of the DBE, the dollar amount
of anticipated hauling before the work is started, and the actual dollar amount after the
500 work is completed. The subcontractor shall certify actual utilization of the DBE at the
end of the work and provide such certification to the Contractor for submission to the
Department.

(i) Records and Reports

The Contractor shall keep such records as necessary to determine compliance with
its DBE utilization obligations and compliance with the Guidelines for Determining
of Good Faith Efforts. The records kept by the Contractor shall indicate the minimum
requirements as follows:

510 1. The number of disadvantaged, non-minority, and women

subcontractors and suppliers and type and dollar value of
work or materials services being performed on or
incorporated into this contract.

2. The progress and efforts being made in seeking out

disadvantaged contractor organizations and individual
disadvantaged contractors for work on this contract.

3. Documentation of all correspondence, contacts, or

520 telephone calls to obtain the services of DBEs on this
contract.

Reports shall be submitted as required by the Department for those contracts and
other business agreements executed with DBEs with respect to the records referred to
above.

24
 103.04

All such records shall be maintained for a period of three years following
acceptance of final payment and shall be available for inspection by the Department
and the FHWA and their authorized representatives.
530
103.02 Specific Equal Employment Opportunity Responsibilities
This requirement will apply only to a federal aid contract.

The Contractor and all subcontractors not including material suppliers, holding
subcontracts of $10,000.00 or more, shall comply with the following minimum
specific requirement activities of equal employment opportunity. The equal
employment opportunity requirements of Executive Order 11246, included in the
Contract Information book, will be applicable to material suppliers as well as
contractors and subcontractors. The Contractor shall include these requirements in
540 each subcontract of $10,000.00 or more with such modification of language as is
necessary to make them binding on the subcontractor.

103.02.1 Record Keeping

All firms performing work on Department contracts, bidding on Department
contracts, or offering quotes for subcontract or trucking services shall register with the
Department, annually, by submitting the following information to the Department’s
Prequalification Engineer:

(a) firm’s name

550 (b) firm’s address
(c) firm’s status as a DBE or non-DBE
(d) the age of the firm and
(e) the annual gross receipts of the firm
(f) in which of the following markets has the firm participated?

1. prime Contractor
2. subcontractor
3. hauler
4. consultant
560 5. supplier.

103.03 Blank

103.04 Insurance
Prior to commencing the work, the Contractor shall obtain and thereafter keep in
force, the following insurance coverages provided by insurance companies acceptable
to the Department and authorized to transact business under the laws of the State of
Indiana. Certificates of insurance shall be filed with the Department. The Department
may temporarily accept an insurance binder pending receipt of the certificate of
570 insurance. When Railroad’s Protective Liability insurance in accordance with
103.04(d) is required, the original policy shall be submitted to the railroad company

25
 103.04

with a copy transmitted to the Department. In addition, certificates of insurance shall

be provided to the railroad, on forms satisfactory to the railroad, covering the
Contractor’s Commercial General Liability and Business Automobile Liability
insurance.

The Contractor may purchase insurance for the full limits required by 103.04(b),
or 103.04(c) or by a combination of primary policies for lesser limits and remaining
limits provided by a Commercial Umbrella Liability policy.
580
Proof of renewal shall be furnished 15 days or more in advance of the policy
expiration. If subject to cancellation, the insurance company shall provide at least 30
days prior notice, and the insurer shall immediately notify the Department in writing
of such impending cancellation.

In the event of cancellation or expiration, all work on the contract shall be

suspended except that necessary for traffic maintenance and the protection of life and
property. No extension in the contract completion time or additional payment will be
allowed on account of this requirement and contract time charges will continue.
590
Nothing contained herein shall modify the Contractor’s obligation of
indemnification and exculpation of the State and its representatives in accordance with
107.17.

(a) Worker’s Compensation and Employer’s Liability

1. Worker’s compensation shall be provided according to the

provisions of the Indiana Worker’s Compensation and
Occupational Diseases Act as amended.
600
2. A certificate from the Worker’s Compensation Board of
Indiana shall be furnished as evidence of compliance with
the provisions of the Indiana Worker’s Compensation and
Occupational Diseases Act.

(b) Commercial General Liability

Required liability insurance coverage shall provide coverage for operations of the
Contractor and operations of subcontractors. Coverages shall include
premises-operations; independent contractors; products; completed operations; broad
610 form property damage; hazards of explosion, collapse, and underground damage; and
contractual liability. The general aggregate limit shall be endorsed so as to provide
coverage for each contract as follows:

1. General Aggregate Limit............................................. $2,000,000

2. Products-Completed Operations
Aggregate Limit .......................................................... $2,000,000

26
 103.04

3. Each Occurrence Limit ............................................... $1,000,000.

620
(c) Business Automobile Liability
This policy shall cover owned, non-owned, and hired vehicles. The combined
single limit of liability for bodily injury and property damage liability per each
accident shall be $1,000,000.

(d) Railroad’s Protective Liability

When required, the Contractor shall carry, with respect to the operations
performed and those performed by others, for and in behalf of each railroad company,
Railroad Protective Liability insurance providing for a limit of not less than a
630 combined single limit of $2,000,000 per occurrence for damages arising out of bodily
injury, death, and property damage with an aggregate limit of $6,000,000 for the term
of the policy.

In addition, the limits specified in 103.04(b)3 shall be increased to $2,000,000.

(e) Owner’s and Contractor’s Protective Liability Insurance Coverage

for Operations of Designated Contractor
The named insured in this policy shall be the State of Indiana, c/o Indiana
Department of Transportation. If specified elsewhere in the contract, the named
640 insured shall also include a local governmental agency.

The limits of coverage shall be not less than $1,000,000 for all damages arising
out of bodily injury or death in one occurrence, and for all damages arising out of
injury to or destruction of property in any one occurrence. Subject to the limit per
occurrence, an aggregate limit for the contract of not less than $3,000,000 shall be
provided during the policy period.

In addition to the limits specified herein, the policy and the binder shall also
include the endorsements to the Owner’s and Contractor’s Protective Liability
650 Insurance as follows:

1. Wherever used in this policy, the term “named insured”

shall include the Indiana Department of Transportation, its
officers, and employees. If so specified in the contract, the
term “named insured” shall also include a local
governmental agency, its officers, and employees.

2. Wherever used in this policy, the term “general

supervision” shall include on-site inspection, field
660 engineering, field testing, and activities incidental thereto.

3. Exclusion (c) is amended to read as follows:

27
 103.05

(c) To bodily injury or property damage occurring after all

work on the project to be performed by or on behalf of
the State at the site of the covered operation has been
completed, and the Contractor designated herein has
been relieved of further maintenance, as set out in the
final acceptance letter of the Indiana Department of
670 Transportation.

4. Not withstanding other terms or conditions, this policy

provides the minimum insurance coverages as of the latest
filing with the Indiana Department of Insurance by the
Insurance Services Office with the endorsements and
amendments specified by 103.04(e) of the Indiana
Department of Transportation Standard Specifications.
The policy is identified as the latest edition of form CG 00
09 as copyrighted by the Insurance Services Office, Inc.
680
(f) Basis of Payment
No direct payment will be made for insurance. The cost thereof shall be included
in the cost of the pay items.

103.05 Waiver of Damages

At the time the contract is ready for final execution, all of the necessary right-of-
way may not have been secured. In order to expedite prompt execution of the contract,
the Contractor may sign a waiver of damages. This will waive all damages that might
accrue to the Contractor for delay, expense, inconvenience, loss of profits, or for all
690 other causes occasioned to the Contractor by the failure of the Department to secure
such right-of-way. The waiver shall be binding upon each subcontractor of the
principal Contractor. This waiver provision will not apply on Federal Aid projects.

103.06 Wage and Labor Requirements

These requirements apply to all contracts let by the Department. These
requirements will apply to all work performed by the Contractor with its own
organization and with the assistance of workers under its immediate superintendence,
and to all work performed by piecework, station work, subcontract, or lease.

700 (a) Non-discrimination of Employees

The Contractor and its subcontractors shall not discriminate against an employee
or applicant for employment, to be employed in the performance of the contract work,
with respect to hire, tenure, terms, conditions, or privileges of employment or matters
directly or indirectly related to employment, because of race, religion, color, sex,
sexual orientation, sexual identity, disability, national origin, or ancestry. Breach of
this covenant may be regarded as a material breach of the contract.

28
 103.06

(b) Affidavits and Payrolls

All labor shall be paid weekly. The payroll and related records of the Contractor
710 and all subcontractors shall be preserved for a period of three years after completion
of the project work, and be open to the inspection of the Department.

The wages of labor shall be paid in legal tender of the United States. However,
this condition will be considered satisfied if payment is made by means of a negotiable
check, on a solvent bank, which may be cashed readily by the employees in the local
community for the full amount, without discount or collection charges. If checks are
used for payment, the Contractor shall make all necessary arrangements for them to
be cashed and shall give information regarding such arrangements.

720 The Contractor on each contract let by the Department shall be responsible for
electronically filing certified payroll for its employees and any subcontractors on a
weekly basis with the appropriate Department personnel and in a format acceptable to
the Department. Failure of the Contractor to timely file certified payroll for its
employees or any subcontractors, may result in the withholding of progress estimate
payments until the certified payroll is properly submitted.

No fee shall be asked or accepted by the Contractor or its agents from a person as
a condition of the contract.

730 No laborers shall be charged for tools used in performing their respective duties
except for reasonable avoidable loss or damage thereto.

Each employee on the work covered by the contract shall be allowed to lodge,
board, or trade where or with whom he or she elects. Neither the Contractor nor its
agents, nor its employees shall directly or indirectly require as a condition of
employment that an employee shall lodge, board, or trade at a particular place or with
a particular person.

No charge shall be made for transportation furnished by the Contractor or its

740 agents to a person employed on the work.

No individual shall be employed as a laborer on the contract except on a wage

basis. This shall not be construed to prohibit the rental of trucks or other equipment
from individuals. No such rental agreement, or charges for fuel, supplies, or repairs on
account of such agreement shall cause deduction from the wages accruing to an
employee except as authorized by the regulation cited herein.

(c) Wage Stipulations

No person employed on a federally funded contract shall be paid less than required
750 by the rate of wages set forth for labor classifications listed in the General Decision as
required by the Davis Bacon Act and related Acts. No person employed on a state
funded contract shall be paid at a rate of less than $11.25 per hour, as required by IC
8-23-9-22 or the rate of wages set forth for labor classifications listed in the General
Decision, whichever is greater.
29
 103.07

1. General Decision Included in Contract Information Book

The Contractor shall pay the workers who are employed in performance of the
contract work, rates of wages which are not less than the rates set forth for labor
classifications listed in the General Decision.
760
The computations used in arriving at the contract unit prices shall be based on the
hourly rates shown in the General Decision and as shown above. The wages herein
stipulated shall become and be a part of the contract as provided by law.

The following statement, shown in the General Decision, will not apply to state
funded contracts.

“Unlisted classifications needed for work not included within

the scope of the classifications listed may be added after award
770 only as provided in the labor standards contract clauses (29
CFR 5.5(a)(1)(ii)).”

2. General Decision Not Included in Contract Information Book

If the General Decision is not included in the Contract Information book, the
requirements of 103.06(c)1 will not apply.

103.07 Accident Prevention and Safety

In the performance of the contract work, the Contractor shall comply with all
applicable federal, State, and local laws governing safety, health, and sanitation. The
780 Contractor shall provide all safeguards, safety devices, and protective equipment. The
Contractor shall take all reasonably necessary actions to protect the life and health of
employees on the project site and the safety of the public, and to protect property in
connection with the performance of the contract work.

It is a condition of the contract, and shall be made a condition of each subcontract

entered into pursuant to the contract, that the Contractor and all subcontractors shall
not require a laborer or mechanic employed in performance of the contract work to
work in surroundings or in working conditions which are unsanitary, hazardous, or
dangerous to his or her health or safety, as determined under construction safety and
790 health standards 29 CFR 1926, as amended at the time the work is performed.

SECTION 104 – SCOPE OF WORK

104.01 Intent of Contract

The intent of the contract is to provide for the construction and completion in
every detail of the work described. The Contractor shall furnish all labor, materials,
equipment, tools, safety equipment, transportation, and supplies required to complete
the work in accordance with the plans, specifications, and terms of the contract.

30
 104.02

It is understood by all concerned that the apparent silence of the specifications as

10 to a detail or the apparent omission of a detailed description concerning a point shall
be regarded as meaning that only the best general practice is to prevail and that only
material and workmanship of the first quality is to be used. All interpretations of these
specifications shall be made on this basis.

In order to avoid cumbersome and confusing repetition of expressions in these

specifications, it is provided that whenever any thing is, or is to be done, if, as, when,
or where contemplated, required, determined, directed, specified, allowed, authorized,
ordered, given, designated, indicated, considered necessary, deemed necessary,
permitted, reserved, suspended, established, approved, disapproved, acceptable,
20 unacceptable, suitable, accepted, satisfactory, unsatisfactory, sufficient, rejected, or
condemned, it shall be understood as if the expression were followed by the words “by
the Engineer” or “to the Engineer”.

It is further provided that all work including the furnishing of materials,

equipment, tools, labor, and incidentals required to carry out the terms of the contract
shall be done by the Contractor, its employees, or subcontractors unless specifically
set out otherwise in the Proposal book. The words “by the Contractor” will not
necessarily be used to so indicate. All work shall be carried out in a thorough, careful,
effective, and satisfactory manner without specifically using these words to describe
30 the action.

Reports and other documents that are determined to be pertinent and necessary to
the effective monitoring of the contract shall be submitted by all applicable contractors
and subcontractors in accordance with appropriately issued instructions.

104.02 Changed Conditions

A changed condition causes the work to substantially differ in kind or nature from
the work as required in the original contract. The Department will adjust the contract
for changed conditions as described herein. A contract adjustment may revise one or
40 more of the following:

(a) the work to be performed

(b) the time required for the work
(c) the amount of compensation due the Contractor.

Changed conditions that will be considered as reason for a contract adjustment

are differing site conditions, suspensions of work ordered by the Engineer, and
significant changes in the character of the work. A request by the Contractor for a
contract adjustment shall be based on one or more of the changed conditions described
50 herein.

(a) Differing Site Conditions

During the progress of the work, if subsurface or latent physical conditions are
encountered at the site differing materially from those indicated in the contract or if

31
 104.02

unknown physical conditions of an unusual nature, differing materially from those

ordinarily encountered and generally recognized as inherent in the work provided for
in the contract, are encountered at the site, the party discovering such conditions shall
promptly notify the other party in writing of the specific differing conditions before
the site is disturbed and before the affected work is performed.
60
Upon written notification, the Engineer will investigate the conditions, and if it is
determined that the conditions materially differ and cause an increase or decrease in
the cost or time required for the performance of any work under the contract, an
adjustment, excluding anticipated profits, will be made and the contract modified in
writing accordingly. The Engineer will notify the Contractor of the determination
whether or not an adjustment of the contract is warranted.

No contract adjustment which results in a benefit to the Contractor will be allowed

unless the Contractor has provided the required written notice of a changed condition
70 in accordance with 105.16.

No contract adjustment will be allowed under this clause for any effects caused
on unchanged work.

(b) Suspensions of Work Ordered by the Engineer

If the performance of all or any portion of the work is suspended or delayed by
the Engineer in writing for an unreasonable period of time (not originally anticipated,
customary, or inherent to the construction industry) and the Contractor believes that
additional compensation, and/or contract time is due as a result of such suspension or
80 delay, the Contractor shall submit to the Engineer in writing a request for adjustment
within seven calendar days of receipt of the notice to resume work. The request shall
set forth the reasons and support for such adjustment.

Upon receipt, the Engineer will evaluate the Contractor’s request. If the Engineer
agrees that the cost and/or time required for the performance of the contract has
increased as a result of such suspension and the suspension was caused by conditions
beyond the control of and not the fault of the Contractor, its suppliers, or
subcontractors at any approved tier, and not caused by weather, the Engineer will make
an adjustment (excluding profit) and modify the contract in writing accordingly. The
90 Contractor will be notified of the Engineer’s determination whether or not an
adjustment of the contract is warranted.

No contract adjustment will be allowed unless the Contractor has submitted the
request for adjustment within the time prescribed in accordance with 105.16.

No contract adjustment will be allowed under this clause to the extent that
performance would have been suspended or delayed by any other cause, or for which
an adjustment is provided or excluded under any other term or condition of this
contract.
100

32
 104.02

(c) Significant Changes in the Character of Work

The Engineer reserves the right to make, in writing, at any time during the work,
such changes in quantities and such alterations in the work as are necessary to
satisfactorily complete the project. Such changes in quantities and alterations shall not
invalidate the contract nor release the surety, and the Contractor agrees to perform the
work as altered.

If the alterations or changes in quantities significantly change the character of the

work under the contract, whether such alterations or changes are in themselves
110 significant changes to the character of the work or by affecting other work cause such
other work to become significantly different in character, an adjustment, excluding
anticipated profit, will be made to the contract. The basis for the adjustment shall be
agreed upon prior to the performance of the work. If a basis cannot be agreed upon,
then an adjustment will be made either for or against the Contractor in such amount as
the Engineer may determine to be fair and equitable.

If the alterations or changes in quantities do not significantly change the character

of the work to be performed under the contract, the altered work will be paid for as
provided elsewhere in the contract.
120
No contract adjustment which results in a benefit to the Contractor will be allowed
unless the Contractor has provided the required written notice of a changed condition
in accordance with 105.16.

The term “significant change” shall be construed to apply only to the following
circumstances:

1. When the character of the work as altered differs materially

in kind or nature from that involved or included in the
130 original proposed construction; or

2. When a major item of work, as defined elsewhere in the

contract, is increased in excess of 125% or decreased below
75% of the original contract quantity. Any allowance for
an increase in quantity shall apply only to that portion in
excess of 125% of the original contract item quantity, or in
case of a decrease below 75%, to the actual amount of work
performed.

140 (d) Pre-established Remedies to Changed Conditions

The Contractor and the Department shall cooperatively work to resolve a request
for a contract adjustment due to a changed condition by means of the pre-established
remedies described herein.

After receipt of a notice of a changed condition in accordance with 105.16, the

Engineer will determine if the Contractor’s request for a contract adjustment is

33
 104.02

justified. The Engineer will respond to the Contractor in writing within two business
days of the receipt of notification, or other time as mutually agreed, as to whether the
request is justified and as to how the changed condition will be remedied.
150
If the Engineer determines that a request for a contract adjustment is justified, the
changed condition will be remedied by means of a contract adjustment based on one
or more of the following pre-established remedies.

1. Calculations and payment involving existing pay items in

the contract.

2. Payment for extra work in accordance with 104.03.

160 3. Extension of contract time in accordance with 108.08.

4. Payment for delay costs in accordance with 109.05.2 as

allowed by 108.08(b).

If the impact of a changed condition will not be known for some length of time,
the following procedure shall be followed in order to expedite a contract adjustment
until the impact of the change can be determined.

1. After submitting notification of the changed condition, the

170 Contractor shall keep daily records, apart from other
records, of all labor, material, and equipment costs incurred
for the work affected. The daily records shall identify each
operation affected and the location where work is affected.

2. The Engineer will also maintain daily records of the work

affected from the date of the notification.

3. Beginning the week following notification of a changed

condition, the Contractor shall meet weekly with the
180 Engineer to exchange and discuss each party’s daily
records of the work affected during the preceding week.

4. The Contractor shall notify the Engineer in writing within

three work days of any disagreements with the Engineer’s
records and include the specific points of disagreement.
These points will be addressed by the Engineer at the next
weekly meeting.

5. Refusal by the Contractor to attend any weekly meeting or

190 to submit daily records at a weekly meeting will constitute
a waiver to any objections to the accuracy of the Engineer’s
records and the Engineer’s records will control for

34
 104.02

purposes of computing any contract adjustment for the

changed condition.

If the Contractor accepts the Engineer’s remedy for a changed condition, the
contract adjustment will be considered to be full and complete compensation for the
changed condition and no further contract adjustment will be made for the
circumstances that gave rise to the Contractor’s request.
200
If the Contractor disagrees with the Engineer’s remedy for a changed condition,
and decides to further pursue compensation, a written notification of a claim may be
submitted in accordance with 105.16.

Pre-established remedies to a changed condition have the following conditions.

1. Acceleration
If the Department gives written direction for the Contractor to accelerate the work,
a contract adjustment will be made specifying the work to be accelerated, the time to
210 be saved by acceleration and the amount of compensation due the Contractor for the
acceleration.

The Department assumes no liability for constructive acceleration unless the

Contractor has provided written notice of the intent to accelerate the work, there is an
excusable delay for which the Department has either improperly rejected the
Contractor's request for an extension of contract time or failed to act on the request,
and the Contractor has incurred additional costs for the acceleration.

2. Inefficiencies
220 If a claimed loss of productivity due to a changed condition cannot be isolated and
remedied separately, the Department will consider payment for inefficiency costs on
the basis of a measured mile analysis performed by the Contractor or other analysis
method approved by the Engineer.

If the claimed inefficiency is that work was performed out of scheduled sequence
due to the changed condition, the current accepted schedule will be analyzed to
determine if the work was performed out of sequence.

3. Unrecoverable Costs
230 The Department will not make payment for any of the following:

a. Loss of anticipated profits.

b. Consequential damages, including but not limited

to loss of bonding capacity, loss of bidding
opportunities and insolvency.

35
 104.03

c. Expense of claim preparation and submission,

including but not limited to attorney’s fees,
240 consultant’s fees and expenses and litigation
expenses.

d. Interest.

e. Home office overhead in excess of that provided

for in the contract.

4. Unacceptable Cost Calculation Methods

The Department will not make any payments for costs calculated using any of the
250 following methods:

a. Total cost methods based on calculation of costs as

the difference between the Contractor’s bid for the
work and the Contractor’s calculation of the costs
for the work.

b. Calculation of home office overhead using the

Eichleay Formula or other formulas used to
calculate home office overhead due to delay.
260
104.03 Extra Work
Unforeseen work, for which there is no price included in the contract, shall be
performed whenever it is deemed necessary to fully complete the contract within its
intended scope, or it is in the best interest of the State to complete the unforeseen work
under the contract. Such work shall be performed in accordance with the specifications
and as directed, and will be paid for in accordance with 109.05.

104.04 Maintenance of Traffic

Unless otherwise provided, the road shall be kept open to all traffic while
270 undergoing improvements. Where so provided on the plans, the traffic may be
bypassed over an approved detour route. The detour route markings shall be erected,
maintained, and removed by the Contractor.

Maintenance of traffic shall be in accordance with the details as shown on the

plans or as directed. If an alternate plan for maintaining traffic is requested, it shall be
submitted in writing as soon as possible for consideration. Such submittal shall include
the complete details of the alternate maintenance of traffic scheme including all traffic
control devices to be incorporated. If approved, the alternate plan shall not increase
the cost of maintaining traffic to the Department.
280
The portion of the roadway being used by public traffic shall be kept in such
condition that such traffic will be adequately accommodated. Drums in accordance
with 801.09 shall be placed at 200 ft intervals where drop-offs of greater than 3 in. are

36
 104.04

adjacent to the shoulder until the aggregate or earth wedge is placed. Temporary
approaches to businesses, parking lots, residences, garages, farms, and crossings and
intersections with trails, roads, and streets shall be provided in a safe condition.

All traffic control devices shall be maintained with no additional payment, except
as set out in 107.18. Regulatory controls shall not be changed by the Contractor
290 without prior approval. Regulatory control devices may be relocated in order to enable
necessary construction, provided these control devices remain effective and convey
the intended meaning after relocation to a position which complies with the
requirements of the MUTCD. After completion of the construction, regulatory control
devices which were relocated to facilitate construction shall be permanently installed
with no additional payment, in accordance with the plans, or as otherwise directed. All
traffic control devices damaged, while being moved or handled, shall be replaced with
no additional payment. All other traffic control devices necessary to maintain safe
traffic operation and routings shall not be removed, changed, or relocated, except as
authorized. Traffic control devices removed without authorization shall be replaced
300 with no additional payment.

The cost of maintaining traffic over the section of road undergoing improvement
and the cost of the construction and maintenance of such necessary features as
approaches, crossings, and intersections shall be included in the contract unit price bid
for maintenance of traffic pay items as set out in the Schedule of Pay Items, except as
provided in 104.04(a), 104.04(b), and 107.18.

(a) Special Detours

When the Schedule of Pay Items contains a pay item for maintenance of detours
310 or removing existing structures and maintaining traffic, the payment for such pay item
shall cover all cost of constructing and maintaining such detour or detours, including
the construction of temporary bridges and accessory features and the removal of the
same in accordance with 713.08.

(b) Maintenance Directed by the Engineer

If special maintenance is directed for the benefit of the traveling public, payment
will be made on the basis of unit prices or in accordance with 104.03 or 105.13. The
Engineer will be the sole judge of whether special maintenance shall be performed.

320 Except as otherwise expressly provided in the contract, existing Department

maintained roads and other public roads and streets within the limits of the contract
shall be kept open to two-way traffic between the dates of December 1 and April 1.

Where the surface on an existing road or street is disturbed by the Contractor and
the entire depth of the new surface is not completed prior to December 1, two-way
traffic shall be maintained between the above dates on the partially completed new
surface or on a temporary surface satisfactory for two-way traffic. Such surfaces shall
be maintained between the above dates with no additional payment. Precautions shall

37
 104.05

be taken to prevent unnecessary damage to partially completed surfaces. All portions

330 which become damaged shall be repaired with no additional payment.

Public roads, commercial and private drives, and mailbox approaches which are
disturbed, and on which the surfacing has not been completed, shall be maintained in
a condition satisfactory for use during the time work is suspended.

Where such approaches have been constructed to grade and drainage structures
installed, the approaches shall be surfaced with compacted aggregate, No. 53, to a
depth as directed. Such surfacing material, which is incorporated in the finished work,
will be paid for at the contract unit price. The following season, the surfacing on the
340 approaches shall be completed to the compacted depth shown on the plans by the
addition of the surfacing material specified in the contract. During suspension of the
work where such approaches have not been constructed to grade, a satisfactory
temporary surface shall be provided with no additional payment.

(c) Blank

(d) Traffic Control for Patching on a Two-Lane Roadway

The work specified shall be arranged and prosecuted in accordance with the
applicable requirements of 107 and 801, and as shown below.
350
Only one lane may be closed at a time.

A minimum of two drums shall be placed on the traffic approach side of each
concrete patch or opened hole.

Patching on a two-lane roadway shall be in accordance with 305 and the details
shown on the plans. Traffic restrictions will be allowed during daylight hours only. If
the Contractor is unable to fill an area to be patched with concrete during daylight
hours, the patch shall be filled with No. 53 aggregate for the times other than daylight
360 hours. Drums in accordance with 801.09 shall be placed at the side of the roadway at
the patch locations. If an opened hole cannot be patched for two or more calendar days,
a 6 in. HMA cap shall be placed in the hole if concrete cannot be obtained. A watcher
will be required while the roadway is temporarily patched.

104.05 Removal and Disposal of Structures and Obstructions

Unless otherwise provided, any existing structure or parts thereof, fence, building,
or other encumbrance or obstruction upon or within the limits of the right-of-way
which interferes in any way with the new construction shall be removed with no
additional payment.
370
All removal of structures and obstructions the Contractor is directed to perform
outside the construction limits for the benefit of the Department, including work
needed for utility relocation, and not simply for the Contractor’s convenience, will be
paid for in accordance with 104.03 or 109.03.

38
 104.06

Materials belonging to abutting property owners shown to be retained for the

property owner shall be stockpiled in an acceptable manner at a designated area off
the right-of-way. Materials not shown to be retained, except those materials mentioned
in 104.06 or 805.03, shall become the property of the Contractor and shall be removed
380 or disposed of according to the contract.

Materials to be salvaged for Department use shall be removed without damage in

sections that can be readily transported. These materials shall be stockpiled neatly at
locations identified on the plans or identified by the Engineer.

104.06 Removal and Disposal of Regulated Materials

The removal, testing, transportation, or disposal of regulated materials, except for
paint removal and disposal operations described in 619, shall be in accordance with
the requirements included herein and the applicable Federal, State, and local laws,
390 regulations, and rules. These include, but will not be limited to, the requirements of
the Federal Toxic Substances Control Act, the Federal Resource Conservation
Recovery Act, the Federal Comprehensive Environmental Response Compensation
Liability Act, OSHA, IDEM, and State rules requiring certification of underground
storage tank removal firms.

Regulated materials will consist of those as follows:

(a) materials which are classified as a hazardous waste, hazardous

substance, or hazardous material under the regulations of the
400 EPA or the United States Department of Transportation; and

(b) materials which contain more than 1% asbestos and are friable,
or have high probability of becoming friable as per 326 IAC
14-10.

The Contractor shall be responsible for proper handling, storage, transportation,

and disposal of all regulated materials which are brought onto the site by the
Contractor. This shall include those materials which are required under the contract.
The Contractor shall comply with all applicable laws, regulations, and rules regarding
410 such materials. All spills of regulated materials, caused by the negligence of the
Contractor shall be cleaned up in accordance with the applicable laws, regulations, and
rules.

Except as provided herein, the Department will be responsible for proper

handling, storage, cleanup, removal, testing, transportation, and disposal of all
regulated materials, which are located within the project limits including materials that
have spread beyond the project limits except for those materials brought onto the site
by the Contractor. The following procedure shall be used for regulated materials under
42 U.S.C. 6921 et seq, 42 U.S.C. 9601 et seq, 40 CFR 260, 49 CFR 171-179, IC 13-7,
420 329 IAC 2-21, or other applicable environmental laws, regulations, or rules:

39
 104.06

(a) For Such Materials which are Identified in the Proposal Book as
Being Present on the Project Site

1. The Department will provide in the Proposal book all

known information of all such materials known or
suspected to exist within or adjacent to the project limits.

2. The Contractor shall act only under the written direction of

430 the Department regarding the removal, testing,
transportation, or disposal of all such materials. Such
written instructions may be provided in the Proposal book
or in accordance with 104.03.

3. Except as provided herein, the Contractor shall follow the

construction requirements shown in 200.

4. The Department will be listed as the owner/generator on all

regulated material manifests. If disposal is required for
440 such materials, the Department will approve, in writing, the
appropriate licensed disposal site. The Department will
retain title to all such regulated materials which are being
disposed.

Payment for all work relating to removal, testing, transportation, or disposal of all
regulated materials will be made in accordance with 202.14.

(b) For Such Materials which are not Identified in the Proposal Book as
Being Present on the Project Site
450 Materials suspected of being regulated and discovered by either the Contractor or
the Department shall be subject to the procedure described below.

1. If such materials are discovered by the Contractor, the

Contractor shall cease all operations in the immediate
vicinity and shall promptly notify the Engineer. If the
material discovered is being released to the surrounding
environment or if there is a perceived health threat, the
Contractor shall immediately notify the State Police,
IDEM’s Office of Environmental Response, the local fire
460 department, the county emergency management
coordinator, and the Engineer.

2. If the Contractor determines that a tank now contains, or

previously contained, a listed hazardous waste as defined
by the RCRA, the Engineer shall be notified. No further
work shall be done with such tank until directed.

40
 104.06

3. If such materials are discovered by the Department, the

Engineer will promptly notify the Contractor. The
470 Contractor shall immediately cease all operations in the
immediate vicinity.

4. If the substance is unknown, the Contractor shall take no

action to identify the substance until receiving written
instructions from the Department to conduct tests
necessary to identify the material.

5. The Contractor shall have tested those areas so directed by

the Department, and shall test for the materials and
480 products so directed by the Department.

6. All required sampling and testing shall be performed by an

environmental engineer or hazardous materials manager,
environmental specialist, qualified laboratory, or other
person experienced in such work.

7. Once an unknown material has been identified and

emergency response is concluded, the Contractor shall
follow written instructions from the Department regarding
490 removal, additional testing, transportation, or disposal of
the regulated material, subject to the requirements as
follows:

a. Except for testing which the Contractor has been

directed to perform, the Contractor shall not
resume work in the vicinity of the hazardous
condition or in such affected area until after the
Department has obtained all required permits,
approvals, notices of intent, or other submittals
500 including, but not limited to, the following, as
applicable:

(1) Air emissions registration or permit.

(2) Stormwater NPDES permit.

(3) Sewer discharge permit/local POTW

approval.

510 (4) Regulated material characterization.

41
 104.06

(5) Treatment/disposal facility profiles and

approvals.

(6) Notification of hazardous waste activity as a

generator and EPA identification number.

(7) Submittal of a waste analysis plan to the EPA

for treatment on-site in tanks and containers.
520
(8) Hazardous waste permit for on-site treatment
or storage of hazardous waste.

(9) Advanced notification to IDEM for asbestos

removal.

b. The Department will have provided written notice

to the Contractor which specifies that such
hazardous condition and such affected area is, or
530 has been, rendered safe for the resumption of work,
or which specifies conditions under which work
may be safely resumed.

Payment for all work relating to removal, testing,

transportation, or disposal of such materials will be
in accordance with 104.03 utilizing pay items in
202.14.

c. Adjustments, as warranted by the specific

540 circumstances, will be made to the contract price,
contract time, or both as a result of such work
stoppage or such special conditions under which
the Contractor agrees to resume work. Contract
time will not be adjusted on completion date
contracts.

d. The Department will be listed as the

owner/generator on all regulated material
manifests or documents.
550
e. If disposal is required for such materials, the
Department will approve, in writing, the
appropriate licensed disposal site.

f. The Department will retain title to all such

regulated materials, which are being disposed.

42
 104.08

8. Except as provided herein, the Contractor shall follow the

construction requirements shown in 202.
560
104.07 Rights in and Use of Materials Found in the Project Site
Except for hazardous wastes, hazardous substances, hazardous materials, and
asbestos which are subject to 104.06, and lead and zinc bridge painting debris which
is subject to 619, all materials designated to be removed from the project and not used
in the work shall become the property of the Contractor, unless otherwise set out in
the Proposal book. The value of these materials shall be taken into account when the
bid is being prepared.

Construction materials such as gravel, stone, or sand found in the excavation shall
570 not be used for purposes other than indicated on the plans without written approval.
When such approval is given, it shall state explicitly the provisions under which it is
granted.

On all contracts involving construction within the corporate limits of cities and
towns in which items such as drainage structure castings, or other items having a
salvage value, are to be removed, the removed items shall remain the property of the
governmental bodies involved if so specified in the Proposal book or on the plans.
Otherwise, these items shall be disposed of in accordance with these Standard
Specifications. The cost of such disposal shall be included in the contract unit prices
580 of the various pay items of the contract, unless otherwise provided.

Archaeological artifacts encountered during construction shall be addressed in

accordance with 107.10.

104.08 Final Clean-Up

Before acceptance and final payment, the right-of-way, borrow and disposal areas,
and all ground occupied in connection with the work shall be cleaned of rubbish,
excess materials, temporary buildings, structures, and equipment. Waterways shall be
left unobstructed.
590
All property which may have been damaged in the prosecution of the work shall
be restored in an acceptable manner. All parts of the work shall be left in a neat and
presentable condition. All equipment shall be removed from the right-of-way.

Unless otherwise provided, all falsework, piling, concrete or timber mudsills, or

similar material placed during construction and not required in the completed work,
shall be removed entirely or cut off at least 2 ft below the finished ground. Within a
low water channel they may be removed or cut off even with the stream bed.

600

43
 105.01

SECTION 105 – CONTROL OF WORK

105.01 Authority of the Engineer

The Engineer will decide all questions which may arise as to the quality and
acceptability of materials furnished and work performed and as to the rate of progress
of the work; which may arise as to the interpretation of the plans and specifications;
and as to the acceptable fulfillment of the contract on the part of the Contractor.

The Engineer will have the authority to suspend the work wholly or in part for
10 failure to carry out provisions of the contract; for failure to carry out orders; for such
periods as may be deemed necessary due to unsuitable weather; for conditions
considered unsuitable for prosecution of the work; or for any other condition or reason
deemed to be in the public interest. Any contract adjustments for suspension of work
will be in accordance with 104.02(b). Work shall not be suspended without written
authority from the Engineer.

105.02 Plans and Working Drawings

Road plans will show in detail structures of up to and including 20 ft spans, lines,
grades, typical cross sections of the improvement, and general cross sections. They
20 may also show general features of bridges. Bridge plans will show general plans and
details of bridges.

Working drawings as defined in 101.74 shall be furnished.

Working drawings required for approval for construction purposes shall be

submitted as soon as practical after contract award in a format acceptable to the
Engineer. Working drawings will be reviewed for design features only. The Contractor
shall be responsible for dimensions, accuracy, and fit of work. Welding symbols used
on working drawings shall be those shown in AWS A2.4 standards.
30
Design calculations required for approval for construction purposes shall be
submitted as soon as practical after contract award in a format acceptable to the
Engineer. When requested, a longhand example of the design methodology shall be
furnished if the design calculations are in a computer-printout format.

Working drawings and design calculations shall be signed by and shall bear the
seal of a professional engineer. All working drawings and design calculations shall
include the contract number, the Contractor’s name, and contact person.

40 Working drawings shall be furnished for commercially available patented devices

that appear on an approved list as published by the Department. Drawings shall be
signed by and shall bear the seal of a licensed professional engineer. However, the
professional engineer signing and stamping these drawings may be licensed in any
state. Manufacturer’s installation manuals shall be provided with the working
drawings and will remain the property of the Department.

44
 105.03

Working drawings and design calculations will be returned either approved or

showing changes or corrections required within 14 calendar days of receipt. If required
to be changed or corrected, the drawings shall be resubmitted until they receive
50 approval.

Fabrication or construction shall not start on an item of work before working

drawings are approved. Authorized alterations will be endorsed on approved plans or
shown on supplementary sheets. All work done or material ordered prior to the
approval of such plans and drawings shall be at the risk of the Contractor. Department
approval of working drawings will not release the Contractor from the responsibility
for errors, adequacy or safety of falsework, cofferdams, or other temporary work or
risk in connection with the work. Prior to final acceptance the Contractor shall provide
a copy of all approved working drawings, including all approved modifications.
60
105.03 Conformance with Plans and Specifications
All work performed, and all materials furnished shall be in reasonably close
conformance with the lines, grades, cross sections, dimensions, and material
requirements, including tolerances, shown on the plans or indicated in the
specifications. Any deviation from the plans or specifications that may be required by
the exigencies of construction will be determined by the Engineer and authorized in
writing.

Plan dimensions and contract specifications values are to be considered as the

70 target value to be strived for and complied with as the design value from which any
deviations are allowed. It is the intent of the specifications that the materials and
workmanship shall be uniform in character and shall conform as nearly as realistically
possible to the prescribed target value or to the middle portion of the tolerance range.
The purpose of the tolerance range is to accommodate occasional minor variations
from the median zone that are unavoidable for practical reasons. When a maximum or
minimum value is specified, the production and processing of the material and the
performance of the work shall not be preponderantly of borderline quality or
dimension.

80 When construction equipment, office equipment, production equipment, or

testing equipment are specified in metric sizes, any such equipment that has been built
to nearly equivalent English system dimensions will be accepted. When such
equipment is specified in English system sizes, any such equipment that has been built
to nearly equivalent metric sizes will be accepted.

If the Engineer finds the materials or the finished product in which the materials
are used are not within reasonably close conformance with the plans and specifications
but that reasonably acceptable work has been produced, the Engineer will determine
if the work will be accepted and remain in place. In this event, the basis of acceptance
90 will be documented by contract modification which will provide for an appropriate
adjustment in the contract price for such work or materials as deemed necessary to
conform to the determination based on engineering judgment.

45
 105.04

If the Engineer finds the materials or the finished product in which the materials
are used or the work performed are not in reasonably close conformance with the plans
and specifications and have resulted in an inferior or unsatisfactory product, the work
or materials shall be removed and replaced or otherwise corrected with no additional
payment.

100 105.04 Coordination of Plans, Standard Specifications, and Special

Provisions
The Standard Specifications, the plans, special provisions, and all supplementary
documents are essential parts of the contract. A requirement occurring in one is as
binding as though occurring in all. They are intended to be complementary and to
describe and provide for a complete work. In case of discrepancy, calculated
dimensions will govern over scaled dimensions; and the following relationships apply:

Instruction to Bidders and

description of pay items listed
in the Schedule of Pay Items hold over: Unique Special Provisions
Plans
Recurring Special Provisions
Standard Specifications

Unique Special Provisions hold over: Plans

Recurring Special Provisions
Standard Specifications

Plans hold over: Recurring Special Provisions

Standard Specifications

Recurring Special Provisions hold over: Standard Specifications

In case of discrepancy relative to other contract documents, the list of approved

110 or Prequalified Materials will be regarded the same as Recurring Special Provisions.
Notes on the plans which are not also included in either the special provisions or
among the general notes portion of the plans, and refer to payment, non-payment, or
cost to be included in that of other pay items, will not govern over specifications. The
precedence outlined herein shall not absolve the Contractor of its responsibility in
accordance with 107.17.

Advantage shall not be taken of any apparent error or omission in the plans or
specifications. In the event such an error or omission is discovered, the Engineer shall
be notified immediately. Such corrections and interpretations as may be deemed
120 necessary for fulfilling the intent of the plans and specifications will then be made.

46
 105.06

105.05 Cooperation by Contractor

The Department will furnish the Contractor all contract documents in electronic
format without charge. The Contractor shall be responsible for supplying all necessary
information for use by contractor and subcontractor personnel.

The work shall be given the constant attention necessary to facilitate the progress
thereof. The Contractor shall cooperate with the Engineer, technicians, inspectors, and
other contractors in every way possible.
130
Where new work is to be fitted to old work, the Contractor shall check all
dimensions and conditions in the field prior to ordering material and assume
responsibility for fit of new work to old.

The Contractor shall have available at all times, and on the work site when work
is in progress, as its agent, a competent superintendent capable of reading and
understanding the plans and specifications and experienced in the type of work being
performed. The superintendent shall receive instructions from the Engineer or its
authorized representatives and shall have full authority to execute orders or directions
140 without delay. They shall promptly supply such materials, equipment, tools, labor, and
incidentals as may be required. Such superintendence shall be furnished irrespective
of the amount of work sublet.

105.06 Cooperation with Utilities

Prior to letting the contract, the Department will notify all known utility
companies, all pipe line owners, or other parties affected. The Department will
endeavor to have all necessary adjustments of the public or private utility fixtures, pipe
lines, and other appurtenances within or adjacent to the limits of construction
completed.
150
Water lines, gas lines, wire lines, service connections, water and gas meter boxes,
water and gas valve boxes, light standards, cableways, signals, and all other utility
appurtenances within the limits of the proposed construction which are to be relocated
or adjusted are to be moved by the owners at their expense, except as otherwise
provided for in the special provisions or as noted on the plans.

The plans show all known utilities located within the limits of the contract
according to information obtained from the various utility companies. The accuracy
of the plans in this respect is not guaranteed by the Department. All of the permanent
160 and temporary utility appurtenances in their present or relocated positions as shown
on the plans shall have been considered in the bid.

If work by one or more utilities is contingent on work by the Contractor or another

utility, the Contractor shall keep all parties informed of the status and estimated
completion date for the advance work in order to give each utility as much notice as
possible to schedule crews and material for their relocation work.

47
 105.07

The contract documents identify each known utility and describe all known
necessary work and an anticipated schedule for completion. However, if a utility fails
170 to relocate or adjust their facilities as provided for in the contract documents and the
Contractor sustains delays, losses, or both, that could not have been avoided by the
Contractor’s judicious handling of forces, equipment, and plant or by reasonable
revisions to the schedule of operations, and the Contractor has documented its utility
coordination efforts and sustained delays and losses, and if the sustained delays and
losses were not caused by the negligence of the Contractor, the Contractor may pursue
appropriate compensation under 104.02 or from the documented offending party in
accordance with Public Law 35-2005. If the Contractor is delayed and it provides the
aforementioned information to the Engineer, the time for completion may be extended
in such amount as the conditions justify or the Contractor may be compensated for an
180 accelerated construction schedule.

105.07 Cooperation Between Contractors

The Department may at any time contract for and perform other or additional work
on or near the work covered by the contract.

When separate contracts are let within the limits of a project, each contractor shall
conduct its work so as to not to unnecessarily interfere with or hinder the progress or
completion of the work being performed by other contractors. Contractors working on
the same project shall cooperate with each other as directed.
190
Each contractor involved shall assume all liability, financial or otherwise, in
connection with its contract and shall protect and save harmless the Department from
all damages or claims that may arise because of inconvenience, delay, or loss
experienced by such contractor because of the presence and operations of other
contractors working within the limits of the same project.

Work shall be arranged and the materials being used shall be placed and disposed
of so as to not to interfere with the operations of the other contractors within the limits
of the same project. Work shall be joined with that of the others in an acceptable
200 manner. It shall be performed in proper sequence to that of the others.

105.08 Construction Stakes, Lines, and Grades

(a) Construction Engineering by the State

Unless otherwise provided, the Engineer will set construction stakes establishing
lines, slopes, continuous profile-grade, centerline of roadway, centerline of piers and
abutments, a bench mark adjacent to the work, and vertical control elevations for items
including but not limited to flow lines, footings, caps, bridge seats, and screed
elevations. In addition, all necessary information will be furnished relating to lines,
210 slopes, and grades. Using the control lines and grades as established, the Contractor
shall be responsible for completing the layout and performing the work.

48
 105.08

The Contractor shall be responsible for the accuracy of transfer from the control
lines and grades and layout of the work. The Contractor shall notify the Engineer to
locate all existing underground traffic signal and lighting wiring. The Engineer will
only perform this locate service once per construction season per contract. The
Contractor shall also be responsible for the preservation of all stakes and marks. If the
construction stakes or marks are carelessly or willfully destroyed or disturbed by the
Contractor or its employees, the cost to the Department for replacing them will be
220 charged against the Contractor. Such costs will be deducted from payment for the
work.

All stakes, templates, straightedges, and other devices necessary for checking,
marking, and maintaining points, lines, and grades shall be furnished with no
additional payment.

The Department will be responsible for the accuracy of control lines and grades
established by the Engineer. If there is an error in the establishment of the original
construction or survey stakes set, and discovered after the work has been fully or
230 partially completed in compliance with the erroneous stakes, payment for such
additional work as may be required because of such error will be made at the contract
unit price for the class of work involved.

(b) Construction Engineering by the Contractor

If set out as a pay item, the construction engineering, including all staking and
layout usually done by the Department, shall be performed by the Contractor.
Construction engineering shall include re-establishing the survey points and survey
centerlines; referencing the necessary control points; running a level circuit to check
or re-establish plan bench marks; running a level circuit to establish elevations on new
240 bench mark tablets; setting stakes for right-of-way, culverts, slopes, subbase,
underdrains, paving, subgrade, bridge piers, abutments, and all other stakes required
for control lines and grades; setting vertical control elevations, such as footings, caps,
bridge seats, and screed elevations; and obtaining flowline elevations. Construction
engineering shall also include documenting the underground wiring as located by the
Department.

The Contractor shall notify the Engineer to locate all existing underground traffic
signal and lighting wiring. The Engineer will only perform this locate service once per
construction season per contract. The required documentation shall be performed and
250 a copy provided to the Engineer as soon as practical after the locations have been
marked. Documentation which is not provided to the Engineer in a timely manner shall
not be considered valid for the purpose of resolving conflicts related to the accuracy
of the location markings. The documentation may be digital pictures, regular photos,
or sketches of the areas marked. The documentation shall be such that the underground
wiring can be easily and accurately re-established in the field by the Contractor, if
needed.

The Contractor shall schedule its construction engineering operation, including

staking, in a timely fashion so as to assist the utilities in the relocation or adjustment
49
 105.08

260 of their facilities as early as possible in the contract. All staking the Contractor is
directed to perform to assist the utilities’ relocation and which is considered to be in
addition to the normal staking required, will be paid for in accordance with 104.03 or
109.03.

A complete cross section shall be taken at each 500 ft interval. Horizontal control
shall be checked at the beginning and ending of the mainline and all “S” lines. This
information shall be used to verify that the planned alignment and elevations will
match existing conditions. Required alignments and elevations will be shown on the
plans. Prior to incorporating established grades, the Contractor will be required to
270 determine that all other planned elevations are in accordance with field conditions.
The profiling of existing pavements beyond tie-in points for proper ride, profiling of
existing ditches for proper flow, and visual observations that driveways or sidewalks
may be constructed satisfactorily, will be required. Interstate routes and other divided
lane pavements shall be checked for the vertical clearance under structures to ensure
that a minimum of 16 ft is maintained over the traffic lanes and paved shoulder. Ramps
which connect to the above type pavements shall provide the same clearance. All other
pavements shall be checked for the vertical clearance under a structure to ensure that
a minimum of 14 ft is maintained over the traffic lanes and paved shoulders. Grade
transitions shall be tapered to meet the grade of the pavement under a structure a
280 minimum of 100 ft away from the structure and at a rate not to exceed 0.14%. All
discrepancies shall be brought to the immediate attention of the Engineer. All changes
in the design will be provided by the Department. Field adjustments that do not affect
the design shall be made by the Contractor and the Engineer shall be notified.
Adequate control stationing shall be maintained throughout the length of the project.
At the end of the contract all survey control points that fall within the right-of-way
shall be established. At the end of the contract, the Contractor shall provide the
necessary centerline layout so that the final sections may be taken by the Department.
The re-establishment of the centerline control points shown on the plans, right-of-way
points used for fence or markers, and section corners shall be performed by a land
290 surveyor who is registered in the State or by people under the direct supervision of
said land surveyor, per the requirements of IAC Title 865 of the State Board of
Registration for Land Surveyors Statutes and Rules.

Bench marks and elevations shall be established on new or rehabilitated bridges.

The elevations shall be tied to the United States Geodetic Survey system providing
there is an existing monument within a radius of 3 mi of the bridge site. If a monument
is not within this distance, the elevation of the new bench mark shall be established
from the bench marks shown on the plans. Tablets will be furnished by the Department
and shall be set in the new concrete at the locations directed. The Contractor shall
300 document the elevation on the proper forms furnished by the Department. The forms
shall be signed, sealed, and dated by a land surveyor or engineer who is registered in
the State. The work shall be performed in accordance with Part 1, Chapter 106 of the
Department’s Design Manual. Copies of the forms shall be provided to the Engineer
for distribution.

50
 105.08

All stakes, templates, straightedges, and other devices necessary for checking,
marking, and maintaining points, lines, and grades shall be furnished.

On a road contract, the level circuit to check the plan bench marks shall be run for
310 the full length of the project. Intermediate bench marks shall be established
approximately every 500 ft through the project. On a bridge contract, the circuit shall
include four plan bench marks, if available, two on each side of the structure.

Field notes shall be kept in hard covered bound field note books in a clear, orderly,
and neat manner consistent with standard engineering practices and in accordance with
the Department’s prescribed note book procedure, including titles, number, and
indexes. Such note books shall be furnished by the Contractor and shall adequately
document all survey information. Copies of field notes shall be furnished to the
Engineer upon request during the life of the contract. The original field notes shall
320 become the property of the Department upon completion of the work. Such field notes
shall be bound. All pages shall be numbered before submission to the Department.

After the grade stakes have been set for earthwork, an elevation on the top of each
stake shall be taken. Such elevation shall be tied in to a permanent plan bench mark.
Using this information in conjunction with the plans, a grade sheet shall be prepared.
Grade sheets shall also be prepared for special ditches.

When staking culverts, the Contractor shall perform the necessary checking to
establish the proper location, length, skew, and grade. Prior to culvert installation the
330 Engineer will approve adjustments in the location, length, skew, and grade to fit best
the conditions on the site. The Contractor will not be responsible to verify that the
culvert is of adequate opening.

Where sumping is shown on the plans, the Contractor shall obtain the existing
flowline elevation. This information will be used to verify that the planned sump depth
matches existing conditions. Prior to culvert or bridge working drawing design the
Engineer will determine adjustments in footing or invert elevation necessary to
provide the appropriate sump depth.

340 The Engineer will make all measurements and surveys that involve the
determination of final pay quantities, including original and final cross sections for all
earthwork. The accuracy of the construction engineering may be checked as necessary,
but responsibility for the accuracy of engineering layout or the final result of
construction accuracy will not be assumed. The staking by the Contractor shall be done
similar to the standard procedure for Department engineering personnel. All inspection
and testing will be performed by the Department personnel.

The supervision of the Contractor’s construction engineering personnel shall be

the responsibility of the Contractor. All errors resulting from the operations of such
350 personnel shall be corrected with no additional payment.

51
 105.08

The Contractor shall not engage, on full-time, part-time, or other basis during the
contract time, professional or technical personnel who are or have been, during the
contract time, in the employment of the Department, except regularly retired
employees, without the written consent of the Commissioner.

Construction engineering as specified herein will be paid for at a contract lump

sum price. The cost of furnishing all necessary personnel, equipment, and supplies to
accomplish the work shall be included in the cost of this work. A change in plans or
360 scope of work which causes the Contractor’s construction engineering cost to increase
or decrease by $500.00 or more per occurrence will be paid for or deducted from the
original lump sum price bid for construction engineering. An amount of less than
$500.00 per occurrence will not be considered for price adjustments.

(c) Production Staking by the Contractor

When specified, production staking shall be performed by the Contractor.
Production staking shall include staking for finishing subgrade and placing subsurface
drains, subbase, adjacent curbs or curbs and gutters, and all types of pavement,
including base and surface. It shall also include the furnishing of all labor, equipment,
370 and supplies except field books required to complete the work and the staking and re-
staking involved in any authorized alteration of the plans or added work in the
specified items. It does not include staking right-or-way, setting slope stakes,
referencing points, and preparing grade sheets for rough grading. Rough grade staking
will be performed by the Department.

Notes for production staking shall be prepared in standard field note books in a
clear, orderly, and neat manner consistent with good engineering practices and in
accordance with the Department’s prescribed note book procedure. Notes shall be kept
in a manner which can be checked readily and shall be available upon request. Grades
380 and other information, which are obtainable from the plans, shall be computed and
transcribed to the books. The Contractor shall be responsible for the accuracy of the
transferral of the information to the finished work. Errors caused by inaccurate staking
of grades and lines shall be corrected with no additional payment. The method of
staking will be subject to approval. Stakes shall be set and marked in a manner that
will enable checking. Completed staking shall be preserved as long as required for
inspection and checking of the work.

Standard field books will be furnished which will remain the property of the
Department and shall be returned at the completion of the work. Point references,
390 required bench mark data, and information which is not obtainable from a complete
set of contract documents will be furnished. The Department will be responsible for
errors in the plans or other information furnished for layout purposes. If an error is
discovered after the work is fully or partially completed and the error is the result of
erroneous information, payment will be made for additional required work at the
contract unit price for the work involved.

52
 105.10

Production staking will not be paid for directly. The cost thereof shall be included
in the cost of the pay items involved.

400 105.09 Duties of Technician and Inspector

The technicians and inspectors employed by the Department are stationed on the
work to:

(a) keep the Engineer informed as to the progress of the work and
the manner in which it is being done;

(b) report whenever it appears that the materials furnished and the
work performed fail to fulfill the requirements of the
specifications and contract; and
410
(c) call to the attention of the Contractor, as the work progresses,
all known deviations from, or infringement upon, the plans and
specifications with respect to materials and workmanship.

Technicians and inspectors will be authorized to inspect all work done and
materials furnished and to exercise such additional authority as may be delegated to
them in writing. Such inspection may extend to all of the work done and material
furnished. They shall have authority to reject defective materials and to suspend any
work that is being improperly done, subject to the final decision of the Engineer.
420
Such inspection will not relieve the Contractor from any obligation to furnish
acceptable materials or to perform all work strictly in accordance with the
requirements of the plans and specifications.

Technicians and inspectors will not be authorized to revoke, alter, enlarge, relax,
or release any requirements of the specifications; not to approve or accept any portion
of the work; not to issue instructions contrary to the plans and specifications.

Technicians and inspectors will not, in any case, act as foremen or perform other
430 duties for the Contractor, nor interfere with the management of the work. Any advice
which technicians and inspectors may give the Contractor will not be construed as
binding the Engineer or the Department in any way or as releasing the Contractor from
the fulfillment of the terms of the contract.

105.10 Inspection of Work

All materials and each part or detail of the work will be subject to inspection. The
Engineer shall be allowed access to all parts of the work and shall be furnished with
such information and assistance as is required to make a complete and detailed
inspection. Such inspection may include preparation and manufacture of the materials
440 at the plant.

53
 105.11

At any time before acceptance of the work, such portions of the finished work
shall be removed or uncovered as may be directed. After examination, said portions of
the work shall be restored to the standard required by the specifications. If the work
thus exposed or examined proves to be acceptable, the uncovering, or removing, and
the replacing of the covering or making good of the parts removed will be paid for in
accordance with 109.05. If the work so exposed or examined proves to be
unacceptable, the uncovering, or removing, and the replacing of the covering or
making good of the parts removed will be with no additional payment.
450
All work done or materials used without supervision or inspection by an
authorized Department representative may be ordered removed and replaced with no
additional payment unless the Department representative failed to inspect after having
been given reasonable notice in writing that the work was to be performed.

When work covered by the contract is being done under an agreement with a unit
of government or political subdivision, or a railroad corporation, its respective
representatives shall have the right to inspect the work. Such inspection shall in no
sense make such unit of government or political subdivision or such railroad
460 corporation a party to the contract, and shall in no way interfere with the rights of
either party hereunder.

105.11 Removal of Unacceptable and Unauthorized Work

All work which is not in accordance with the contract will be considered as
unacceptable work, subject to conditions set out in 105.03.

Unacceptable work, whether the result of poor workmanship, use of defective

materials, damage through carelessness, or any other cause found to exist prior to the
final acceptance of the work, shall be removed immediately and replaced in an
470 acceptable manner.

No work shall be done unless lines and grades have been given or approved. Work
done contrary to instructions, work done beyond the lines shown on the plans or as
given, except as herein specified, or any extra work done without authority will be
considered as unauthorized and will not be paid for under the provisions of the
contract. Work so done may be ordered removed or replaced with no additional
payment.

If the Contractor fails to comply forthwith with any order made under the
480 provisions of this subsection, the Engineer will have authority to cause unacceptable
work to be remedied or removed and replaced; to cause unauthorized work to be
removed; and to deduct the costs from any monies due or to become due.

105.12 Load Restrictions

Legal load restrictions shall be complied with on public roads beyond the limits
of the project. A special permit will not relieve the Contractor of liability for damage
which may result from the moving of equipment.

54
 105.14

The operation of equipment of such weight or so loaded as to cause damage to

490 structures or the roadway or to any other type of construction will not be allowed. No
loads will be allowed on concrete pavement, concrete bases, or structures before the
expiration of the curing period. The Contractor shall be responsible for all damage
done by the Contractor, its employees, agents, or subcontractors.

This requirement will serve as written notice that hauling or handling of materials
on completed or partially completed structures, pavement structures, or paved
shoulders in excess of legal weight limits will not be allowed unless approved in
advance of the operation. Approval shall be obtained from the authority having
jurisdiction over the structures, pavement structures, or paved shoulders.
500
105.13 Maintenance During Construction
The work shall be maintained during construction and until the contract is
accepted. This maintenance shall constitute continuous and effective work prosecuted
day by day with adequate equipment and forces to the end that the roadway, structures,
barricades, and construction signs are kept in satisfactory condition at all times.

Once construction operations have begun within the project limits, and through
traffic is required to be maintained, the Contractor shall repair areas as directed which
require special maintenance. If the repair work is determined to be required during
510 construction and is due to the Contractor’s operations, the cost of such work shall be
included in the cost of other pay items. If the areas of the roadway which require repair
are due to use by the traveling public or the elements of nature, and are not the fault of
the Contractor, the Contractor will be paid to repair those areas of the roadway. Such
work will be paid for under the appropriate pay items or in accordance with 104.03.

If the contract includes work for the placing of a course upon a course or subgrade
which the Contractor has constructed previously, such previous course or subgrade
shall be maintained during all construction operations. The cost of maintaining this
work shall be included in the cost of other pay items.
520
105.14 Failure to Maintain Roadway, Structures, Barricades, and
Construction Signs
If the Contractor at any time fails to comply with the requirements of 105.13 and
107.12, it will immediately be notified of such non-compliance. If satisfactory
maintenance is not furnished or unsatisfactory maintenance is not remedied within 24
h after receipt of such notice, the Engineer may order suspension of work and proceed
to maintain the project, and all progress estimates will be withheld until the Contractor
complies. The entire cost of this maintenance will be deducted from the money due or
to become due on the contract. No additional contract time will be considered.
530
The Contractor may be assessed damages for failure to maintain the required
traffic control devices, except for construction warning lights, in accordance with
801.03. For each day, or portion thereof, during which a type of traffic control device

55
 105.15

is in non-compliance, damages will be assessed at a rate of $40.00 for each day, per
non-compliant unit within a device. If the pay unit for a traffic control device is per
day, the damage assessment will equal twice the unit price.

Non-compliance caused by events beyond the control of the Contractor may not
be assessed damages. Immediate repairs shall be made to protect the traveling public.
540
Assessment of damages for non-compliance of construction warning lights will
be in accordance with 801.14.

105.15 Acceptance and Final Inspection

(a) Partial Acceptance

The Contractor may request a final inspection and partial acceptance if:

1. a usable portion of the contract one mile or more in

550 length is completed;

2. a portion of the contract designated therein as a project

is completed; or

3. a portion of the contract physically and functionally

separate from other work areas is completed.

If the inspection shows the completed portion to be satisfactory and in accordance

with the contract, that portion may be accepted and the Contractor may be relieved of
560 further responsibility. Such partial acceptance shall in no way void or alter any of the
terms of the contract.

(b) Final Acceptance

When the Contractor gives notice of presumptive completion of the entire
contract, an inspection will be made. If all construction provided for and contemplated
by the contract is found completed satisfactorily, that inspection shall constitute the
final inspection and the Contractor will be notified in writing of final acceptance. The
date of final acceptance shall be the date the Contractor is relieved of further
maintenance in accordance with 107.18 and as set out in the final acceptance letter.
570 This date shall not be prior to the date of the final inspection or the date of last work.
The date of last work will normally be the date the Contractor removes the last
construction traffic control device.

If the work is not acceptable at the time of such inspection, the Contractor will be
advised in writing as to the particular defects to be remedied before final acceptance.
If, within a period of 10 days after such notice, steps have not been taken to complete
the work speedily as outlined, the Department, acting through the Commissioner, may,
without further notice and without in any way impairing the contract, make such other
arrangements as may be necessary to have the work completed in a satisfactory

56
 105.16

580 manner. The cost of so completing the work may be deducted from money due or
which may become due the Contractor on the contract.

105.16 Notice of Changed Conditions and Claims

Nothing in this subsection shall be construed as establishing a claim contrary to
the terms as set out in 104.02.

(a) Contractual Notice of a Changed Condition

If the Contractor requests a contract adjustment for a changed condition in
accordance with 104.02 notification shall be made in writing before the work is begun
590 or expenses relating to the request are incurred.

The written notification of a changed condition shall be submitted to the Engineer

and shall include the following minimum information.

1. A statement that the submittal is notification of a

changed condition.

2. The date the circumstances believed to have caused

the changed condition were discovered and an
600 explanation of how and by whom the changed
condition was discovered.

3. A detailed and specific statement describing the nature

and circumstances of the changed condition.

4. A statement of the estimated effect of the changed

condition on the controlling operation and the cost and
contract time of the project.

610 If written notification of a changed condition is not given and the Engineer is not
afforded the opportunity to remedy the changed condition, then no request for a
contract adjustment will be considered. Notification of a changed condition and the
estimate of the cost of the change shall not be construed as validation of a changed
condition. If the Engineer determines that a contract adjustment is due, payment will
be made as provided for herein.

No contract adjustment will be made for work performed or for expenses incurred
prior to the date of notification of a changed condition. The Contractor shall diligently
prosecute the work unaffected by the changed condition to the maximum extent
620 possible.

(b) Claims
When the Contractor disputes the Engineer’s determination of a remedy for a
changed condition and decides to pursue further relief, a written notification of a claim
shall be submitted to the Engineer within 15 days of receipt of the Engineer’s

57
 105.16

notification of the remedy. If the Contractor fails to submit a notice of a claim within
the time specified, the Contractor shall waive any further rights to a contract
adjustment due to the circumstances from which the claim arose.

630 1. Required Documentation

The Contractor shall submit a claim in writing to the Engineer within 30 days, or
other time as mutually agreed, of when the circumstances giving rise to the claim have
ended or otherwise been resolved.

The claim shall contain sufficient detail to enable the Engineer to determine the
basis and amount of the claim. At a minimum, the following information shall be
included in a claim in a format that can readily be analyzed by the Engineer. The
format shall include, but not be limited to, document length page numbering, a table
of contents and cross references as applicable throughout the claim documentation.
640
a. A detailed factual statement of the claim providing all
necessary dates, locations, and items of work affected
by the changed condition.

b. The date on which the changed condition resulting in

the claim occurred or became evident and an
explanation of how and by whom the changed
condition was discovered.

650 c. A copy of the notification of changed condition as

originally submitted by the Contractor.

d. Copies of the Contractor’s daily records of the changed

condition as kept in accordance with 104.02(d).

e. The name and function of each individual involved in

or knowledgeable about the claim.

f. The specific provisions of the contract which support

660 the claim and a statement of the reasons why the
provisions support the claim.

g. A detailed factual statement of any actions taken by the

Contractor to mitigate the claim.

h. The identification of documents and the substance of

communications relating to the claim.

i. A detailed factual statement supporting the

670 Contractor’s contention that the Department’s decision
was a breach of contract if the claim is related to a

58
 105.16

decision that the contract leaves to the Department as

discretionary or final.

j. The specific amount and basis of costs sought broken

down in the categories specified for force account in
109.05, including a separate calculation of markup as
allowed in 109.05.

680 k. The specific amount of contract time extension sought

and the basis for the request, including approved and
as-built bar chart or critical path method schedules
depicting the affected work.

l. A notarized statement, signed by an officer of the

Contractor, under the penalties of perjury, that the
claim is made in good faith, that no portion of the claim
has previously been paid and that the amount of the
claim and the supporting documents are true, accurate,
690 and reflect what the Contractor believes to be the
Department’s liability.

The Engineer will provide a written notice to the Contractor of receipt of a claim.
If the information provided by the Contractor with a claim does not contain sufficient
detail to enable the Engineer to determine the basis and amount of the claim, the
Engineer will notify the Contractor in writing of the specific details required. The
Contractor shall provide the required details within 14 days, or other time as mutually
agreed, of receipt of the Engineer’s request. If the Contractor fails to provide the
requested details within the time frame, the Engineer’s original remedy for the
700 changed condition will be the final determination by the Department and the
Contractor shall waive any further right to contest the remedy.

2. Auditing of Claims
Claims filed by the Contractor against the Department shall be subject to audit at
any time following the filing of such claim, whether or not such claim is part of a suit
in the courts of the State. The audit may begin a minimum of 30 days after written
notice to the Contractor, subcontractor, or supplier and may be extended as mutually
agreed by all parties. The Contractor, subcontractor, or supplier shall make a good
faith effort to cooperate with the auditors. Failure to cooperate shall constitute a waiver
710 by the Contractor of the claim in its entirety. Failure of the Contractor, subcontractor,
or supplier to maintain and retain sufficient records to allow the Department’s auditor
to verify the claim shall constitute a waiver of that portion of the claim that cannot be
verified and shall bar recovery.

(c) Claim Resolution Process

1. Project Level Review

The Contractor shall submit the claim to the Engineer at the project level. The
59
 105.16

Engineer will review the claim and make an effort to resolve the claim at the project
720 level within 30 days of receipt of the claim, or other time as mutually agreed. Meetings
may be requested by either the Engineer or the Contractor to discuss the claim in an
effort to reach resolution. The Engineer will make a project level ruling on the claim
and notify the Contractor in writing of the ruling.

If the Contractor disagrees with the project level ruling or if a ruling is not issued
within the specified or agreed upon time, a written request for a District Office review
may be submitted to the Engineer within 30 days of receipt of the project level ruling
or the end of the time for the ruling to be issued. Failure to submit a request for District
Office review within the specified time will constitute an acceptance of the project
730 level ruling by the Contractor and a contract adjustment will be made in accordance
with the ruling. The contract adjustment will be considered as full and complete
compensation for the changed condition and the Contractor shall waive any right to
further contest the ruling.

When a District Office review of the project level ruling is requested, the claim
will be sent from the project office to the District Office for the review. The Contractor
shall not modify the basis of the claim or the method for calculating the amount
claimed after submittal to the District Office.

740 2. District Office Review

The Engineer will review the claim as submitted to the District Office. Meetings
may be requested by either the Engineer or the Contractor to discuss the claim in an
effort to reach resolution.

For claims with a total value less than or equal to $150,000, 20% of the original
contract amount and 100 days of contract time extension, the Engineer will review the
project level ruling and issue a written District Office ruling within 45 days, or other
time as mutually agreed, of the Contractor’s request for a District Office claim review.
A claim review by the District may affirm, overrule, or modify the project level ruling.
750 The District ruling will specify the portions, if any, of the project ruling that are being
overruled or modified and the rationale supporting the portions overruled or modified.

The Contractor may accept or reject a claim review ruling made by the District
Office. If the Contractor accepts the ruling, it will be considered as the final decision
by the Department and a contract adjustment will be made in accordance with the
ruling.

If a District ruling is rejected, the Contractor may submit a written request for a
final hearing before a District Claim Review Board. The request shall be submitted to
760 the Chief Engineer within 30 days of the Contractor’s receipt of the District ruling.
The Chief Engineer will respond in writing to the Contractor and will convene a Board
to review the claim. Failure to submit a request for a hearing within the specified time
will constitute an acceptance of the District Office ruling by the Contractor and a
contract adjustment will be made in accordance with the ruling. The contract

60
 105.16

adjustment will be considered as full and complete compensation for the changed
condition and no further claim shall be made for the circumstances that gave rise to
the claim.

The District Claim Review Board will consist of three Department personnel
770 selected by the Chief Engineer and will include one member from District
Construction in the District involved in the claim and two members from the Division
of Construction Management. The Chief Engineer will assign one member as the
chairperson who will then schedule a hearing with the Contractor at a mutually agreed
time and location. The Contractor will be given sufficient time at the hearing to present
arguments and exhibits in support of the claim. The Board will issue a written decision
within 30 days of the hearing and the decision will be considered as the final decision
by the Department and no further appeal will be considered by the Department. A
contract adjustment will be made in accordance with the decision of the Board and
will be considered as full and complete compensation for the changed condition and
780 no further claim shall be made for the circumstances that gave rise to the claim.

For claims with a total value greater than $150,000 or 20% of the original contract
amount or 100 days of contract time extension, the District will forward the claim,
along with the project level ruling and a District Office written opinion to Central
Office for a ruling. The Contractor shall not modify the basis of the claim or the
method for calculating the amount claimed after submittal to Central Office.

3. Central Office Review

The Engineer will review the claim as submitted to Central Office from the
790 District. Meetings may be requested by either the Engineer or the Contractor to discuss
the claim in an effort to reach resolution.

The Engineer will review the claim and issue a written final ruling within 60 days,
or other time as mutually agreed, of receipt of the claim from the District. A claim
review ruling by Central Office may affirm, overrule, or modify the ruling made at the
project level. The ruling will specify the portions, if any, of the project ruling that are
being overruled or modified and the rationale supporting the portions overruled or
modified.

800 The Contractor may accept or reject a claim review ruling made by Central Office.
If the Contractor accepts the ruling, it will be considered as the final decision by the
Department and a contract adjustment will be made in accordance with the ruling.

If a Central Office ruling is rejected, the Contractor may submit a written request
that the matter be discussed before a civil mediator. The request shall be submitted to
the Chief Engineer within 30 days of the date of the Central Office ruling. Failure to
request mediation within the specified time shall constitute acceptance of the Central
Office ruling by the Contractor and a contract adjustment will be made in accordance
with the ruling. The contract adjustment will be considered as full and complete

61
 106.01

810 compensation for the changed condition and no further claim shall be made for the
circumstances that gave rise to the claim.

Upon receipt of the request for civil mediation, the parties will select a mutually
agreed upon certified mediator from the list of mediators eligible to perform civil
mediations in the State of Indiana. The mediator shall be familiar with the highway
and bridge construction industry but shall not have any financial interests in the parties.
The mediation shall be conducted in Indianapolis, Indiana pursuant to the applicable
rules of the Indiana Supreme Court governing civil mediations in the State of Indiana.
The mediator will schedule the mediation as soon as practicable, preferably within 60
820 days of selection. In the event settlement is reached, a summary of agreement will be
prepared. Either party or the mediator may declare the mediation to be unsuccessful.
By requesting mediation, it is agreed that, as with other civil mediations, the
discussions and proceedings at mediation are considered part of settlement
negotiations and are inadmissible in any civil proceeding.

The Contractor and the Department mutually agree that use of the claim resolution
process up to and including the utilization of a mediator is a condition precedent to the
filing of any lawsuit concerning claims or alleged breaches of the Contract. The costs
and expenses associated with use of the mediator shall be borne by both parties
830 equally. Each party to the mediation shall bear its own costs in preparation and
participation.

SECTION 106 – CONTROL OF MATERIAL

106.01 Source of Supply and Quality Requirements

The Contractor shall furnish the Engineer a complete statement of the origin,
composition, and manufacture of any or all materials to be used in the construction of
the work at the preconstruction conference. If, during the course of the contract,
changes or additions to the statement are required, the Contractor shall provide the
information five calendar days prior to the source supplying materials to the project.

10 (a) Approved or Prequalified Materials

Certain materials and equipment require pre-approval by brand name or source of
manufacture. The lists of approved materials, equipment and sources are maintained
by the Department as provided in the specifications. The Department will review all
approved materials lists prior to January 1 of even numbered years. Unless otherwise
provided, any item listed for three years prior to the review without being supplied to
a contract will be removed from the list.

The materials used shall be those prescribed for the several items which constitute
the finished work and shall comply with all the requirements for such materials in
20 accordance with this specification and 900. In any combination of materials, even
though the individual components meet the specifications, such combination shall also

62
 106.01

meet the specifications and produce the required results. Failure to do so will be cause
for rejection.

Approval of a material at its source will not necessarily constitute acceptance of

materials from that source. All materials tested at the source may be subjected to
further testing from production to after incorporation into the work. Approval will be
based on the results of tests made nearest to incorporation into the work. Material
tested prior to incorporation into the work and not in accordance with the requirements
30 will be rejected. Material tested after incorporation into the work and not in accordance
with the requirements will be governed by 105.03.

If a material from a source has a continued approval as shown by five or more

consecutive tests, it may, if allowed, be put on an immediate usage basis and while on
that basis may be incorporated into the work prior to the receipt of test results. If any
subsequent test reveals non-conformance with the specifications, material from that
source shall be removed at once from the immediate usage basis and shall not be used
until tests indicate conformance. If, after any test showing non-conformance, five or
more consecutive tests show conformance, the material may be restored to an
40 immediate usage basis.

If a material on an immediate usage basis has been incorporated into the work and
later is found as not being in accordance with the specifications, the Engineer may, in
accordance with 105.03, require its removal from the work or allow it to remain. If
allowed to remain, the appropriate contract unit price will be reduced.

All packaged materials shall be marked plainly showing the amount and nature of
contents and shall be delivered intact.

50 (b) Material Records

The Engineer will prepare the material record from the documentation provided
by the Contractor. The Engineer will submit the completed forms to the Contractor by
the end of the fifth business day of each month for the preceding month. The
Contractor shall distribute this information to the appropriate subcontractors as
required. The Contractor shall review, sign, and return the material record to the
Engineer by the 28th day of each month, along with documentation to support the
Contractor’s recommended adjustments to the record.

1. Documentation of Material Delivery

60 The Contractor shall provide a copy of each delivery ticket and certifications, if
required, to the Engineer not later than the next business day. If providing this
information on the next business day is not possible, the Contractor and the Engineer
will agree upon other arrangements for the receipt of the necessary documentation
prior to the event.

2. Delivery Ticket Information

The material delivery ticket shall include an itemized quantity of all materials
delivered, the date of delivery, and the contract number. The material delivery ticket
63
 106.02

shall document the source of supply and source code if known, and shall contain
70 information necessary to obtain a basis for use as required by Department
specifications. All required certifications shall be in accordance with 916 or as
directed.

3. Payment Procedures
If the Contractor does not provide the necessary documentation for the materials,
such materials will not be paid for. The Engineer will notify the Contractor of those
materials held from the estimate with the justification for withholding payment. If
corrective action has not been taken within six weeks of the materials delivery to the
project site, the entire estimate payment may be withheld.
80
(c) Buy America Requirement
All contracts, whether financed entirely or partially with State or Federal funds,
shall comply with IC 5-16-8 and the 23 CFR 635.410.

Except for pig iron and processed, pelletized, and reduced iron ore, steel shall be
made in the United States by the open hearth, basic oxygen, electric furnace,
Bessemer, or other steel making process. Except for pig iron and processed, pelletized,
and reduced iron ore, all steel and cast iron materials and products permanently
incorporated in the contract shall be manufactured in the United States. Manufactured
90 products include those which are rolled, formed, shaped, drawn extruded, forged, cast,
or fabricated. The United States includes all territories, continental and insular, subject
to the jurisdiction of the United States of America.

Except for pig iron and processed, pelletized, and reduced iron ore, no steel or
cast iron products produced in the United States may be modified in a foreign country
and still comply with the Buy America Requirement.

A Buy America Certification shall be submitted and received for each product or
source of material prior to being incorporated into the contract in accordance with
100 916.02(g) and 916.03(a).

106.02 Samples, Tests, Cited Specifications

Such facilities as may be required for collecting and forwarding samples shall be
provided and the materials represented by the samples shall be held until tests have
been made and such materials found to have the qualities required in the specifications.
All samples required and additional material required to replace samples shall be
furnished without charge.

To facilitate the sampling and testing of materials, the Engineer shall promptly be
110 advised when orders for materials are placed and when such materials are received.
The quantity, source of supply, and the locations where the materials have been stored
shall be included in the notice.

All tests of materials will be made in accordance with the methods described or
designated in these specifications. When tests are made at places other than the
64
 106.03

laboratory, every needed facility shall be furnished for the verification of all scales,
measures, and other devices which are used.

If the Contractor elects to supply materials other than structural steel and
120 prestressed structural members which require on-site sampling or testing as they are
manufactured in out-of-state manufacturing plants located more than 60 mi outside a
State line, the Contractor shall provide the sampling or testing services required. No
additional payment will be made for such services. Such services shall be conducted
by a Department-approved testing laboratory.

The standards for materials and methods of tests of AASHTO and ASTM or other
specification referred to herein or elsewhere shall be the standard, interim, or tentative
specifications included in the latest published edition which is on file on January 1,
unless otherwise specified. Indiana Test Methods will become effective immediately
130 upon approval by the ITM Committee unless otherwise directed. In case of
discrepancy, the following relationships apply:

Special Provisions hold over: ITM, AASHTO and ASTM or other

specification for materials and
methods of tests

ITM hold over: AASHTO and ASTM or other

specification for materials and
methods of tests

AASHTO hold over: ASTM or other specification for

materials and methods of tests

Tests will be made by and at the expense of the Department unless otherwise
specified. The minimum required number of samples and tests will be as set out in the
Frequency Manual. Samples will be taken by or under the supervision of a
representative of the Department. All materials being used are subject to inspection,
test, or rejection at any time.

140 106.03 Plant Inspection

The Engineer may undertake the inspection of materials at the source.

If plant inspection is undertaken, the following conditions shall be met:

(a) The Engineer shall have the cooperation and assistance of the
Contractor and the material supplier. All reasonable facilities to
assist in determining whether the materials meet the
requirements of the specifications shall be furnished without
additional payment.
150

65
 106.04

(b) The Engineer shall have entry at all times to such parts of the
plant as may concern the manufacture or production of the
materials being furnished.

(c) Adequate safety measures shall be provided and maintained.

106.04 Blank

106.05 Storage of Materials

160 Storage of materials shall be such that will assure the preservation of their quality
and fitness for the work. When considered necessary, materials shall be placed on
raised, clean platforms, constructed of wood or other hard surfaced material and under
cover. Stored materials shall be located to facilitate proper inspection. Materials to be
used for all contracts shall be stored separately and intact and, after being tested for
such work, shall not be used for other purposes except unless otherwise approved.

The portion of the right-of-way not required for public travel may be used for
storage purposes and for placing the Contractor’s plant and equipment, subject to
requirements set out in 107.08 and only by written request. Approval will be based on
170 compliance with 107.08 and the Contractor’s proposed procedure for re-establishing
vegetation in the affected area to its original condition or better. Except as provided in
105.07 and except where necessary for drainage, if storage limits are shown on the
plans, the right-of-way within such storage limits will be available for construction
operations and storage of materials. Private property shall not be used for storage
purposes without written permission of the owner or lessee. If requested, copies of
such written permission shall be furnished. All storage sites shall be restored to their
original condition with no additional payment. This shall not apply to the stripping and
storing of topsoil, or to other materials salvaged from the work.

180 106.06 Handling of Materials

All materials shall be handled in such manner as to preserve their quality and
fitness for the work.

106.07 Unacceptable Materials

All materials not in accordance with the specifications shall be considered as
unacceptable and all such materials will be rejected and shall be removed immediately
from the site of the work unless otherwise instructed. No rejected material, the defects
of which have been corrected, shall be used until approval has been given.

190 If rejected materials are not removed within the time specified, the Department
may order their removal with no additional payment, or complete the contract in
accordance with 108.09.

106.08 Hazard Communication Program

The Contractor and all subcontractors will be required to furnish the Engineer
with Material Safety Data Sheets for each hazardous material which each firm uses or

66
 107.01

stores on the project site for Department maintained roadways. Such sheets shall be
generated by each hazardous material manufacturer and shall be in accordance with
Indiana OSHA requirements.
200
106.09 Department Furnished Materials
The Contractor shall furnish all materials required to complete the work except
those specified to be furnished by the Department. Materials furnished by the
Department will be delivered or made available at the locations specified. The cost of
handling and placing materials after they are delivered to the locations specified shall
be included in the contract price for the item in connection with which they are used.
The Contractor will be held responsible for all materials delivered. Deductions will be
made from any monies due to the Contractor to make good all shortages or deficiencies
and for all damage which might occur after delivery or for demurrage charges.
210
106.10 Proportioning Materials
All materials used shall be proportioned as specified for each type of work, kind
of unit, or item of work required by the contract. No change in the source or kind of
materials or blending of asphalt materials will be allowed during construction without
written consent. Application for such consent shall be in writing, a material which is
not in accordance with the quality requirements set out in these specifications shall not
be blended with a better quality material to upgrade the end product.

Where not explicitly set out, the size and amount of aggregate as well as the grade
220 and amount of asphalt material to be used shall be as ordered.

106.11 Sample Asbestos Exclusion Letter

Asbestos-containing materials shall not be used in the construction or
reconstruction of buildings or bridges. A letter of exclusion for each building or bridge
shall be submitted by the Contractor to the Engineer prior to acceptance of work and
final payment. Such letter shall indicate that no asbestos-containing material was used
as a building material during the project using the exclusion form in 916.03(f).

SECTION 107 – LEGAL RELATIONS AND RESPONSIBILITY TO PUBLIC

107.01 Laws to be Observed

The Contractor shall keep fully informed of Federal and State laws; local laws;
ordinances; and rules, regulations, orders, and decrees of bodies or tribunals having
any jurisdiction or authority which in any manner affect those engaged or employed
on the work or which in any way affect the conduct of the work. The Contractor shall
at all times observe and comply with all such laws, ordinances, rules, regulations,
orders, and decrees. The Contractor shall protect, indemnify, and exculpate the State
10 and its representatives, in accordance with 107.17, against civil claim or civil liabilities
arising from or based on the violation of such law, ordinance, rule, regulation, order,
or decree, whether by itself or its employees, even if such violation is due wholly or
in part to violation of said law, ordinance, rule, regulation, order, or decree by the State
or its representatives.
67
 107.01

Certain counties in the State are considered by the United States Department of
Agriculture to be generally infested with various harmful pests such as, but not limited
to, various types of beetles. In an effort to prevent these pests from being spread by
shipments of infested materials, quarantines have been imposed. Under the
20 regulations, materials and equipment that may be infested must be treated before they
are moved from an infested area. Such items as hay, straw, fodder, small grains, corn,
sod, earth moving equipment, and other articles that might be infested are subject to
these regulations. All State, Federal, and local regulations and quarantines pertaining
thereto shall be observed. No additional allowance or compensation will be made for
any delay or inconvenience incurred conforming to such requirements, but the cost
thereof shall be included in the various pay items.

It shall be a condition of each contract let for the construction of a State

maintained highway or bridge, financed entirely with state funds that all unskilled
30 laborers employed on such work shall be residents of the county or counties in which
such highway or bridge is being constructed, if such labor is available. The Department
will designate the class of labor which is unskilled. This provision will not apply to
any contract on which federal funds are to be used.

The Contractor and its subcontractors shall not discriminate against an employee
or applicant for employment to be employed in the performance of any contract with
respect to his or her hire, tenure, terms, conditions or privileges of employment, or any
matter directly or indirectly related to employment, because of race, color, sex,
disability, religion, national origin, or ancestry. Breach of this covenant may be
40 registered as a material breach of the contract.

Water wells or test wells to be drilled shall be in strict accordance with the Indiana
Code. Such wells shall be drilled only by a water well driller licensed in the State. A
copy of the driller’s license shall be furnished prior to commencement of work.

The Contractor may hire only citizens and nationals of the United States, and
aliens authorized to work in the United States. The Contractor shall verify the identity
and employment eligibility of all employees, in accordance with the Immigration and
Nationality Act.
50
Maintaining a drug-free workplace will be required in accordance with Executive
Order 90-5, as follows:

(a) The Contractor shall agree to make a good faith effort to provide
and maintain a drug-free workplace during the contract time. It
shall give written notice to the Department within 10 days after
receiving actual notice that an employee of the Contractor has
been convicted of a criminal drug violation occurring on the
project site.
60

68
 107.03

(b) If the total bid amount shown in the Schedule of Pay Items is in
excess of $25,000.00, the Contractor shall further agree that the
contract is expressly subject to the terms, conditions, and
representations contained in the Drug-Free Workplace
certification executed by the Contractor in conjunction with the
contract, and which is included in the Proposal book.

(c) The failure of the Contractor to comply in good faith with the
terms of (a) above, or falsifying or otherwise violating the terms
70 of the certification referenced in (b) above, shall constitute a
material breach of the contract. Such failure shall entitle the
Department to impose sanctions against the Contractor
including, but not limited to, suspension of contract payments,
termination of the contact, or debarment of the Contractor from
doing further work for the Department for up to three years.

Indiana Code 4-13-18-5 requires all bidders to submit an employee drug testing
plan which complies with the requirements of the cited Code. The Contractor is
directed to implement the employee drug testing plan as submitted. Material breaches
80 of this requirement may constitute an independent basis to invoke 108.10.

107.02 Permits, Licenses, and Taxes

All permits and licenses which may be required due to construction methods such
as, but not limited to, borrow or disposal pits, stream crossings, causeways, work
bridges, cofferdams, etc., but which are not part of the contract documents, shall be
procured by the Contractor prior to beginning the work which requires the permit. All
charges, fees, and taxes shall be paid. All notices necessary and incidental to the due
and lawful prosecution of the work shall be given.

90 The Department is exempt from State, Federal, and local taxes and will not be
responsible for any taxes levied on the Contractor as a result of the contract.

The Department may have acquired environmental permits, including, but not
limited to, U.S. Army Corps of Engineers Permit, IDNR Certificate of Approval of
Construction in a Floodway, IDEM Section 401 Water Quality Certification, or a
permit for construction of temporary pavement across a state line. If the Department
has acquired one or more of such permits, the restrictions or conditions which were
issued with such permits will be made available to bidders prior to letting. The
Contractor shall prosecute the work in accordance with all such restrictions or
100 conditions.

107.03 Patented Devices, Materials, and Processes

If a design, device, material, or process covered by letters of patent or copyright
is employed by the Contractor, such use by suitable legal agreement with the patentee
or owner shall be provided. The Contractor and the surety shall indemnify and save
harmless the State, affected third party, or political subdivision from all claims for
infringement by reason of the use of such patented design, device, material, process,
69
 107.04

trademark, or copyright. The State shall be indemnified for costs, expenses, and
damages which it may be obliged to pay by reason of infringement during the
110 prosecution or after the completion of the work.

107.04 Restoration of Surfaces Opened by Permit

The right to construct or reconstruct utility service in the highway or street or to
grant permits for same is hereby expressly reserved by the Department for the proper
authorities of the municipality in which the work is done.

An individual, firm, or corporation wishing to make an opening in the highway

shall obtain a permit from the Department. Parties bearing such permits, and only those
parties, will be allowed to perform work on the right-of-way.
120
107.05 Federal Aid Provisions
When the United States Government pays all or a portion of the cost of a project,
the Federal laws and the rules and regulations made pursuant to such laws shall be
observed. The work shall be subject to inspection by the appropriate Federal agency.
Such inspection will in no sense make the Federal Government a party to the contract
and will in no way interfere with the rights of any party.

The U.S. Department of Labor has designated the Administrator of the Wage and
Hour and Public Contracts Division to conduct investigations with the compliance and
130 enforcement of labor standards. However, the administration and enforcement of labor
standards remain the responsibility of the U.S. Department of Transportation.

107.06 Equal Employment Opportunity Trainees

Equal Employment Opportunity trainees will be required if the Equal
Employment Opportunity Trainees hours are shown in the Proposal book. The number
of trainees required will be one trainee for each 1,000 h shown.

When the project is funded in total or in part by the United States Government
and no Equal Employment Opportunity hours are shown in the Proposal book, the
140 Contractor shall participate in the Department’s Equal Employment Opportunity
Trainee Program. Requirements for participation in the program are available on the
Department’s website or from the Department’s Equal Opportunity Division. Failure
by the Contractor to comply with this requirement may result in reduction or loss of
prequalification to bid for future work.

As part of the Contractor’s equal opportunity affirmative action program, training

shall be provided as on-the-job training aimed at developing full journeymen in the
type of trade or job classification involved.

150 If the Contractor subcontracts a portion of the work, it shall determine as to how
many, if any, of the trainees are to be trained by the subcontractors, provided, however,
that the Contractor shall retain the primary responsibility for meeting the training
requirements imposed herein. The Contractor shall also ensure that these requirements

70
 107.06

are made applicable to such subcontract. Where feasible, 25% of apprentices or

trainees in each occupation shall be in their first year of apprenticeship or training.

The trainees shall be distributed among the work classifications on the basis of
the Contractor’s needs and the availability of journeymen in the various classifications
within a reasonable area of recruitment. Prior to commencing construction, the
160 Contractor shall submit to the Department for approval the number of trainees to be
trained in each selected classification and training program to be used. Furthermore,
the Contractor shall specify the starting time for training in each of the classifications.
The Contractor will be credited for each trainee employed on the contract work that is
currently enrolled or becomes enrolled in an approved program.

Training and upgrading of minorities and women toward journeymen status is the
primary objective. Accordingly, the Contractor shall make every effort to enroll
minority and women trainees, for example, by conducting systematic and direct
recruitment through public and private sources likely to yield such minority and
170 women trainees to the extent that such persons are available within a reasonable area
of recruitment. The Contractor will be responsible for demonstrating the steps taken
in pursuance thereof, prior to a determination as to whether the Contractor is in
compliance with this provision. This training commitment is not intended, and shall
not be used, to discriminate against an applicant for training, whether a member of a
minority group or not.

No employee shall be employed as a trainee in a classification in which he or she

has successfully completed a training course leading to journeyman status or in which
he or she has been employed as a journeyman. The Contractor shall satisfy this
180 requirement by including appropriate questions in the employee application or by
other suitable means. Regardless of the method used, the Contractor’s records shall
document its findings in each case.

The minimum length and type of training for each classification will be as
established in the training program selected by the Contractor and approved by the
Department. The Department and the FHWA will approve a program if it is reasonably
calculated to meet the equal employment opportunity obligations of the Contractor and
to qualify the requirement for journeyman status in the classification concerned by the
end of the training period. Furthermore, apprenticeship programs registered with the
190 U.S. Department of Labor, Bureau of Apprenticeship and Training, or with a State
apprenticeship agency recognized by such Bureau, and training programs approved
but not necessarily sponsored by the U.S. Department of Labor, Manpower
Administration, Bureau of Apprenticeship and Training shall also be considered
acceptable provided they are being administered in a manner consistent with the equal
employment obligations of the contract. Approval or acceptance of a training program
shall be obtained from the State prior to commencing work on the classification
covered by the program. Training shall be provided in the construction crafts rather
than clerk-typists or secretarial-type positions. Training programs for other than
traditional training programs may be submitted for consideration where the training is

71
 107.07

200 oriented toward construction applications. Training in the laborer classification may
be allowed provided that significant and meaningful training is provided and approved
by the Department. Some offsite training is allowable as long as the training is an
integral part of an approved training program and does not comprise a significant part
of the overall training.

It is normally expected that a trainee shall begin his or her training on the project
as soon as feasible after start of work utilizing the skill involved and shall remain on
the project as long as training opportunities exist in his or her work classification or
until he or she has completed the training program. It is not required that all trainees
210 be on board for the entire contract time. The Contractor shall have fulfilled its
responsibilities if it has provided acceptable training to the number of trainees
specified. The number trained shall be determined on the basis of the total number
enrolled on the contract for a significant period.

Trainees will be paid at least 60% of the appropriate minimum journeyman’s rate
paid by the Contractor for the first half of the training period, 75% for the third quarter
of the training period, and 90% for the last quarter of the training period, unless
apprentices or trainees in an approved existing program are enrolled as trainees on the
project. In that case, the appropriate rates approved by the United States Department
220 of Labor or Transportation in connection with the existing program shall apply to all
trainees being trained for the same classification who are covered by this specification.
However, the salary shall never be less than specified in IC 8-23-9-22.

The trainee shall be furnished a copy of the program to be followed in providing

the training. Each trainee shall be provided with a certification showing the type and
length of training satisfactorily completed.

The maintenance of records and the furnishing of periodic reports documenting

its performance shall be in accordance with these requirements.
230
107.07 Sanitary Conditions Requirements
Accommodations for the use of employees shall be provided and maintained in a
neat sanitary condition as may be necessary to comply with the requirements of the
Federal, State, and local Boards of Health, or of other bodies or tribunals having
jurisdiction.

107.08 Public Convenience and Safety

All safeguards, safety devices, and protective equipment shall be provided.
Responsibility reasonably necessary to protect the lives of employees on the job, the
240 safety of the public, and property in connection with the performance of the work,
shall be taken.

(a) Worker Safety

All workers within the right-of-way who are exposed either to traffic or
construction equipment within the work area shall wear high visibility safety apparel
in accordance with Section 6D.03 of the MUTCD.
72
 107.08

If a trench, 5 ft or more in depth, is constructed on a project, the requirements for

trench safety systems as specified in OSHA regulations 29 CFR 1926, Subpart P, shall
250 be performed. Unless otherwise specified, trench safety systems work will not be paid
for separately, but the cost thereof shall be included in the cost of the pay item covering
the trench excavation work.

(b) Dust and Air Pollution

Provision shall be made for prompt removal from traveled roadways of all dirt
and other materials that have been deposited thereon by operations concerned with the
project whenever the accumulation is sufficient to cause the formation of dust or mud,
interfere with drainage, damage pavements, or create a traffic hazard. Construction
methods and means shall be employed to keep flying dust and air pollution to a
260 minimum. Provision shall be made for the control of dust on the project and on roads,
streets, and other areas affected by the project wherever traffic or buildings, or
construction materials are affected by such dust. The materials and methods used for
dust control shall be subject to approval. The cost of controlling dust and air pollution
shall be included in the cost of other pay items and no additional payment will be
made.

(c) Protection to Traffic

The work shall be arranged so that all operations on the pavement will be held to
a minimum by using the new grade insofar as possible. The work shall be conducted
270 in a manner that will ensure the least obstruction to traffic. Materials stored on the
right-of-way shall be placed so as to cause only such inconvenience to the traveling
public and residents as is considered unavoidable. Non-operating construction
equipment, worker’s vehicles, materials, field offices, field laboratories, and
temporary offices may be stored on the right-of-way no less than 30 ft from the edge
of pavement lanes open to traffic except, storage may be allowed closer to such lanes
if traffic is protected by guardrail in good condition or other suitable barrier. However,
if the area has a posted speed limit of 40 mph or less prior to the start of construction,
this distance may be reduced to 10 ft, if approved.

280 Temporary crossings and approaches in passable condition shall be provided and
maintained as shown on the plans and in accordance with 104.04, with no additional
payment.

(d) Notice to Local Public Officials

On construction work, the chief administrative officer of the local governmental
unit shall be given 24 h notice, in writing, before it becomes necessary to blockade a
cross street.

If it is desired to use water from public hydrants, application shall be made to the
290 proper authorities and in accordance with the city ordinances, rules, and regulations
concerning their use. Fire hydrants shall be accessible at all times to the fire
department. No material or other obstruction shall be placed closer to a fire hydrant

73
 107.09

than specified by ordinances, rules, or regulations, or within 5 ft of a fire hydrant in

the absence of such ordinances, rules, or regulations.

The local governmental agencies for each jurisdiction in the State have the legal
authority to establish load limits on their roads. Prior to submitting a bid, each bidder
shall contact the local governmental agency in which the use of roads is contemplated
and confirm allowable routing of bidder’s equipment.
300
(e) Convenience to Traffic and Property Owners
Frontage roads, public roads, and private and mailbox approaches which are
disturbed shall be reconstructed as soon as possible to avoid unreasonable
inconvenience to traffic and adjacent property owners.

The grading of all approaches and frontage roads shall be completed and the
drainage structures shall be placed concurrently with the roadway excavation and
embankment construction except as directed or specified. It is the general intent to
construct frontage roads, public roads, and private drive approaches, including at least
310 the grading, structures, and base course, as soon as possible to minimize inconvenience
to the abutting property owners when their access to existing outlets is being cut off
by the construction.

If postponement of the above construction causes unreasonable inconvenience to

traffic and adjacent property owners, the Contractor shall construct an adequate,
approved, temporary surface on all such frontage roads, public roads, and private
approaches with no additional payment. All cost thereof shall be considered as
included in the various pay items of the contract.

320 If the contract involves widening, one-lane traffic shall be maintained across all
public, private, and commercial approaches either by leaving gaps in the widening or
by use of temporary crossing bridges.

107.09 Railroad-Highway Requirements

Whenever it is necessary or required for personnel or construction equipment to
be on operating railroad right-of-way, all necessary arrangements shall be made with
the railroad company regarding a temporary or existing railroad grade crossing for this
purpose. Such railroad grade crossing shall be in accordance with these specifications
and shall meet all requirements of the railroad company. All cost involved in
330 establishing the crossing shall be included in the contract price for various pay items
and will not be paid for directly.

All work on the railroad right-of-way shall be performed at such times and so as
not to interfere unnecessarily with the movement of trains or traffic upon the tracks of
the railroad company. All care and precautions shall be used in order to avoid
accidents, damage, or unnecessary delay or interference with the trains or other
property of the railroad company.

74
 107.10

When necessary, adjacent structures, embankments, and tracks of the railroad

340 company shall be protected and shored adequately. The Contractor shall assume all
risks and liability for damage done to such property as a result of its operations or
negligence. No method of work which affects the tracks, movement of trains, or other
operations of the railroad shall be used without the approval of the railroad company.

When bridge deck work is being performed over railroad property, including
tracks and wires, and the bridge floor slab is penetrated, the work shall be stopped in
the area of the penetration. Both the Engineer and the railroad company shall be
notified. The railroad property shall be protected as approved before resuming work.

350 (a) Protection of Track Ballast

Operations shall be conducted both on and off railroad right-of-way so that earth,
mud, silt, or other foreign matter shall not be allowed to foul railroad track ballast.
Temporary earth dikes, sheeting, tie cribbing, silt fences, or other precautions to
prevent the fouling of railroad track ballast shall be installed as directed.

Where demolition work, concreting, or hauling along or across tracks, in the

opinion of the railroad company, will result in ballast becoming fouled, preventive
measures shall be taken to protect the entire ballast section. This may be accomplished
by nailing canvas, plywood, or similar material to the ties in the entire area likely to
360 be affected. This protective material shall remain in place until there is no further
possibility of fouling the ballast. At that time it shall be removed.

These protective measures shall be performed with no additional payment under

the supervision and to the satisfaction of the chief engineer of the railroad company or
its authorized representative. The railroad company will assume no responsibility for
the adequacy of the protective measures. However, in addition to the aforementioned
protective measures, if the railroad track ballast does become fouled, the railroad
company, with its own forces, will remove the fouled ballast and replace it with clean
ballast. The charges for this work will be billed by the railroad company against the
370 Contractor.

(b) Hold Harmless Clause

The Contractor shall indemnify and save harmless the Railroad Company and the
State from all suits, actions, or claims of any character brought for or on account of
any injuries or damages received or sustained by any person, persons or property from
the acts of the Contractor or its forces, or in consequence of any neglect in
safeguarding the work, or on account of any claims or amounts recovered for any
material furnished or labor performed, or for any infringement of patent, trademark or
copyright, or any claims arising or amount recovered under the Worker’s
380 Compensation Laws, Federal Employer’s Liability Act, or under any other laws,
by-laws, ordinances, orders or decrees.

107.10 Archaeological Artifacts

If archaeological artifacts, including cultural features or skeletal remains are
discovered, all work within a minimum 100 ft radius of the discovery shall cease
75
 107.11

immediately, the area shall not be further disturbed and the Contractor shall notify the
Engineer immediately.

In accordance with IC 14-21-1-27, if skeletal remains are encountered, the

390 Contractor shall notify the local law enforcement agency immediately and the
Engineer immediately thereafter. The Department will notify IDNR within two days.
Work within the area of the discovery shall not resume without written authorization.

For discoveries other than skeletal remains, the Department will coordinate with
IDNR to mitigate impacts to the discovery. Work within the area of the discovery shall
not resume without written authorization.

In no event shall an employee of the Contractor or the State of Indiana share in

ownership or profit from salvaged archaeological findings.
400
107.11 Bridges over Navigable Waters
All work on navigable waters shall be conducted so as not to interfere with free
navigation of the waterways nor to impair the existing navigable depths. Exceptions
may be allowed by permit issued by the authority having jurisdiction over the
navigable waters.

107.12 Traffic Control Devices

All necessary barricades, suitable and sufficient lights, danger signals, signs, and
other traffic control devices shall be provided, erected, and maintained. All necessary
410 precautions shall be taken for the protection of the work and safety of the public.
Highways closed to traffic shall be protected by effective barricades. Obstructions
shall be illuminated during hours of darkness. Suitable warning signs shall be provided
to control and direct traffic. All construction vehicles and equipment shall have amber
lights in accordance with 801.14(d) when in the work area and located on the
pavement, sidewalk, or shoulder with the road open to traffic. Vehicles delivering
materials to the job site, if displaying headlights, clearance lights and hazard warning
lights which are in compliance with Indiana statutes, shall be exempt from this
requirement.

420 Warning signs shall be erected in advance of any location on the project where
operations may interfere with the use of the road by traffic and at all intermediate
points where the new work crosses or coincides with an existing road. Such warning
signs shall be constructed and erected in accordance with the plans. Temporary
pavement markings, when required, shall be placed in accordance with 801.12 or as
directed.

Barricades, warning signs, lights, signals, markings, and other protective devices
shall be in accordance with the plans and the MUTCD current on the date of
advertisement for bids.
430
All signs, barricades, and other protective devices shall be maintained in good
condition and in accordance with 105.13, 801, and 802. Barricades and the
76
 107.13

backgrounds and messages of all signs shall be kept clean and bright. They shall be
renewed or replaced as often as necessary to keep them effective. Failure to maintain
these devices may result in the assessment of damages in accordance with 105.14 and
801.14.

Pavements and shoulders having an edge drop of more than 3 in. shall be
delineated with drums in accordance with 801.09. Delineation shall be at a maximum
440 spacing of 200 ft. The use of cones in accordance with 801.08 will be allowed as shown
on the plans except cones shall not be used for interstate lane restrictions.

At least 14 days before a road is to be closed to traffic, notification shall be given

of such intention. Detour route marker assemblies shall be erected and maintained
along the detour route designated by the Department. Barricades shall not be erected
nor the traffic interfered with until the posted detour or the temporary runaround is
approved.

If it is necessary to close a road for the purpose of replacing a drainage structure,

450 the road shall not be closed until the pipe structure is at the project site.

Sufficient barricades, supplemented by watchers or flaggers when necessary, shall

be provided continuously to protect any and all parts of the work and to promote safe
and orderly movement of traffic. When a road is closed or posted for official detour
but is still usable by local traffic, barricades and road closure sign assemblies, in
addition to the closure barricades, required at the beginning and end of the portion of
such road being detoured, shall be erected at the site of bridge removals, pipe removals,
or other high hazard locations. Such barricades shall be located within 150 ft of the
removal location. These barricades shall be of the type shown on the plans, and in
460 accordance with 801.07. Such barricades shall extend from shoulder to shoulder, or to
the limit of area that is readily traversable by a motor vehicle, as directed. During non-
working hours, no opening shall exist in the barricades. The road closure sign
assembly shall be placed at or near the center of the roadway. If these requirements
are violated, operations shall be suspended until adequate measures are taken for full
compliance. The use of hand signaling flags will not be allowed except for emergency
situations. The “Stop”/“Slow” paddle shall be required as a primary hand signaling
device to control traffic through work areas. The “Stop”/“Slow” paddle shall be in
accordance with section 6E.03 of the MUTCD, except it shall be at least 24 in. wide.

470 Unless otherwise specified, sufficient watchers shall be furnished and be on duty
24 h a day during the time widening or patching is in progress. These workers shall
have adequate transportation facilities to patrol the entire portion under construction.
They shall maintain the signs, barricades, and lights at all times for the safety of
pedestrian and vehicular traffic.

107.13 Use of Explosives

When the use of explosives is necessary for the prosecution of the work, the
utmost care shall be exercised not to endanger life or property, including new work.
The Contractor shall be responsible for all damage resulting from the use explosives.
77
 107.14

480 All explosives shall be stored in a secure manner in accordance with all laws and
ordinances. All such storage places shall be clearly marked in large black letters on a
red background “Dangerous Explosives”. Where no local laws or ordinances apply,
satisfactory storage shall be provided no closer than 1,000 ft from the road or from a
building or camping area or place of human occupancy. Detonators shall not be stored
with explosives.

Each public utility company having structures in proximity to the site of the work
shall be notified of intentions to use explosives. Such notice shall be given sufficiently
in advance to enable the companies to take such steps necessary to protect their
490 property from injury. The notification shall in no way relieve responsibility for damage
to the structures.

107.14 Protection and Restoration of Property and Landscape

Private property shall not be entered for any purpose in connection with the work,
without first obtaining proper permission. The Contractor shall be responsible for the
preservation of all public and private property. All land monuments and property
marks shall carefully be protected from disturbance or damage until the Engineer has
witnessed or otherwise referenced their location and approved their removal. All areas
on the right-of-way that are used for storage of any kind shall be restored to their
500 original condition, or to that set out in the Proposal book, when no longer required for
that purpose.

The Contractor shall be responsible for damage or injury to property resulting

from defective work or materials and from any act, omission, or misconduct in its
manner or method of executing the work. When direct or indirect damage or injury is
done, such property shall be restored with no additional payment to a condition similar
or equal to that existing before such damage or injury, or such damage or injury shall
be made good in an acceptable manner.

510 Construction equipment shall not be stored in wetland replacement sites shown
on the plans. Such sites shall not be used for purposes other than for the creation of
wetlands.

On those portions of the project where fence is required on the right-of-way, the
required permanent fence shall be erected and maintained at locations where the
property owner desires to use the adjacent area for pasturage or livestock. If the
permanent fence has not been erected by the time the adjacent property owner desires
to use such pasturage, a temporary fence shall be erected and maintained. The fence
shall be sufficient to prevent encroachment of livestock onto the right-of-way until the
520 permanent fence is erected.

At locations involving temporary right-of-way where it is necessary to remove

existing fence, unless otherwise directed, a temporary fence shall be erected and
maintained along the temporary right-of-way. The fence shall be sufficient to prevent
encroachment of livestock on the right-of-way. Except when included as a bid item in

78
 107.17

the contract, temporary fence will not be measured and paid for directly, but will be
included in the cost of various pay items.

On those portions of the project where a fence is not required, but the removal of
530 an existing fence from the right-of-way is required, the property owner, and tenant, if
any, must be notified at least 10 days before the fence is removed from the right-of-
way.

107.15 Erosion Control Plan and Proof of Publication

The Department will prepare the necessary information to initiate the submittal
requirement of 327 IAC 15-5. The Contractor shall supply all remaining requirements
of 327 IAC 15-5 in accordance with 108.04.

The Department will prepare a preliminary Erosion Control Plan as required by

540 327 IAC 15-5 and will submit it to the appropriate Soil and Water Conservation
District.

No construction activity shall begin until the Notice of Intent is filed by the
Department. The Engineer will notify the Contractor of such filing.

107.16 Forest Protection

In carrying out work within or adjacent to State or National Forests and other
wooded areas, the Contractor shall comply with all regulations or the State Fire
Marshal, Natural Resources Commission, Forestry Department, or other authority
550 having jurisdiction, governing the protection of forests and the carrying out of work
within forests. The Contractor shall observe all sanitary laws and regulations with
respect to the performance of work in forest areas. The Contractor shall keep the areas
in an orderly condition, dispose of all refuse, and obtain permits for the construction
and maintenance of all construction camps, stores, warehouses, residences, latrines,
cesspools, septic tanks, and other structures in accordance with the requirements of the
forest supervisor.

Reasonable precautions shall be taken to prevent and suppress forest fires. The
Contractor’s employees and subcontractors shall be required, both independently and
560 at the request of forest officials, to do all reasonably within their power to prevent and
suppress and to assist in preventing and suppressing forest fires and to make every
possible effort to notify a forest official at the earliest possible moment of the location
and extent of all fires seen by them.

107.17 Responsibility for Damage Claims

The Contractor shall indemnify, defend, exculpate, and hold harmless the State of
Indiana, its officials and employees from all liability due to loss, damage, injuries, or
other casualties of whatsoever kind, or by whomsoever caused, to the person or
property of anyone on or off the right-of-way arising out of or resulting from the
570 performance of the contract or from the installation, existence, use, maintenance,

79
 107.18

condition, repairs, alteration, or removal of any equipment or material, whether due in

whole or in part to the negligent acts or omissions:

(a) of the State, its officials, agents, or employees;

(b) of the Contractor, its agents or employees, or other persons

engaged in the performance of the contract;

(c) the joint negligence of any of them, including any claim arising
580 out of the Worker’s Compensation law or any other law,
ordinance, order, or decree.

The Contractor also agrees to pay all reasonable expenses and attorney’s fees
incurred by or imposed on the State in connection herewith in the event that the
Contractor shall default under the provisions of this section. As much of the money
due the Contractor under and by virtue of its contract as the Department may consider
necessary for such purpose may be retained for the use of the State. If no money is
due, the Contractor’s surety may be held until such suit or suits, action or actions,
claim or claims for injuries or damages as aforesaid shall have been settled and suitable
590 evidence to that effect furnished to the Department. Money due will not be withheld
when the Contractor produces satisfactory evidence that it is protected adequately by
public liability and property damage insurance. The obligation of the Contractor under
this section and 107.01 shall not extend to the indemnification or exculpation against
claims arising out of the preparation or approval of plans, specifications, or special
provisions unless furnished by the Contractor.

It is specifically agreed between the parties executing the contract that it is not
intended by the provisions of any part of the contract to create the public or any
member thereof a third party beneficiary hereunder, or to authorize anyone not a party
600 to the contract to maintain a suit for personal injuries or property damage pursuant to
the terms or provisions of the contract.

107.18 Opening Sections of Project to Traffic

Shoulders shall be graded and shaped to assure reasonable safety to traffic before
opening any completed pavement to traffic.

Work which is in suitable condition for travel, or any portion thereof, shall be
opened to traffic as directed. Such opening shall not be construed as acceptance of the
work or any part thereof, or as a waiver of any of the provisions of the contract.
610
When it is desirable to open a structure or portion of a highway to traffic, such
opening shall be delayed until traffic will cause no injury to completed portions of the
work. When opening to traffic is required or allowed, the Contractor shall make
provisions for the safety of the public as specified or directed. Opening to traffic will
not relieve the Contractor of its liability and responsibility during the period the work
is so opened prior to final acceptance.

80
 107.19

When a contract time has expired, the Contractor shall be responsible for all
damage resulting from traffic and any other cause occurring on the incomplete portions
620 of the project, whether these portions have been opened to traffic by order of the
Department or not.

On those portions of an incomplete contract that have been ordered opened to

traffic or are constructed under traffic and the contract time has not yet expired, the
Department will assume the responsibility for repairs of damages resulting directly
from traffic, provided that such damage is not the direct or indirect result of the
operations of the Contractor and provided the Contractor is unable to collect damages
from the responsible party or parties.

630 The Department will only assume such responsibility

(a) if the Contractor documents those damages with all available

information, including but not limited to photos and
investigative materials, and

(b) if the Contractor preserves all documentation, evidence, photos

and information regarding the nature, extent and cause of such
damage.

640 Also, the Department will only assume such responsibility if, within 90 days from
the date such damage is discovered by the Contractor or the Contractor receives notice
of that damage, whichever is earlier,

(a) the Contractor demonstrates to the Department that despite its

good faith, vigorous efforts, it has been unable to collect those
damages from the responsible party or parties, and

(b) the Contractor provides to the Department all documentation,

evidence, photos and information regarding the nature, extent
650 and cause of such damage.

Ordered repairs for damage for which the Department assumes responsibility will
be paid for at the contract unit price for the item involved in making the repairs, where
such items are applicable.

Opening a portion of a project to traffic does not preclude the responsibility of the
Contractor for providing necessary safety measures, as required in these Standard
Specifications, to protect persons using the highway.

660 107.19 Contractor’s Responsibility for Work

Until the date the Contractor is relieved of further maintenance as stated in the
final written acceptance of the project, or portion thereof in accordance with 105.15,

81
 107.20

the Contractor shall have the charge and care thereof. The Contractor shall be
responsible for injury or damage to any part thereof, by the action of the elements or
from any other cause except as set out in 107.18, whether arising from the execution
or from the non-execution of the work. All portions of the work occasioned by the
above causes shall be rebuilt, repaired, and restored. All injuries or damages shall be
made good before final acceptance. The Contractor shall bear the expense thereof
except as otherwise provided in these specifications or otherwise determined.
670
In case of suspension of work, the Contractor shall be responsible for the contract
work and shall take such precautions as may be necessary to prevent damage to the
contract work. Normal drainage shall be provided, and all necessary temporary
structures, signs, or other facilities shall be erected with no additional payment. During
such period of suspension of work, newly established plantings, seedlings, and
soddings furnished under the contract shall be properly and continuously maintained
in an acceptable growing condition.

107.20 Contractor’s Responsibility for Utility Property and Services

680 At points where the Contractor’s operations are adjacent to properties of railroad,
telegraph, telephone, and power companies or are adjacent to other property, damage
to which might result in considerable expenses, loss, or inconvenience, work shall not
be commenced until all arrangements necessary for the protection thereof have been
made.

The Contractor shall coordinate and cooperate with the owners of all underground
or overhead utility lines in their removal and relocation operations in order that this
work may progress in a reasonable manner, that duplication of relocation work may
be reduced to a minimum, and that services rendered by those parties are not
690 unnecessarily interrupted.

If it is necessary to place pipes or conduits through structures, sheet metal sleeves

shall be provided around the pipe or conduit to make a sliding joint or provide suitable
openings as required, with no additional payment.

If there is an interruption to water or utility services as a result of accidental

breakage or as a result of being exposed or unsupported, the Contractor shall promptly
notify the proper authority, and shall cooperate with the said authority in the
restoration of service. If water service is interrupted, repair work shall be continuous
700 until the service is restored. No work shall be undertaken around fire hydrants until
provisions for continued service have been approved by the local fire authority.

The Contractor shall establish and maintain open communication with each utility
affected by the construction and document and report all communication to the
Engineer. The Contractor shall prepare its construction schedule to accommodate all
of the utility work plans included in the contract documents including some allowance
for unexpected minor variation in the anticipated utility work plan and schedule.

82
 107.23

Regardless of previous notification by the Department, the Contractor shall give

710 notice to the owners of each utility located within the contract limits, or which might
be affected by the work, in sufficient time before beginning work for the owners to
relocate or protect their property. No work shall be done which injures or damages
such property until satisfactory arrangements have been completed with the owner for
its protection, relocation, or reconstruction.

Prior to any work which penetrates any existing soil or pavement surface, the
Contractor shall notify both the Indiana Underground Plant Protection Service, IUPPS,
in accordance with IC 8-1-26 requirements and the Engineer in accordance with
105.08 prior to commencing construction operations in an area that may affect
720 underground utilities.

If abandoned underground utilities are encountered during construction, sections

of which are to be removed, ends of pipes that remain in place shall be sealed with
class A concrete as directed. Concrete used for this purpose will be paid for at the
contract unit price per cubic yard for concrete, A, in structures. Cutting of abandoned
gas lines shall be by mechanical methods. A cutting torch shall not be used.

If a permit is issued to a city or other governmental unit for the installation of

conduits, poles, or other appurtenances for artificial lighting of the structure, it may be
730 necessary or desirable to revise the plans or make structural changes as needed to
accommodate such installation. In this event, the provisions of 104.02 shall apply to
all changes in quantities of work.

107.21 Furnishing Right-of-Way

The Department will be responsible for securing necessary right-of-way in
advance of construction. Exceptions will be indicated in the contract.

107.22 Personal Liability of Public Officials

In carrying out any of the provisions of these specifications, or in exercising any
740 power or authority granted to them by or within the scope of the contract, there shall
be no liability upon the Department, Commissioner, Engineer, or their authorized
representatives, either personally or as officials of the State, it being understood that
in all such matters they act solely as agents and representatives of the State.

107.23 Waiver of Legal Rights

Upon completion of the work, the Department will expeditiously make final
inspection and notification of acceptance. Such final acceptance, however, shall not
preclude or estop the Department from correcting any measurement, estimate, or
certificate made before or after completion of the work, nor shall the Department be
750 precluded or estopped from recovering from the Contractor or its surety, or both, such
overpayment as it may sustain by failure on the part of the Contractor to fulfill its
obligations under the contract. A waiver on the part of the Department of any breach
of any part of the contract shall not be held to be a waiver of any other or subsequent
breach.

83
 107.24

The Contractor, without prejudice to the terms of the contract, shall be liable to
the Department for latent defects, fraud, or such gross mistakes as may amount to
fraud, or with regard to the rights of the Department under any warranty or guaranty.

760 107.24 Governing Law

This contract shall be construed by the laws of the State of Indiana. Suit, if any,
shall be brought in the State of Indiana.

107.25 Severability
The invalidity in whole or in part of a provision of the contract shall not void or
affect the validity of all other provisions.

SECTION 108 – PROSECUTION AND PROGRESS

108.01 Subletting of Contract

The contract, contracts, or portions thereof; or the right, title, or interest therein
shall not be sublet, sold, transferred, assigned, or otherwise disposed of without written
consent. In case such consent is given, the Contractor will be allowed to sublet a
portion thereof, but shall perform with its own organization, work amounting to not
less than 50% of the original or revised contract amount, whichever is less. All items
designated in the contract as specialty items may be performed by subcontract. The
10 cost of such specialty items so performed by subcontracts may be deduced from the
total cost before computing the amount of work required to be performed by the
Contractor with its own organization. No subcontracts or transfer of contracts will
release the Contractor of liability under the contract and bonds. Approved
subcontractors will not be allowed to further subcontract their work.

Unless the Department provides written consent, the Contractor shall not be
entitled to any payment for subcontracted work or materials unless it is performed or
supplied by a subcontractor approved on the contract prior to the work being
performed.
20
The minimum wage for labor as stated in the Proposal book shall apply to all labor
performed on all work sublet, assigned, or otherwise disposed of in any way.

The Contractor or subcontractor may enter into leases or rental agreements for
equipment with operators or trucks with drivers. When certified payrolls are required,
they shall be submitted for all such equipment operators and truck drivers who perform
work. This payroll shall verify that these employees have been paid not less than the
predetermined wage rate set out elsewhere in the contract for the classification of work
performed.
30
The subcontractor shall be in accordance with the requirements of
105 IAC 11-2-10, Subcontractors.

84
 108.04

The Contractor shall submit payment records through the Department’s

Subcontractor Payment Tracking System (http://itap.indot.in.gov) of all payments
made to subcontractors and DBE firms approved by the Department. Reports shall be
submitted no later than 10 days after the end of each month in which a subcontractor
is paid for work on the contract. Reports shall include any release of retainage
payments made to subcontractors.
40
108.02 Release of Retainage to Subcontractors
If the Contractor is withholding portions of payments due subcontractors as
retainage, the Contractor shall release such retainage to the subcontractor within 30
calendar days after satisfactory completion of the work performed by the
subcontractor.

For the purposes of this section, satisfactory completion will be interpreted as

when the subcontractor has completed all physical work and completed other contract
requirements, including the submission of all submittals required by the specifications
50 and the Department.

108.03 Notice to Proceed

Unless otherwise provided, the Contractor will be expected to start active and
continuous work on the contract within 15 calendar days after the date of the notice to
proceed. Work shall not begin prior to the date of the notice to proceed.

If a delayed starting date is indicated in the proposal, the 15 calendar day

limitation will be waived. Work day charges will then begin on a date mutually agreed
upon, but not later than the delayed starting date specified. If the contract is canceled
60 after an award has been made but prior to the issuing of the notice to proceed, no
reimbursement will be made for any expenses accrued relative to this contract during
that period.

If the contract involves demolition work, the Contractor shall not enter the parcel
or proceed with the demolition without written authority from the Engineer. The
Contractor will be compensated only for those houses and buildings which are actually
removed from the right-of-way. Time of commencing demolition work and time of
completion shall be in accordance with 108.08.

70 108.04 Prosecution of the Work

A pre-construction conference will be held at the earliest possible date, at which
time it will be determined at what point the Contractor’s operations will start.

The Contractor shall furnish the Engineer with a bar graph type schedule which
shows the estimated times required to prosecute the major or critical items of work for
acceptance unless the contract has less than 60 calendar days completion time, less
than 35 work days, or less than 60 days between the date of the notice to proceed and
the calendar completion date. This schedule shall incorporate all contract requirements

85
 108.04

regarding the order of performance of work and each activity. The schedule shall
80 graphically show the calendar time for which each activity is scheduled for work. The
schedule may be used as the basis for establishing major construction operations and
as a check on the progress of the work. Sufficient materials, equipment, and labor shall
be provided to guarantee the completion of the project in accordance with the plans
and specifications within the specified completion time. The Engineer shall be notified
at least three days in advance of the date on which the work is expected to begin. The
schedule shall be submitted at the pre-construction conference.

The Department and the Contractor shall meet at least once each month to review
actual and proposed schedules. The Contractor shall submit the correspondence to the
90 district after each monthly meeting addressing each item of work that is behind
schedule and as to what action will be taken to get the work back on schedule.

If, in the opinion of the Engineer, construction progress has been or will be
materially affected by changes in the plans or in the quantities of work, or if
performance has failed to conform to the accepted schedule, a revised schedule shall
be submitted when requested. Acceptance of the schedules will in no way justify them,
but will simply indicate concurrence in their reasonableness and feasibility on the
assumption that every effort shall be made to meet them. Existence of a current and
accepted schedule will be a condition precedent to the processing and payment of a
100 partial pay estimate.

If the prosecution of the work is discontinued, the Engineer shall be notified at

least 24 h in advance of resuming operations.

During the progress of the work, the Engineer shall be notified at least 24 h in
advance of undertaking construction operations. This advance notification shall also
apply anytime a DBE is scheduled to work on a project or deliver material or supplies
to a project site.

110 If the plans for a road contract provide for the construction of an interchange,
interchanges, or approaches at bridge locations, regardless of the actual date of
completion on the bridge contract or contracts, the road contractor will be required,
unless otherwise directed, to complete the planned pavement, including approaches
and interchanges, as planned and set out in the road contract. The road contract may
be modified to allow additional compensation or time if the bridge contract has delays
which affect the work of the road contractor and was not under the control of, or caused
by, the road contractor.

For those contracts requiring 327 IAC 15-5, having waterway permits, and
120 stormwater management, the Contractor shall locate, install, inspect, maintain, and
remove temporary sediment and erosion control BMPs, for earth disturbing activity
areas, and develop a SWQCP, for the Engineer’s acceptance, in accordance with 205.

86
 108.04

Where required by 327 IAC 15-5, stockpile and storage sites shall be permitted
by an IDEM NOS. An NOI with an IDEM time stamp 48 hours prior to the beginning
of operations at the sites shall also meet these requirements. The Contractor shall
obtain an NOS, or IDEM time stamped NOI submitted to the Engineer prior to the
beginning of operations at those locations. Borrow and disposal sites shall be in
accordance with 203.08.
130
For those contracts not requiring 327 IAC 15-5, having no waterway permits, and
not requiring stormwater management, the Contractor shall submit a written site plan
to the Engineer describing the following:

1. A description of the contract site.

2. The locations of all equipment storage areas, fueling

locations, construction trailers, batch plants, and
designated concrete truck washout locations.
140
3. A material handling and spill prevention plan.

The site plan shall be submitted for acceptance 14 calendar days prior to the start
of construction activity.

The cost of preparation and implementation of the site plan described above shall
be included in the cost of the other items of the contract.

When temporary construction materials are no longer required or used for

150 maintenance of traffic or for other temporary purposes, such materials shall be
removed and disposed of as provided herein. If temporary roadbed or asphalt
pavement materials are used for embankment construction, such materials will be
classified as excavation and paid for at the contract unit price per cubic yard for the
type of excavation shown in the Schedule of Pay Items. No allowance will be made
for overhaul or added haul. If temporary HMA pavement materials are used in the
work for subbase, base, approaches, or for new shoulder construction, such materials
will be paid for as salvaged road material in accordance with 613.

Temporary concrete pavement, temporary concrete base, or temporary concrete

160 widening, when no longer required for maintenance of traffic, shall be removed and
disposed of in accordance with 202.05. Such removal and disposal will be paid for in
accordance with 202.14.

Temporary drainage structures, temporary concrete median barriers, and other

temporary devices required and used for the maintenance of traffic shall remain the
property of the Contractor. All costs for furnishing, placing, maintaining, removal, and
disposal of temporary drainage structures shall be included in the contract lump sum
price for maintaining traffic. If there is no pay item for maintaining traffic, these costs

87
 108.05

shall be included in the various pay items listed in the proposal, unless otherwise
170 provided.

108.05 Pre-phase Site Construction Meetings

A pre-phase site construction meeting shall be scheduled and conducted by the
Contractor prior to the beginning of work on each major work phase. These meetings
are intended to help improve the quality of construction, personnel safety on the
project site, and safety of the traveling public. These meetings shall include all
subcontractors connected with the particular phase. When the conditions described in
105.07 are possible during a particular phase, the other Contractors shall be invited to
attend. The Department’s project staff and the Area Engineer shall be invited to attend.
180
At each meeting, the Contractor shall indicate its current schedule for the phase,
discuss maintenance of traffic control, project site personnel safety, compliance with
the plans and specifications including quality construction, and all other pertinent
subjects.

The number of pre-phase site construction meetings will be determined at the

pre-construction conference. No additional payment will be made for these meetings.

108.06 Limitation of Operations

190 The work shall be conducted in such a manner and in such sequence as ensures
the least interference with traffic. Due regard shall be given to the location of detours
and to the provisions for handling traffic. Work shall not be started to the prejudice or
detriment of work already begun. The completion of a section on which work is in
progress may be required before work is started on additional sections, if opening such
section is essential to public convenience.

Except as hereinafter specified, no load of material for any construction shall be

dispatched so late in the day that it cannot be placed, finished, and protected within
the specification’s limits and provisions during daylight of that same day. Daylight
200 will be defined as the period between sunrise and sunset as established by the National
Weather Service. When it is important that construction shall be completed at an early
date, work may be allowed at times other than daylight hours provided sufficient
illumination is available and that work performed under these conditions complies in
every respect with the terms and conditions of the contract.

108.07 Character of Workers, Methods, and Equipment

Sufficient labor and equipment for prosecuting the several classes of work shall
be employed at all times to full completion in the manner and time required by these
specifications.
210
All workers shall have sufficient skill and experience to perform properly the
work assigned to them. Workers engaged in special or skilled work shall have
sufficient experience in such work and in the operation of the equipment required to
perform all work properly and satisfactorily.

88
 108.07

Each person employed by the Contractor or by each subcontractor who does not
perform in a proper and skillful manner or is intemperate or disorderly shall, at the
written request of the Engineer, be removed forthwith by the employer of such person.
The person shall not be employed again in any portion of the work without approval.
220 If the person is not removed as required herein, or if suitable and sufficient personnel
for proper prosecution of the work are not furnished, all estimates may be withheld or
the work suspended by written notice until these requirements have been met.

All equipment which is proposed to be used on the work shall be of sufficient size
and in such mechanical condition as to meet requirements of the work and to produce
a satisfactory quality of work. Equipment which was originally developed to be used
in performing work in International System measurements may be used in performing
work in English System measurements. Where possible, such equipment shall be
adjusted to the English System measurements. Where equipment cannot be adjusted,
230 it shall then be made compatible, as required, to satisfactorily be used for performing
work in English System measurements in accordance with 101.43, 105.03, 109.01(a),
and 109.01(i). Equipment used on the project shall be such that no injury to the
roadway, adjacent property, or other highways will result from its use.

Construction equipment, which is used in recreational areas, shall not be left

parked in existing parking areas or on existing park road pavements except as may be
necessary during the time construction work is in progress. All damage to such
roadways or parking lot pavements caused by equipment, such as gouge marks or
petroleum leakage, shall be repaired with no additional payment in accordance with
240 the applicable requirements of 107.14 or as directed.

When the methods and equipment to be used in accomplishing the construction

are not prescribed in the contract, any methods or equipment that will accomplish the
work in accordance with the contract may be used.

When the contract specifies that the construction be performed by the use of
certain methods and equipment, such methods and equipment shall be used unless
others are authorized. If the use of a method or type of equipment other than those
specified in the contract is desired, authority to do so may be requested. The request
250 shall be in writing and shall include a full description of the methods and equipment
proposed to be used and an explanation of the reasons for desiring to make the change.
If approval is given, it will be on the condition that the Contractor will be fully
responsible for producing construction work in accordance with contract
requirements. If, after trial use of the substituted methods or equipment, it is
determined that the work produced does not meet contract requirements, the use of the
substitute methods or equipment shall be discontinued and the remaining construction
shall be completed with the specified methods and equipment. The deficient work shall
be removed and replaced with work of specified quality or other corrective action shall
be taken as directed. No change will be made in basis of payment for the construction

89
 108.08

260 items involved or in contract time as a result of authorizing a change in methods or

equipment under these provisions.

108.08 Determination and Extension of Contract Time

The number of days allowed for the completion of the work included in the
contract will be stated in the Proposal book and will be known as the contract time.

If the contract time is on a work day basis, as defined in 101.73, a weekly

statement showing the number of days charged to the contract to date and for the
preceding week, the number of days specified for completion of the contract, and the
270 days remaining and the controlling operation will be furnished. The Contractor will be
allowed one week from the date it receives the statement in which to file a written
protest setting forth in what respect said weekly statement is incorrect. Otherwise, the
statement will be deemed to have been accepted by the Contractor as correct. For the
purpose of computation, work days will be considered as beginning on the fifteenth
calendar day after the date of the notice to proceed. All calendar days elapsing between
the effective dates of orders to suspend work and to resume work for suspensions
which are not the fault of the Contractor will be excluded.

If the contract time is on a calendar day basis, it shall consist of the number of
280 calendar days stated in the contract including all Sundays, holidays, and non-work
days counting from the date of the notice to proceed. All calendar days elapsing
between the effective dates of any orders to suspend work and to resume work for
suspensions not the fault of the Contractor will be excluded. A weekly statement
showing the controlling operation will be furnished. The Contractor will be allowed
one week from the date it receives the statement in which to file a written protest
setting forth in what respect said weekly statement is incorrect. Otherwise, the
statement will be deemed to have been accepted by the Contractor as correct.

If the contract time is a fixed calendar date, it shall be the date on which all work
290 on the contract shall be completed. For such contracts, an extended date of completion
will be considered for delay in the issuance of the notice to proceed if the notice to
proceed is not issued within 30 days of the letting, except if the delay is due to the
failure of the Contractor to furnish requested forms or information. Unless otherwise
determined, an extension to the contract completion date and intermediate completion
date will be allowed for each calendar day from 30 days after the date of the letting to
and including the date of the notice to proceed. A weekly statement showing the
controlling operation will be furnished. The Contractor will be allowed one week from
the date it receives the statement in which to file a written protest setting forth in what
respect said weekly statement is incorrect. Otherwise, the statement will be deemed to
300 have been accepted by the Contractor as correct.

The number of days for performance shown in the contract as awarded will be
based on the original quantities as defined in 104.02.

90
 108.08

(a) For a completion date contract, unless otherwise determined, an

increase in quantities will not increase the time specified for the
performance of the contract.

(b) If intermediate completion times are specified, unless otherwise

310 determined, an increase in quantities will not increase the time
specified.

If an intermediate completion time is specified for road closure

or restriction, the first day or portion thereof of the closure or
restriction will constitute the first chargeable day. The date the
road is opened to unrestricted traffic will be counted as a
chargeable day, regardless of the time of day when the roadway
is opened. Open to unrestricted traffic shall be as defined in
101.33. Temporary pavement marking materials in accordance
320 with 801.12 shall be placed if the final marking materials cannot
be placed in accordance with 808.07(b).

If the Contractor finds it impossible for reasons beyond its control to complete the
work within the contract time as specified prior to the expiration of the contract time,
a written request in accordance with 105.16 may be made for an extension of time
setting forth therein the reasons which will justify the granting of the request. A plea
that insufficient time was specified is not a valid reason for extension of time. If the
Engineer finds that the contract controlling operation was delayed due to an excusable
delay under 108.08(a) or 108.08(b), the Department will extend the contract time for
330 completion in such amount as the conditions justify. The extended time for completion
shall then be in full force and effect, the same as though it were the original time for
completion. The Department will not extend contract time for a non-excusable delay
under 108.08(c).

Contractors shall not work during the following holiday periods unless prior
written approval is received from the Engineer. All deliveries and traffic coming from
suppliers shall cease during the Department-ordered suspensions of work listed below.
No time extensions to closure periods, intermediate completion dates, or contract
completion dates will be granted for suspending work during these holiday periods.
340
(a) New Year’s Day. If New Year’s Day falls on a Sunday, work
shall be suspended from noon December 31 until sunrise
January 3. If New Year’s Day falls on a Monday through
Saturday, work shall be suspended from noon December 31
until sunrise January 2.

(b) Good Friday. Work shall be suspended from noon on Good

Friday until sunrise Monday.

91
 108.08

350 (c) Memorial Day. Work shall be suspended from noon the Friday
before Memorial Day until sunrise Tuesday, the day after
Memorial Day.

(d) Independence Day. If Independence Day falls on a:

Sunday - Work shall be suspended from noon Friday,

July 2, until sunrise Tuesday, July 6.

Monday - Work shall be suspended from noon Friday,

360 July 1, until sunrise Tuesday, July 5.

Tuesday - Work shall be suspended from noon Friday,

June 30, until sunrise Wednesday, July 5.

Wednesday - Work shall be suspended from sunset on

Tuesday, July 3, until sunrise Thursday, July 5.

Thursday - Work shall be suspended from noon

Wednesday, July 3, until sunrise Monday, July 8.
370
Friday - Work shall be suspended from noon Thursday,
July 3, until sunrise Monday, July 7.

Saturday - Work shall be suspended from noon Thursday,

July 2, until sunrise Monday, July 6.

(e) Labor Day. Work shall be suspended from noon the Friday
before Labor Day until sunrise Tuesday, the day after Labor
Day.
380
(f) Thanksgiving Day. Work shall be suspended from noon the
Wednesday before Thanksgiving Day until sunrise the Monday
after Thanksgiving Day.

(g) Christmas Day. Work shall be suspended from noon December

24 until sunrise December 27.

The Department may order the suspension of work, either wholly or in part, for a
period of time for certain holidays not already specified herein. For such orders, if the
390 contract suspension is not stated in the contract documents, the contract completion
time will be adjusted as follows:

(a) If the contract completion time is on a work day basis, no work

days will be charged on those days that work on the controlling
operation is suspended.

92
 108.08

(b) If the contract completion time is on a calendar day basis, all

calendar days on which work on the controlling operation is
suspended will be excluded.
400
(c) If the contract completion time is a fixed calendar date, the
contract will be extended by the number of days that work on
the controlling operation is suspended.

(d) If the contract contains an intermediate completion time, said

time will be adjusted in accordance with the requirements of (a)
or (b), above as appropriate, provided that the suspension occurs
within the time period while the intermediate completion time
is in effect.
410
If the Department does not order the suspension of work for certain holidays, work
may be performed on those holidays. On a work day contract, a work day will be
charged for each holiday worked. On a completion date contract, the contract
completion time will not be shortened by the number of holidays worked.

Contract time will not be charged during the required cure period for concrete
surfaces requiring a sealer, provided all other contract work is completed and all lanes
are open to traffic. Charging of contract time will resume after the required cure period.
The contract time will be adjusted as follows:
420
(a) If the contract completion time is on a work day basis, work
days will not be charged for those days on which work is
suspended.

(b) If the contract completion time is on a calendar day basis, all

calendar days on which work is suspended will be excluded.

(c) If the contract completion time is a fixed calendar date, the

contract will not be extended.
430
If an extension of time on a calendar day contract or a calendar completion date
contract extends the completion date past November 30, the days remaining after
November 30 will be added to April 1, of the following year for the contract
completion date, providing the project could be suitably opened to traffic in
accordance with 107.18.

Completion of the removal of houses and buildings on time, if specified, shall be

in accordance with the requirements herein.

440 Not all of the parcels shown in the Schedule of Pay Items will be available for
demolition at the time of the letting. Houses and buildings shall be removed as soon

93
 108.08

as they are vacated in accordance with the procedure as follows:

(a) The 15 calendar days limitation after the date of notice to

proceed as specified in 108.03 will not apply.

(b) The contract time extension consideration for 30 days delay in

issuing the notice to proceed as specified in 108.08 will not
apply to a contract for which demolition is the majority of the
450 contract work.

(c) When parcels become available for demolition, the Engineer

will notify the Contractor of the availability of such parcels. The
Contractor shall commence work within five calendar days
from the date of receipt of such notification. Inspection and
testing for asbestos presence, or filing a notification of
demolition with the IDEM will be considered as part of the
work.

460 (d) If the Contractor fails to commence work within five calendar
days of the date of receipt of notification, $100.00 will be
assessed as liquidated damages, not as a penalty, but as damages
sustained for each calendar day after five on which work has not
commenced.

(e) Once work has commenced, in accordance with (c) and (d)
above, the work shall progress continuously and shall be
completed within 60 calendar days. If such work is not
completed within 60 calendar days, $100.00 will be assessed as
470 liquidated damages, not as a penalty, but as damages sustained
for each calendar day after 60 on which work is not completed.

(f) Each notification received by the Contractor shall establish a

separate five calendar day starting period and 60 calendar day
completion time, regardless of the number of parcels which are
shown in each notification.

(a) Excusable, Non-Compensable Delays

Excusable, non-compensable delays are delays that are not the fault or
480 responsibility of the Contractor or the Department. The following are excusable, non-
compensable delays:

1. Delays due to acts of the public enemy, civil disturbances,

acts of Government or political subdivision other than the
Department.

94
 108.08

2. Delays due to floods, lightning strikes, tornadoes,

earthquakes or other cataclysmic phenomena of nature.

490 3. Delays due to fires or epidemics.

4. Delays due to labor strikes that are beyond the Contractor’s

reasonable power to settle.

5. Extraordinary delays in material deliveries the Contractor

or its suppliers cannot foresee or avoid resulting from
freight embargoes, government acts or wide-area material
shortages. Delays due to the Contractor’s, subcontractor’s
or supplier’s insolvency or mismanagement are not
500 excusable.

6. Delays due to above normal inclement weather as defined

in 101.02.

7. Delays due to changes in quantities that are not significant

changes as defined in 104.02(c).

The Department will extend the contract time for completion but will not pay for
any costs associated with an excusable, non-compensable delay.
510
(b) Excusable, Compensable Delays
Excusable, compensable delays are delays that are not the fault or responsibility
of the Contractor and are the fault or responsibility of the Department. The following
are excusable, compensable delays:

1. Delays due to differing site conditions in accordance with

104.02(a), significant changes in the character of work in
accordance with 104.02(c), or extra work in accordance
with 104.03.
520
2. Delays due to suspension of work ordered by the Engineer
in accordance with 104.02(b).

3. Delays due to work that utilities or other third parties

perform within the project limits.

The Department will extend the contract time for completion and will pay for
delay costs covered under item 1 above in accordance with 104.03.

530 The Department will make payment for delay costs under items 2 and 3 above in
accordance with 109.05.2.

95
 108.09

(c) Non-Excusable Delays

Non-excusable delays are delays that are the fault or responsibility of the
Contractor. The Department will not extend the contract time or compensate the
Contractor for delay costs due to non-excusable delays.

(d) Concurrent Delays

Concurrent delays are separate delays to the controlling operation or critical path
540 that occur at the same time. When an excusable, non-compensable delay is concurrent
with an excusable, compensable delay, the Department will extend the contract time
but will not make payment for delay costs. When a non-excusable delay is concurrent
with an excusable delay, the Department will not extend the contract time and will not
make payment for delay costs.

108.09 Failure to Complete on Time

For each calendar day, as specified, that work shall remain incomplete during the
months of April through November inclusive, after the control time specified for the
completion of the work provided for in the contract, the sum specified in the schedule
550 below will be deducted, as liquidated damages, from any money due the Contractor.
Account will be taken of adjustment of the contract time for completion of the work
granted in accordance with 108.08. Calendar days will not be charged while waiting
for final inspection as defined in 105.15 provided all contract work has been
satisfactorily completed. However, five work days will be allowed after notification
from the Department to complete all corrective or clean up work necessary for final
inspection. Thereafter, time will be charged for each day the work remains
uncompleted. Further, 10 calendar days will be allowed after notification by the
Department to remove all construction signs and temporary traffic control devices.
Thereafter, time will be charged for each day the signs and devices remain.
560
For each calendar day, as specified, that any work shall remain incomplete during
the months of December through March inclusive, liquidated damages will be
deducted. However, when the project is open for its intended purpose or modified for
safe use, liquidated damages will not be deducted, and payment for the field office and
field laboratory, if set out as a pay item in the itemized proposal, will not be made.
Intended purpose will include all pavement lanes, sidewalks, trails, drainage features,
and all safety appurtenances. The Contractor may be required to make temporary
repairs to the pavement or structures. Liquidated damages will be assessed until
temporary repairs are made. No payment will be made for such temporary repairs.
570
If the contract is not completed, or the pavement or structure is not opened to
traffic within the stipulated time as set out in the Proposal book, the Department may
reduce the qualified rating of the Contractor for bidding on future contacts.

Allowing the Contractor to continue and finish the work or a part of it after the
time fixed for its completion, or after the date to which the time for completion may
have been extended, will in no way operate as a waiver on the part of the Department
of any of its rights under the contract.

96
 108.10

580 Schedule of Liquidated Damages for

Each Day of Overrun in Contract Time
Original Contract Amount Daily Charge
From Greater To Less Than Calendar Day
Than or Equal To or Fixed Date
$0 $500,000 $500.00
$500,000 $2,000,000 $1,000.00
$2,000,000 $5,000,000 $1,500.00
$5,000,000 $10,000,000 $2,000.00
$10,000,000 and higher $2,250.00

When the contract time is on either the calendar day or fixed calendar date basis,
the schedule for calendar days shall be used.

Adjustments to the contract payment with respect to liquidated damages will be

included in a liquidated damages pay item. The unit price for this pay item will be
$1.00 and the quantity will be in units of dollars. The quantity is the total calculated in
accordance with the above schedule.
590
108.10 Default and Termination of Contract
Notice in writing will be given to the Contractor and its surety of delay, neglect,
or default if the Contractor:

(a) fails to begin work under the contract within the time specified;

(b) fails to perform the work with sufficient workmen and

equipment or with sufficient materials to ensure the prompt
completion of said work;
600
(c) performs the work unsuitably, neglects or refuses to remove
materials or performs anew such work as may be rejected as
unacceptable and unsuitable;

(d) discontinues the prosecution of the work;

(e) fails to resume work which has been discontinued within a

reasonable time after notice to do so;

610 (f) becomes insolvent or is declared bankrupt, or commits an act of

bankruptcy or insolvency;

(g) allows final judgment to stand against it unsatisfied for a period

of 10 days;

(h) makes an assignment for the benefit of creditors;

97
 108.11

(i) for other causes whatsoever, fails to carry on the work in an

acceptable manner; or
620
(j) fails to implement the employee drug testing plan as submitted
with the bid; or fails to provide information regarding the
implementation of the employee drug testing plan when
requested by the Department; or provides false information
regarding implementation of the employee drug testing plan.

If the Contractor or surety does not proceed in accordance therewith within a

period of 10 days after such notice, then the Department will, upon written notification
from the Engineer of the fact of delay, neglect, default, or the failure of the Contractor
630 to comply with such notice, have full power and authority, without violating the
contract, to take the prosecution of the work away from the Contractor. The
Department may appropriate or use materials and equipment on the ground as may be
suitable and acceptable and may enter into an agreement for the completion of said
contract according to the terms and provisions thereof. Other methods required for the
completion of the contract in an acceptable manner may be used.

All costs and charges incurred by the Department, together with the cost of
completing the work under the contract, will be deducted from any monies due or
which may become due. If such expense exceeds the sum which would have been
640 payable under the contract, the Contractor and the surety shall be liable and shall pay
to the Department the amount of such excess.

108.11 Termination of Contractor’s Responsibility

The contract shall be considered as completed after all work provided for therein
has been accepted. The Contractor shall then be released from all further obligations
except as provided in 107.23 and 109.08.

The Department may, by written order, terminate the contract or a portion thereof
only after a meeting with the Contractor, and after determining that termination would
650 be in the public interest. Reasons for termination will include, but will not be limited
to, the following:

(a) executive orders of the President relating to prosecution of war

or national defense;

(b) national emergency which creates a serious shortage of

materials;

(c) budgetary concerns of the Department;

660
(d) errors in the plans or Proposal book which make the project
unbuildable;

98
 109.01

(e) orders from duly constituted authorities relating to energy

conservation;

(f) restraining orders or injunctions obtained by third-party citizen

action resulting from national or local environmental protection
laws, or where the issuance of such order or injunction is
670 primarily caused by acts or omissions of persons or agencies
other than the Contractor;

(g) when it is the finding of the Department that the Contractor is

unable to complete the contract and the construction covered
thereby within a reasonable length of time on account of
inability to obtain materials or satisfactory substitutes therefore
which do not change the general type of construction or labor.

In such cases, work performed, including partially completed items, will be paid
680 for in full at the contract unit prices for the actual quantities of work done, which prices
will not be subject to change if the quantity for a pay item or items is increased or
decreased more than 20%. Should such relief from performance of a portion of the
contract or such elimination of a portion of the contract directly cause the loss of work
or material already furnished under the terms of the contract, the actual cost of such
work or of salvaging such material will be reimbursed. All such material may, at the
option of the Department, be purchased at its actual cost. Anticipated profit on work
not performed will not be allowed. Final settlement will depend upon the merits of the
individual case. All actual damages will be paid following a meeting with the
Contractor to determine if payment of actual damages is appropriate and in accordance
690 with applicable laws.

108.12 Contract Documentation

The Contractor shall furnish upon request, all documentation relating to its
performing as a Contractor or subcontractor on a contract. The requested information
may be, but is not limited to the following: payroll records, material invoices,
subcontract agreements with pertinent attachments, lease agreements, and Equal
Employment Opportunity documentation.

SECTION 109 – MEASUREMENT AND PAYMENT

109.01 Measurement of Quantities

(a) General Requirements

All measurements of work completed under the contract will be according to the
English System unless otherwise specified.

The standard measures shown in this publication are primarily in the English

99
 109.01

10 System of Units such as feet and inches, pounds, gallons, and acres. Any metric
equivalents, shown in parentheses, are intended only for those contracts in which they
are specified, or to maintain consistency with industry standards. No guarantee is
provided, explicit or implicit, that the units are accurate conversions.

The method of measurement and computations to be used in determination of

quantities of material furnished and of work performed under the contract will be those
methods generally recognized as conforming to good engineering practice. Results are
to be determined using the standard “5” up procedures as defined in General Note 9
on Page vi herein. When the quantities to be measured are shown in English System
20 units, and the Contractor uses equipment or materials that were originally developed
to be used in performing work in the International System measure, there will be no
allowance if the International System dimensions exceed the English System
measurements. When the quantities to be measured are shown in International System
measure, and the Contractor uses equipment or materials that were originally
developed to be used in performing work in the English System units, there will be no
allowance if the International System dimensions exceed the English System
measurements.

Unless otherwise specified, longitudinal measurements for base, surface, and

30 shoulder area computations will be made along the centerline of the actual surface of
the roadway. No deduction will be made for individual fixtures having an area of 10 sq
ft or less. Unless otherwise specified, transverse measurements for area computations
will be the neat line dimensions shown on the plans or ordered in writing.

Structures will be measured according to neat lines shown on the plans or as

altered to fit field conditions.

When a complete structure or structural unit, in effect lump sum work, is specified
as the unit of measurement, the unit will be construed to include all necessary fittings
40 and accessories.

All work which is measured by the linear foot will be measured parallel to the
base or foundation upon which such work is placed, unless otherwise specified.

A station when used as a definition or term of measurement in the English System

will be 100 linear feet. A station when used as a definition or term of measurement in
the International System will be l km.

When metric dimensioned materials are specified, the Contractor shall convert to
50 metric all weigh tickets, delivery receipts, or other material documentation before
submitting the documentation.

The term gage, when used in connection with the measurement of metal plates or
sheets, will mean the U.S. Standard Gage except when the referenced AASHTO,

100
 109.01

ASTM, or other specification for a material specifies that it be ordered and measured
in terms of thickness.

When the term gage refers to the measurement of wire, it will mean the U.S. Steel
Wire Gage except when the reference AASHTO, ASTM, or other specification for the
60 wire specifies that it be ordered and measured in terms of wire size number or
diameter.

The term ton will mean the short ton consisting of 2,000 pounds avoirdupois. (The
term megagram will mean 1,000,000 g or 1,000 kg.) All materials which are measured
or proportioned by weight (mass) shall be weighed on accurate approved scales which
are in accordance with all requirements and specifications adopted by the Indiana State
Board of Health, Division of Weights and Measures. The weighing shall be
accomplished by competent qualified personnel at designated locations. Materials
specified according to metric unit weights may be weighed on a scale that uses English
70 system units and then converted to the metric equivalent using the conversion factors
shown elsewhere in the specifications.

(b) Scales and Measurement by Weight (Mass)

All materials for which measurements are obtained by weight (mass) shall be
weighed on approved scales which, except as hereinafter provided for out-of-state
scales, shall be tested and sealed by the Indiana State Board of Health, Division of
Weight and Measures. This inspection shall have been made within a period of not
more than one year prior to the date of use for weighing material. A scale which has
been tested and approved within this one year period and which has been repaired or
80 dismantled or moved to another location, shall again be tested and approved before it
is eligible for weighing. All interested parties, such as the Department, the Contractor,
or the owner of the scales, may request an inspection of the scales in question. The
latest inspection shall take precedence over all previous inspections. Automatic printer
systems may be used with HMA plant scale systems under certain conditions in
accordance with 409.02(a). If automatic printer systems are used, the same inspection,
testing, and sealing requirement specified herein for scales shall apply to HMA plant
batch scales and printer systems.

A motor-truck scale shall have a suitable undercarriage of such construction that

90 shall safely carry and weigh an amount equal to 80% of the rated capacity of the scale
on either end of the scale platform. When so loaded, the stresses in the lever system
shall not exceed the stresses allowable under AREA specifications. The load carried
per 1 in. of knife-edged bearing shall not exceed 5,000 lb.

The scale platform shall be of such length and width as to conveniently

accommodate all trucks containing materials which need to be weighed. The entire
truck load shall rest on the scale platform and shall be weighed as one draft.

If material is weighed on truck scales, weigh tickets showing the net weight of
100 each load of material delivered shall be supplied for use in computing quantities. The

101
 109.01

tickets shall be prepared at the weighing site under the supervision of the State
weighman, and shall contain the ticket serial number, date, contract number, source of
supply, material designation such as size or type, DMF or JMF number for HMA,
truck number, time weighed, gross weight direct reading if scale is of the direct reading
type, tare, net weight, and moisture content if applicable. Two spaces shall be provided
on each ticket for signatures of representatives of the Engineer. One space shall be
designated for the state weighman and the second space for the technician or inspector.
A duplicate ticket may be furnished by the Contractor for its records. The original, and
duplicate if furnished, tickets will be signed at the weighing site and at the point of
110 incorporation into the work. No additional payment will be made for furnishing,
maintaining, and operating scales.

The weight of materials weighed outside the State and intended for use on the
contact may be determined on scales tested and approved by the proper governmental
unit having authority where the scales are located. In such case, the Department shall
be furnished with a certified copy of such inspection and approval which, to be
acceptable, shall have been made within one year to the time of such weighing. Out-
of-state truck scales used shall be in accordance with all pertinent provisions as they
apply to truck scales accepted within the State of Indiana. They shall be subject to
120 approval and inspection by the Department and to the requirements applicable to such
scales located within the State.

If materials are shipped by rail, the car weight may be accepted provided payment
is made for only the actual weight of the materials. Car weights will not be acceptable
for material to be passed through mixing plants. Trucks used to haul material being
paid for by weight shall be weighed empty daily at such times as directed. Each truck
shall bear a plainly legible identification mark.

(c) Measurement by Volume

130 Materials to be measured by volume in the hauling vehicle shall be hauled in
approved vehicles and measured therein at the point of delivery. Vehicles for this
purpose may be of the size or acceptable type provided the body is of such shape that
the actual contents may be determined readily and accurately. All vehicles shall be
loaded to at least their water level capacity. All loads shall be leveled when directed,
after the vehicles arrive at the point of delivery.

When requested and approved in writing, material specified to be measured by

the cubic yard may be weighed. Such weights will be converted to cubic yards for
payment purposes. Factors for conversion from weight measurement to volume
140 measurement will be determined and shall be agreed to by the Contractor before such
method of measurement of pay quantities is used.

In computing volumes of excavation, the average end area method or other

acceptable methods will be used.

If excavation is measured by cross sections, the following will apply:

102
 109.01

1. Unless otherwise provided, where sodded areas are

involved, the cross sections will be considered as located
150 at the surface of the sod.

2. If the cost of excavation is specifically included in the

payment for a pay item of work, the final sections will be
taken at the finished surface of the work.

3. If the cost of excavation is not specifically included in the

payment for a pay item of work, the final sections will be
taken at the limits of the authorized excavation.

160 Unauthorized wastage of material will be deducted. Only such quantities as are
actually incorporated into the completed work will be included in the final estimate.

(d) Measurement of Asphalt Materials

If an asphalt material is to be paid for directly, it will, except as hereinafter
provided, be weighed and paid for by the ton. If the Engineer decides that weighing is
not feasible, the asphalt material may be measured by volume and converted to tons.
The conversion will be based on the unit weight as determined in the laboratory.

If asphalt material is to be measured by volume, it will be measured by the gallon

170 in tank cars, distributor tanks, tanks, or drums. Certified calibration of tank cars,
distributor tanks, tanks, and certified quantities in drums in which asphalt materials
are delivered or stored shall be furnished.

If asphalt material is furnished in drums, the amount in each drum shall be

stenciled plainly on the drumhead by the producer. The amount so indicated will be
accepted as the quantity furnished. However, the amount in each drum may be checked
in accordance with the requirements set out herein.

Tank car deliveries will be measured by volume and converted to tons.

180
Volumes will be measured at 60°F or will be corrected to the volume at 60°F in
accordance with ASTM D 1250 for asphalts or ASTM D 633 for tars.

Net certified scale weights or weights based on certified volumes in the case of
rail shipments will be used as a basis of measurement, subject to correction when
asphalt material has been lost from the car or the distributor, is wasted, or is otherwise
not incorporated into the work.

(e) Measurement of PCC

190 For design and production, PCC will be measured by the cubic yard. The relative
yield will be determined in accordance with 505.01. Payment for PCC will be in the
unit designated for the specified use.

103
 109.01

(f) Measurement of Aggregates

Unless otherwise provided, all aggregates for which measurements are obtained
by the cubic yard will be measured at the truck loading point in truck beds that have
been measured, stenciled, and approved. They may be weighed and converted to cubic
yards by a conversion factor computed at sufficient intervals to ensure correct
measurement.
200
Free water in all aggregates for which payment is made as a separate pay item on
a weight basis shall be drained prior to weighing and selection of samples. Samples
for determination of moisture content shall be taken immediately prior to the time the
material is to be weighed. The number of moisture tests will be governed by moisture
conditions. Moisture contents shall be determined on the basis of oven dry weight by
drying samples to constant weight at 230°F, ±9°F. However, if ovens are not available
for drying samples, other methods which give equivalent results may be used.
Moisture content shall be computed to the nearest 0.5% in accordance with the formula
as follows:
210
Wet weight of sample-Dry weight of sample
Percent of Moisture (M) = x 100
Dry weight of sample

The percent of moisture shall be noted on each weight ticket.

The wet weight will be used for the basis of payment, if the % of moisture is
determined to be less than 6% for B borrow; 9% of optimum moisture content, as
determined in accordance with AASHTO T 99, whichever is greater, for size No. 53
or No. 73 aggregates or modifications thereof when specified; or 4% for aggregates of
all other specified sizes including sand.
220
If the percent of moisture exceeds the limitations set out above, the weight to be
paid for will be the gross weight of aggregate minus the weight of the excess moisture
computed as follows:

(100 + m)
Weight to be paid for = G x
(100 + M)

in which:

G = Gross weight of material,

230
M = Percent of moisture in the aggregate to the nearest
0.5% based on oven dry weight,

m = Percent of moisture allowed in the wet aggregate to

be paid for based on oven dry weight.

104
 109.02

(g) Measurement of Timber or Lumber

Timber or lumber will be measured by the thousand feet board measure or MFBM
actually incorporated into the work. Measurement will be based on nominal widths
240 and thicknesses and the extreme length of each piece.

(h) Rental of Equipment

Rental of equipment will be measured in hours of actual working time and
necessary traveling time of the equipment within the project limits. If special
equipment has been ordered in connection with force account work, travel time and
transportation costs to the project site will be recorded. If equipment has been ordered
and held on the project site on a standby basis, full time rates for such equipment will
be paid.

250 (i) Manufactured Materials

If standard manufactured materials are specified such as fence, wire, plates, rolled
shapes, pipe, or conduit, and such materials are identified by gage, unit weight, or
section dimensions, such identification will be considered to be nominal weights or
dimensions. Unless more stringently controlled by tolerances in cited specifications,
manufacturing tolerances established by the industries involved will be accepted.
Nearly equivalent metric dimensioned manufactured items will be accepted in lieu of
English dimensioned items, provided they are within the specified tolerances, when
English sizes are specified. Nearly equivalent English dimensioned manufactured
items will be accepted in lieu of metric dimensioned items, provided they are within
260 the specified tolerances, when metric sizes are specified.

109.02 Scope of Payment

Compensation provided for in the contract shall be received and accepted as full
payment for furnishing all materials and for performing all work specified in the
contract in a complete and acceptable manner. This shall also be payment in full for
all risk, loss, damage, or expense of whatever character arising out of the nature of the
work or the prosecution thereof, in accordance with 107.23.

If the basis of payment clause in the specifications relating to a unit price in the
270 Schedule of Pay Items requires that said unit price cover and be considered
compensation for certain work or material essential to the pay item, this same work or
material will not also be measured or paid for under another pay item which may
appear elsewhere in the specifications.

The term lump sum when used as a unit of payment will mean complete payment
for the pay items of work described in the contract.

The payment of a current estimate before final acceptance of the work shall not
affect the obligation of the Contractor to repair or renew any defective parts of the
280 construction. The responsibility for all damages due to such defects will be determined
in accordance with 107.19.

105
 109.03

If it is agreed in writing that the quantities of certain items or portions of items of

work, as set forth in the contract, are in substantial agreement with actual quantities of
work performed, compensation therefore will be based on the quantities set forth in
the contract without measurement thereof upon completion of the work. Compensation
based on contract quantities as agreed shall be accepted as full payment for such items
or portions of items.

290 If the Contractor has previously agreed in writing to accept photogrammetric

methods of measurement for common excavation and borrow, the Department may
utilize such methods of measurement as the basis of payment. Computation of volumes
shall be in accordance with 203.

109.03 Compensation for Altered Quantities

If the accepted quantities of work vary from the quantities shown in the Schedule
of Pay Items, the Contractor shall accept as payment in full, so far as contract items
are concerned, payment at the original contract unit prices for the accepted quantities
of work done. No allowance, except as provided in 104.02, will be made for increased
300 expense, loss of expected reimbursement, or loss of anticipated profits suffered or
claimed by the Contractor resulting either directly from such alterations or indirectly
from unbalanced allocation among the contract items of overhead expense on the part
of the bidder and subsequent loss of expected reimbursement therefore, or from any
other cause.

If an increase or decrease in a contract item is in accordance with 104.02, the

contract unit price will be the rate of payment unless an adjusted price is agreed to by
the parties to the contract. The contract unit price for a minor item may be adjusted if
agreed to by parties for only that portion of the item which exceeds 6% of the total bid
310 amount of the contract. A loss or gain of overhead costs will not be a consideration for
adjusting the unit prices.

If such alteration directly causes the loss of any work or materials already
furnished under the terms of the original contract, the actual cost of such work or of
salvaging such materials will be reimbursed. All such materials may, at the option of
the Department, be purchased at the actual cost including freight to the Contractor,
plus 12%.

109.04 Cost Reduction Incentive, CRI

320 The Contractor may submit a written proposal for modifying the Contract
Documents for the purpose of reducing construction costs or contract time. The
proposal shall produce a savings without impairing essential functions, characteristics,
and timing of the project including, but not limited to, safety, service life, economy of
operations, the traveling public, ease of maintenance, desired appearance, design
standards and construction schedules.

106
 109.04

(a) CRI Initial Requirements

The Contractor shall initially submit five copies of a brief proposal to the
Department to illustrate the concept or idea. At a minimum, the Contractor shall
330 submit the following:

1. A statement that the proposal is submitted as a conceptual

CRI.

2. A brief proposal with graphics, if appropriate, to illustrate

and describe the concept.

3. A brief description of the existing work and the proposed

changes for performing the work including a discussion of
340 the comparative advantages and disadvantages for each
and how the proposal meets the original intent of the
design.

4. An approximate cost estimate for performing the work

under the existing contract and under the proposed change.

5. An approximate cost estimate of design and engineering

fees associated with the proposed change.

350 6. A description of any effects the proposed change would

have on Department costs other than those in the contract
such as future construction, design, right-of-way, utilities,
maintenance, and operations costs.

7. The amount of time that will be needed to develop a formal

CRI proposal.

8. A statement of the date by which the Department must

execute an agreement adopting the proposal to obtain the
360 maximum cost reduction during the remainder of the
contract time, the date the work must begin in order to not
delay the contract, and the reasoning for this time schedule.

9. An approximate estimate of the effect the proposal will

have on the time for completion of the contract, including
development of the formal proposal, review by the
Department and implementation.

10. The name of the redesign professional engineer, if any.

370
11. Reference to the applicable Indiana Design Manual
provisions.

107
 109.04

12. A statement regarding impacted permit requirements.

13. Identification of any material not in the current contract

that the contractor proposes to use and corresponding
applicable specifications.

380 The Department will notify the Contractor in writing within five business days
after receipt of the proposal that the proposal has been rejected, accepted, or that a
meeting needs to be arranged to discuss the proposed conceptual CRI. If the
Department fails to respond within five business days, the proposal will be deemed
rejected. If a meeting is requested, the Contractor shall arrange a meeting involving
any professional engineer that will be used in development of the proposal; the
engineer who designed the original plans or review engineer designated by the
Department; contractor personnel; and Department personnel as determined by the
Engineer. This meeting shall be held within 10 business days of receipt of the written
notification, unless the Engineer approves additional time. At least two business days
390 prior to the meeting, the Contractor shall provide a copy of its conceptual CRI to all
persons invited to the meeting. Within 10 business days or a mutually agreed upon
time after this meeting, the Department will notify the Contractor in writing as to
whether a complete CRI may be developed.

(b) CRI Formal Proposal Requirements

If a concept is accepted by the Department, a formal proposal shall be submitted
with a statement identifying the proposal as a CRI and shall contain, at a minimum,
information as follows:

400 1. A description of the difference between the planned work

and the proposed change with a comparison of effects on
safety, service life, economy of operations, the traveling
public, ease of maintenance, desired appearance, design
standards, and construction schedules.

2. Proposed changes in the contract documents. Documents

showing design changes shall be signed and bear the seal
of a Professional Engineer. Design changes shall be
supported by design computations as necessary for a
410 thorough and expeditious evaluation.

3. The pay items, unit prices, and quantities affected by the

change.

4. Complete, detailed cost estimates for performance of the

work both as planned and as proposed.

108
 109.04

5. The calendar date required for approval of the proposal in

order to produce the savings indicated.
420
6. Locations and situations, including test results, in which
similar measures have been successfully used.

7. A statement regarding the effect the proposal will have on

the contract completion time.

8. A signed contract between the Contractor and the

Contractor’s redesign engineer, who prepared and sealed
the plans for the CRI proposal, shall be submitted to the
430 Department. The contract shall provide for the following:

a. The Contractor’s redesign engineer shall be

responsible for the professional quality, technical
accuracy, and the coordination of all designs,
drawings, specifications, load rating analysis, and
other services furnished by the redesign engineer
under this contract. The redesign engineer shall
correct or revise any errors or omissions in its
designs, drawings, specifications, and other
440 services. The Contractor’s redesign engineer shall
indemnify, defend, and hold harmless the State and
its agents, officials, and employees, from all claims
and suits including court costs, attorney’s fees, and
other expenses caused by any acts, errors, or
omissions of the Contractor’s redesign engineer,
its agents, or employees, in connection with the
CRI proposal.

b. Neither the Department’s review, approval, nor

450 acceptance of the plans for the CRI shall be
construed to operate as a waiver of rights under the
contract or cause of action arising out of the
contract. The Contractor’s redesign engineer shall
be and shall remain liable to the Department for all
damages caused by the Contractor’s redesign
engineer.

c. The rights and remedies of the Department

provided in the contract are in addition to all other
460 rights and remedies provided by law.

109
 109.04

d. No terms between the Contractor and the redesign

engineer shall adversely affect the Department’s
liability protection.

9. The Contractor’s engineering costs to develop the proposal

shall be submitted with full documentation.

Additional information shall be provided as required to properly evaluate the

470 proposed change. Failure to do so may result in rejection of the cost reduction incentive
proposal.

(c) Approval of Formal CRI Proposal

The Engineer will be the sole judge as to whether a formal CRI proposal qualifies
for consideration, evaluation, and approval. A proposal which requires excessive time
or cost for review, evaluation, or investigation, or which is not consistent with
Department design policies, may be rejected. A proposal may also be rejected if not
submitted within the time frame specified in the Contractor’s conceptual proposal,
unless the Engineer approves additional time. Proposed changes in pavement design
480 including materials or pavement type, changes in materials required to be installed by
a certified installer, or changes in right-of-way will not be approved. A proposal which
uses empirical design (AASHTO LRFD Bridge Design Specifications, Section 9.7.2)
of the concrete bridge deck will not be considered or approved. Only proposals which
result in the Department’s portion of the estimated net savings being $10,000.00 or
more will be considered. Except as provided in 109.04(d), the Department will not be
liable for failure to accept or act upon a proposal submitted in accordance with the
requirements herein or for delays to the work attributable to such proposal, unless an
extension of time is provided as part of the agreed CRI proposal.

490 Original contract bid prices shall not be based on the anticipated approval of a
CRI proposal. If the proposal is rejected, the contract shall be completed at the original
contract prices. If a CRI proposal is not approved on or before the calendar date
submitted by the Contractor in the CRI shown on the proposal, such proposal will be
deemed rejected. In determining the estimated net savings, the contract prices bid may
be disregarded if it is determined that such prices do not represent a fair measure of
the value of the work to be performed or deleted.

The CRI proposal will not be approved if equivalent options are already available
within the contract, or if the Department is already considering a change order to the
500 contract which includes the proposal revisions.

When a CRI proposal is received which changes superstructure type,

superstructure dimensions, or superstructure dead load, the Engineer will perform a
load rating analysis on the proposed structure. The load rating analysis must yield an
inventory rating of 1.0 or greater for the design live load in order to be considered for
approval. If the inventory rating is less than 1.0, the proposed design shall be modified

110
 109.04

so that the load rating analysis yields an inventory rating of 1.0 or greater for the design
live load before the CRI proposal is considered for approval.

510 If the CRI proposal is approved, it will be executed by means of a change order.
The change order will show the changes in the plans and specifications necessary to
enable the proposal to be put into effect and the net estimated savings will be set forth
on the change order.

Upon approval, the Department will have the right to use, duplicate, and disclose
in whole or in part, all data necessary for the subsequent adoption of the proposal for
future projects.

The provisions of this specification will apply only to a contract awarded to the
520 lowest bidder in accordance with the Department’s competitive bidding requirements.

(d) Payment for Design of Formal Proposal, if Rejected

Except as provided elsewhere herein, if the Department rejects the formal CRI
proposal, the Contractor will be reimbursed for 50% of the Contractor’s reasonable
design costs incurred after the Department’s acceptance of the CRI conceptual
proposal.

The Contractor will also be reimbursed for 50% of the Contractor’s reasonable
design costs of an approved CRI proposal if the Department determines that the
530 proposal is no longer feasible because of changes in field conditions or other
conditions beyond the control of the Contractor. If written approval was given to
proceed with the work, procure materials, begin fabrication, and rejection occurs, the
work and fabrication costs will be reimbursed in accordance with 109.05. The
Contractor will be compensated for materials ordered which are unique to the project
based on the Contractor’s cost minus salvage value if the Contractor is unable to return
these items to the vendor. All such material may, at the option of the Department, be
purchased at its actual cost. There will be no reimbursement for costs incurred prior to
the acceptance of the conceptual CRI proposal. The Contractor will not be reimbursed
for design costs if a formal CRI proposal is rejected because it was not submitted
540 within the time frame specified in the Contractor’s conceptual proposal or additional
time approved by the Engineer, if the Contractor fails to submit additional information
requested by the Department, or if the design criteria used in the proposal does not
comply with the Department’s design standards.

(e) Other Conditions

The Contractor shall continue to perform the work in accordance with the contract
requirements until a change order incorporating the CRI proposal has been approved.
However, no contract work that will be affected by a CRI proposal shall be performed
until the CRI proposal has been approved or rejected.
550
Prior to approval, the Engineer may modify a proposal with the concurrence of
the Contractor, to enhance it or make it acceptable. If any modification increases or

111
 109.04

decreases the net savings resulting from the proposal, the Contractor’s 50% share will
be determined upon the basis of the proposal as modified.

The Department reserves the right to include in the change order the conditions it
deems appropriate for consideration, approval and implementation of the CRI
proposal. Acceptance of the change order by the Contractor shall constitute acceptance
of such conditions. As a condition for considering a Contractor’s CRI proposal, the
560 Department also reserves the right to require the Contractor to share in the
Department’s costs of investigating the proposal. If this condition is imposed, the
Contractor shall indicate acceptance in writing. Such acceptance shall constitute full
authority for the Department to deduct amounts for the investigation from moneys due
the Contractor under the contract.

The Engineer may reject, in accordance with 105.03 and 105.11, all or any portion
of work performed under an approved CRI proposal.

(f) Time Savings Proposals

570 The Contractor may submit a CRI proposal that reduces contract time by changing
phasing of the work, the traffic control plan, or design elements.

The Department will consider proposals that result in time savings and at the same
time may increase the cost of the project. The Department will be the sole judge as to
whether the benefits of completing the project or a project phase before the scheduled
completion date or milestone offsets an increase to the cost of the project.

The submittals for time savings will be reviewed using the CRI proposal process.
The Contractor shall provide the Department sufficient information to enable the
580 Department to evaluate the cost benefit of the savings.

(g) Adjustments to Contract Time

For approved formal CRI proposals the Department will adjust the applicable
contract time as set out in the proposal. Any adjustment will be set forth in the change
order for the CRI proposal. Depending on the Contractor’s proposal, the adjustment
will be an increase or decrease in the appropriate completion date.

(h) Method of Measurement

The work, as revised by the formal CRI proposal, will be measured as complete
590 and in place and in accordance with the change order.

(i) Basis of Payment

The work, as revised by the formal CRI proposal, will be paid for as complete and
in place and in accordance with the change order. In addition, the Contractor’s
Reasonable Design Cost and 50% of the total net savings of the CRI proposal will be
paid for separately as follows:

112
 109.04

1. The Contractor’s Reasonable Design Cost for the CRI

proposal will be paid for after approving the formal CRI
600 proposal with the change order.

2. Upon completion of all items of work included in the

change order, the total net savings will be calculated and
the Contractor will be paid 50% of the total net savings.

The total net savings resulting from the CRI will be

calculated as follows:

TNS = OCW – RCW – CRDC – DC

610 where:

TNS = total net savings

OCW = original cost of the work required by the original contract
RCW = revised cost of the work
CRDC = Contractor’s reasonable design cost for the CRI proposal
DC = Department’s cost for investigating, evaluating, and
implementing the CRI proposal.

3. A cost savings of not less than $5,000.00 shall be

guaranteed to the Department.

The actual formal CRI proposal net savings will be checked upon completion of
the contract and determination of final quantities to determine if any payment
adjustment is required.

620 Only those work items directly affected by the plan change will be considered in
making the determination of net cost savings. Subsequent plan changes affecting the
modified work items but not related to the CRI proposal will be excluded from such
determination. Upon completion of all work included in the CRI proposal, the final
total net savings will be determined by comparing the cost of the work based on the
original contract quantities with the cost of the actual CRI proposal work performed.
In determining the savings, the Department reserves the right to consider other factors
in addition to the contract bid prices and proposed unit prices if, in the judgment of the
Department, such prices do not represent a fair measure of the value of the work to be
deleted from or added to the contract.
630
The net savings of a CRI proposal to reduce contract time will be determined by
multiplying the number of days saved by the daily liquidated damages as set forth in
Section 108.08 or as otherwise provided in the contract.

Redesign engineering, in accordance with this section, is defined as 50% of the

contractor’s reasonable design costs incurred after the Department’s acceptance of the

113
 109.05

CRI proposal. Redesign Engineering will be paid when a conceptual CRI has been
accepted by the Department but the final proposal is rejected.

640 Payment will be made under:

Pay Item Pay Unit Symbol

Contractor’s Reasonable Design Cost

for CRI Proposal No. ____ ................................................. LS
Cost Reduction Incentive Proposal No. ____ ............................ LS
Redesign Engineering, CRI Proposal No. ____ ........................ LS

109.05 Payment for Extra Work

650 A Change Order Request form, available on the Department's website, shall be
submitted for review for all extra work prior to the Engineer drafting a change order.
The form shall describe any unique circumstances and shall include unit prices or lump
sum prices utilizing standard Department pay items.

Extra work performed in accordance with 104.03 will be paid for by one of the
following methods:

(a) Agreed Price

Extra work will be paid for at agreed upon unit prices or lump sum prices as
660 documented on approved change orders. The Department will perform a cost analysis
of the Contractor's unit price or lump sum price indicated on the Change Order Request
form.

Based on the results of the cost analysis, the Engineer may direct the Change
Order Request form to be amended to incorporate additional information, including:

1. A detailed explanation of unique circumstances of the

extra work.

670 2. The effect of the circumstances on the requested price.

3. A breakdown of the estimated costs for the categories

of labor, equipment, and materials in sufficient detail
to enable the Engineer to determine the basis and
amount of the requested price.

(b) Force Account

The Department may require the Contractor to perform extra work on a force
account basis when a price cannot be agreed upon in accordance with 109.05(a). The
680 Contractor shall, when directed, submit a written proposal for the extra work prior to
the start of the work. When directed, the proposal shall include the planned labor,
materials, equipment, and schedule for the work. Extra work performed by force

114
 109.05

account will be documented on an approved change order and will be compensated in

the following manner:

1. Labor Costs
For all labor and foremen in direct charge of the specific operations, the
Contractor will receive the rate of wage, or scale, agreed upon in writing before
beginning work for each hour that said labor and foremen are actually engaged in such
690 work.

The Contractor will receive the actual costs paid to, or in behalf of, workmen by
reasons of subsistence and travel allowances, worker’s compensation insurance
premiums, unemployment insurance contributions, social security taxes, health and
welfare benefits, pension fund benefits, or other benefits when such amounts are
required by collective bargaining agreement or other employment contract generally
applicable to the classes of labor employed on the work. The Contractor shall furnish
satisfactory evidence of the rate or rates paid for insurance premiums and tax.

700 An amount equal to 20% of the sum of the above items will also be paid to the
Contractor.

2. Bond and Insurance

For bond premium and property damage and liability insurance premiums, the
Contractor will receive the actual cost, to which cost 10% will be added. The
Contractor shall furnish satisfactory evidence of the rate or rates paid for such bond
premium and insurance premiums.

3. Materials
710 For materials accepted and used, the Contractor will receive the actual cost of
such materials delivered on the work, including transportation charges paid by the
Contractor, exclusive of machinery rentals as hereinafter set forth, to which cost 12%
will be added.

4. Equipment
For Contractor owned machinery or special equipment other than small tools as
defined herein, the rates shall be not more than those listed in the current Rental Rate
Blue Book as published by EquipmentWatch®. The rate used shall be the FHWA
hourly rate which is the ownership cost rate plus the operating cost rate. Regardless of
720 the time used, the ownership cost rate shall be the hourly rate obtained by dividing the
monthly Blue Book rate by 176 with appropriate adjustments made for region and age.
Actual transportation costs may be added to the FHWA rate. Small tools will be
defined as tools costing less than $500 each, or an aggregate total of $1,000 or less.

For machinery or special equipment not owned by the Contractor, the rate shall
be as shown on invoices. Actual fuel, lubricant and transportation costs may be added
to the rental cost. The Engineer may designate the use of the fuel percentage of the
Rental Rate Blue Book operating cost rate in lieu of actual fuel and lubricant costs. No
payment will be made for repairs to rented equipment.
115
 109.05

730
For equipment that is operational, on-site, and necessary for force account work,
but is idle due to conditions beyond the control of the Contractor, a standby rate will
apply. The standby rate will also apply during the period of transportation and on-site
assembly and disassembly of the equipment for transportation purposes. The standby
rate will be the published ownership cost rate reduced by 50%. Standby time will not
be paid for in excess of 8 hours per day minus the number of hours paid for at the
FHWA rate per day; or 40 hours per week minus the number of hours paid for at the
FHWA rate per week. If rented equipment necessary for force account work is idle,
the Department will pay the Contractor for the actual invoice rates for the duration of
740 the idle period.

The Contractor shall provide a list of all information needed to verify the Blue
Book rental rate for each piece of equipment. The information shall include the
equipment type, manufacturer name, model number, year, any attachments used, and
any other information necessary to determine the proper rate.

The Contractor will receive payment for the total costs agreed upon to which sum
12% will be added.

750 5. Miscellaneous
No additional allowance will be made for general superintendence or other costs
for which no specific allowance is herein provided.

6. Subcontracting
For administration costs in connection with approved subcontract work, the
Contractor shall receive an amount equal to 7% of the total cost of such work computed
as set forth above.

7. Compensation
760 The Contractor and the Engineer shall compare records of the cost of work done
as ordered on a force account basis at the end of each day. These records shall be made
in duplicate and signed by both. Each shall retain one copy.

8. Statements
No payment will be made for work performed on a force account basis until the
Contractor has furnished triplicate itemized statements of the cost of such force
account work detailed as follows:

a. name, classification, date, daily hours, total hours,

770 rate, and extension for each laborer and foreman;

b. designation, dates, daily hours, total hours, rental rate,

and extension for each unit of machinery and
equipment;

116
 109.05.1

c. quantities of materials, prices, and extensions;

d. transportation of materials;

780 e. cost of property damage, liability and worker’s

compensation insurance premiums, unemployment
insurance contributions, and social security tax.

Statements shall be accompanied and supported by receipted invoices for all

materials used and for transportation charges. However, if materials used on the force
account work are not specifically purchased for such work but are taken from the
Contractor’s stock, then in lieu of the invoices the Contractor shall furnish an affidavit
certifying that such materials were taken from its stock, that the quantity claimed was
actually used, and that the price and transportation claimed represent the actual cost to
790 the Contractor.

If the Contractor fails or refuses to prosecute extra or force account work as

directed, the Department may withhold payment of all current estimates until the
Contractor’s failure or refusal is eliminated.

109.05.1 Quality Adjustments

Quality adjustments are those adjustments in the payment for work done or
materials furnished and incorporated into the work which either exceed or fall below
the standards established by the contract.
800
A change order will be prepared to reflect these adjustments. The unit price for
these adjustments will be $1.00 and the quantities will be in units of dollars.

Payment will be made under:

Pay Item Pay Unit Symbol

Quality Adjustments, _____ ...................................................... DOL

type
810
The dollars shown shall be the amount of the quality adjustments for the following
types and may consist of plus or minus adjustments.

(a) HMA
Quality adjustments with respect to mixture, density, and smoothness for mixture
produced will be computed in accordance with 401.19.

(b) PCCP
Quality adjustments will be calculated in accordance with 501.28.
820
(c) Temporary Traffic Control Devices, TTCD
Quality adjustments with respect to non-compliance with the ATSSA brochure
117
 109.05.2

titled Quality Standards for Work Zone Traffic Control Devices will be assessed when
the device is deemed to be in non-compliance in accordance with 801.03. Adjustments
will be determined in accordance with 105.14.

Adjustments for non-compliance of construction warning lights will be

determined in accordance with 801.14.

830 (d) Failed Materials, FM

Quality adjustments for materials which are deemed below the standards
established, but which are allowed to remain in place by the Department’s Failed
Materials Committee in accordance with 105.03, will be as determined by that
committee.

(e) Pavement Traffic Markings, PTM

Quality adjustments will be calculated in accordance with 808.07.

(f) Stormwater Management

840 Quality adjustments will be calculated in accordance with 205.08.

109.05.2 Delay Costs

When the Engineer determines that an excusable, compensable delay has occurred
as defined in 108.08(b), the Department will pay for the costs incurred by the
Contractor as a result of the delay. The Department will not pay for unrecoverable
costs as defined in 104.02(d) and will not make duplicate payment for compensation
made in accordance with 109.05.

The Department will not make payment for delays that occur during the period
850 from December 1 through March 31 unless the Contractor’s current accepted progress
schedule, as required by 108.04, indicates work on the controlling operation or critical
path during this period.

The Contractor shall provide satisfactory documentation to support payment for

delay costs. The Department will not make any payment for delay costs until the
documentation is submitted.

Payments made under this specification shall constitute full compensation for all
delay costs and associated costs, including overhead.
860
(a) Allowable Delay Costs

1. Labor
Payment will be made for all necessary salaried and non-salaried personnel that
must remain on the project, as approved by the Engineer, during the delay period and
cannot be assigned to unaffected work. Necessary personnel will include field
superintendents, assistants, watchmen, clerical and other field support staff, and those
persons required for maintenance within the project limits, including maintenance of

118
 109.05.2

traffic control devices, maintenance of erosion and sediment control measures and
870 similar activities as approved by the Engineer. Payment for labor costs will be
calculated in accordance with 109.05(b)1.

2. Insurance
Payment will be made for the increased cost of insurance resulting directly from
the delay and will be calculated in accordance with 109.05(b)2.

3. Equipment
Payment will be made for idle equipment that must remain on the project, as
approved by the Engineer, during the delay period and cannot be used for active work.
880 Payment for idle equipment will be calculated in accordance with 109.05(b)4.

If the Engineer determines that idle equipment should not remain on the project,
the Department will pay for the cost to demobilize the equipment during the delay and
remobilize it at the end of the delay.

4. Field Office Costs

Payment will be made for the cost to maintain a Contractor’s field office, if
determined necessary by the Engineer, during the delay period.

890 Field office costs include, but are not limited to, the Contractor’s field office
facilities, tool trailers, office equipment rental, temporary toilets, incidental supplies,
and utility expenses. Payment will be made only for the actual costs incurred during
the delay period as documented on paid invoices.

5. Escalation Costs
Payment for escalation costs due to an excusable, compensable delay will be
limited to the escalated cost of labor, materials, and equipment on that portion of the
work which is delayed beyond an original intermediate completion date or the contract
completion date and is caused to be performed during a period when the costs were
900 higher than when the work was planned to be performed as shown on the accepted
schedule prior to the delay. The Contractor shall submit satisfactory documentation of
escalation costs in a format approved by the Department.

a. Labor Escalation
Payment for escalated labor costs will be calculated as the difference in labor cost
between the time the work was performed and the time the work was planned. Labor
costs will be calculated in accordance with 109.05(b)1 except that no markup will be
paid for labor escalation.

910 b. Materials Escalation or Storage

Payment for escalated material costs will be calculated as the difference in the
material cost between the time the work was performed and the time the work was
planned. No material escalation cost will be paid for any item covered by a separate
escalation or indexing clause under the contract.

119
 109.05.3

The Department will pay for storage of materials, as approved by the Engineer,
due to the delay. Only the actual cost of storing the materials will be paid. No markup
will be paid for materials storage.

920 c. Equipment Escalation

Payment for equipment escalation costs will be calculated as the difference
between the Rental Rate Blue Book FHWA hourly rate at the time the work was
performed and the Rental Rate Blue Book FHWA hourly rate at the time the work was
planned. No markup will be paid for equipment escalation costs.

(b) Blank

109.05.3 PG Asphalt Binder Material Cost Adjustments

The Contractor shall elect at the time the bid proposal is submitted, in a manner
930 determined by the Department, whether or not to enact PG asphalt binder material cost
adjustments. If the Contractor elects not to enact such adjustments, there will be no
adjusted payment made to the Contractor for changes in the cost of PG asphalt binder
materials used on the project and the provisions of this specification will not be applied
to the contract. PG asphalt binder material cost adjustments will not be added to the
contract at any time after the Contractor has elected not to enact such adjustments with
submittal of the bid proposal. PG asphalt binder material cost adjustments will not be
applied to alternate bid pavement items, but may be applied to the common items on
contracts containing alternate bid pavement items.

940 When the Contractor elects to enact PG asphalt binder material cost adjustments
at the time the bid proposal is submitted, the Department will adjust payment to the
Contractor due to an increase or decrease in the cost of PG asphalt binder material
used on the project to produce HMA mixtures that are paid in accordance with 304,
401, 402, 410, 414, 610, or 718. Payment will be adjusted when an increase or decrease
in the PG asphalt binder index for the contract is greater than or equal to 10.01%.
Payment will only be adjusted when the total original or revised quantity of at least
one HMA pay item exceeds 2,000 tons.

For contracts without any original HMA pay item quantity equal to or greater than
950 2,000 tons, adjusted payment will not be made until the revised quantity of at least one
HMA pay item meets the quantity criteria.

The initial 2,000 tons of HMA will not be eligible for a payment adjustment.

The Department will determine a PG asphalt binder index from one or more
commercial services that provide regional indices. The PG asphalt binder index will
be maintained by the Office of Materials Management and posted on the Department’s
website. The posting will include an explanation of how the index is determined. A
monthly payment adjustment will be calculated for each HMA pay item placed on the
960 contract during that month. The total PG asphalt binder adjustment applied to the

120
 109.05.3

contract each month will be the sum of the calculations for each HMA pay item. The
payment adjustment for each HMA pay item will be calculated as follows:

For a price increase:

MPA = (Q x Pb)/100 x LI x [(BI-LI)/LI - 0.10]

For a price decrease:

970 MPA = (Q x Pb)/100 x LI x [(BI-LI)/LI + 0.10]

Where:

MPA = Mixture Payment Adjustment, in dollars, calculated to the

nearest 0.01 dollar for each HMA pay item.

Q = Quantity of a HMA pay item placed, in tons, entered to the

actual 0.01 unit placed. The quantity will be calculated
prior to calculation of any other quantity adjustment.
980
Pb = Percent of virgin asphalt binder from the DMF, in the
adjustment period, or JMF for the HMA mixture, entered
to the nearest 0.1.

BI = PG asphalt binder index for the month the HMA pay item
is placed, reported to the nearest whole dollar.

LI = PG asphalt binder index for the contract. The LI for all

original contract HMA pay items equals the BI for the
990 month immediately prior to the month of letting for the
contract. The LI for any HMA extra work pay item will be
the BI for the month the unit price for the pay item is
submitted by the Contractor.

The calculation of (BI-LI)/LI will be rounded to the nearest 0.001. Payment will
only be adjusted when the absolute value of (BI-LI)/LI is equal to or greater than 0.101.

If HMA pay items are placed beyond the specified contract completion date for
the contract, the Department will calculate pay adjustments on the BI for the month of
1000 the specified completion date or the month of placement, whichever result is less.

The unit price of PG asphalt binder payment adjustment will be $1.00 and the pay
quantities will be in units of dollars.

Payment will be made under:

121
 109.06

Pay Item Pay Unit Symbol

Payment Adjustment, PG Asphalt Binder ................................. DOL

1010
109.06 Eliminated Pay Items
If pay items contained in the Schedule of Pay Items are found unnecessary for the
proper completion of the work, they may be eliminated from the contract as a change
order. Such action shall not invalidate the contract. When notified of the elimination
of pay items, the Contractor will be reimbursed for actual work done and all costs
incurred, including mobilization of materials prior to said notification. This material
may, at the option of the Department, be purchased at the actual cost including freight
to the Contractor, plus 12%.

1020 109.07 Partial Payments

The contract may contain more than one project. Partial payments may be made
once each month as the work progresses or twice each month if it is determined that
the amount of work performed is sufficient to warrant such payment. These payments
will be based on estimates, prepared by the Engineer, of the value of the work
performed and materials complete in place in accordance with the contract. No partial
payment will be made or estimates will not be submitted when the total value of the
work done since the last estimate amounts to less than $500.

Except as set out in 105 IAC 11-3-8 of the Rules For Prequalification of
1030 Contractors and Bidding, the balance, less all previous payments and less amounts
claimed which are required to be held by the Department in accordance with Indiana
Code 8-23-9-26 through 8-23-9-39, will be certified for payment.

Within 10 business days of receipt of payment for any such estimate, the
Contractor shall make payment to all subcontractors, including lessors and material
suppliers, for the value of their work performed and materials complete in place in
accordance with the contract. Failure to comply with this clause shall constitute a
material breach of the contract and may result in sanctions under the contract.

1040 Any delay or postponement of payment among the parties may take place only
for good cause, with the Department’s written approval. The explanation from the
Contractor shall be made in writing to the Department.

Upon receipt of a claim under Indiana Code 8-23-9-26, the Department will retain
out of the amount due the Contractor the amount of the claim. The amount to be
retained will be withheld from partial payment estimates until the total amount of the
claim has been retained.

In order to retain an amount when required by Indiana Code 8-23-9-26, the

1050 Engineer will apply a negative quantity to the contract liens pay item for the actual
dollar amount of the claim. Upon resolution of the claim, the Engineer will post a

122
 110.02

positive quantity to the contract liens pay item equal to the amount originally retained.
The final quantity of the contract liens pay item will be zero prior to final payment.

The contract unit price for contract liens will be $1.00.

Payment will be made under:

Pay Item Pay Unit Symbol

1060
Contract Liens ........................................................................... DOL

No allowance will be made for materials received which have not been
incorporated into the work except in accordance with 111.

109.08 Final Payment

When the work has been completed in accordance with the terms of the contract,
a final estimate will be prepared for the work done and a copy will be furnished to the
Contractor. Final payment will not be made to the Contractor until allowed by Indiana
1070 Code 8-23-9-26 through 8-23-9-39.

All prior partial estimates and payments will be subject to correction in the final
estimate and payment.

Except as otherwise provided herein, final payment will be made within 180 days
after acceptance of the project. Acceptance shall be considered as the date the
Contractor is relieved of further maintenance as provided in 107.19 and as set out in
the final acceptance letter. However, final payment shall not be made on an amount
which is in dispute or the subject of a pending claim. However, final payment may be
1080 made on that portion of the contract or those amounts which are not in dispute or
subject of a pending claim. Such partial payment shall not constitute a bar, admission,
or estoppel or have any other effect as to those payments in dispute or the subject of a
pending claim. For the purpose of this section, a dispute exists when the Contractor
makes a claim for increase or decrease to any part of the contract, or seeks additional
compensation for any reason.

SECTION 110 – MOBILIZATION AND DEMOBILIZATION

110.01 Description
This work shall consist of all work necessary for the movement of personnel and
equipment to and from the project site, except for seeding, and for the establishment
and removal of all field offices, buildings, and other facilities necessary to the
performance of the work.

110.02 Limitations
10 For the purpose of payment, the mobilization portion of this work will be limited
to 5% of the original total contract price. The remainder of the work will be considered
123
 110.03

demobilization. The first progress estimate will include a percentage payment of the
pay item for mobilization and demobilization that is equal to the lesser of 5% of the
original total contract price or the contract lump sum price for the pay item
mobilization and demobilization. The balance of the lump sum price will be paid when
the contract has been completed and accepted.

110.03 Method of Measurement

No measurement will be made.
20
110.04 Basis of Payment
This work will be paid for at the contract lump sum price for mobilization and
demobilization.

Payment will be made under:

Pay Item Pay Unit Symbol

Mobilization and Demobilization .............................................. LS

30
The cost of all materials, equipment, tools, labor, transportation, operations, and
incidentals required for mobilization and demobilization shall be included in the cost
of this work.

If no pay item for mobilization and demobilization is shown in the Schedule of

Pay Items, the cost of the work described above shall be included in the total cost of
the contract, with no direct payment for the work.

SECTION 111 – STOCKPILED MATERIALS

111.01 Description
This work shall consist of the partial payment for certain stockpiled materials.

111.02 General Requirements

After certified copies of costs are presented, partial payments may be allowed for
tested and accepted non-perishable materials purchased or produced expressly to be
incorporated into the work and delivered in the vicinity of the project, or stored in
10 approved storage facilities. Such materials shall be limited to structural steel, concrete
structural members, reinforcing bars, pavement contraction joints, granular base and
subbase materials, aggregates for HMA and concrete pavements, and structural
supports for signals, signs, and luminaires.

In addition to the aforementioned, the Department will consider the stockpiling of

other products, such as guardrail and culvert pipe, if it has been determined that a
critical shortage of material would cause delay to the project.

124
 111.05

111.03 Structural Steel and Concrete Structural Members

20 Partial payment for either of these pay items will be considered only when the
total quantity for an entire structure, or designated unit of a structure as specified on
the plans, has been completely fabricated.

(a) Delivered to the Job Site

Partial payment made under the requirements of this paragraph will be the
delivered cost of the structural steel and concrete structural members, as verified by
invoices, including freight, furnished by the Contractor. However, such partial
payment will not exceed 75% of the contract unit price as set out in the Schedule of
Pay Items for structural steel or concrete structural members. Prior to authorizing
30 partial payment, verification will be obtained that all required inspection has been
made and the members are acceptable.

(b) Acceptably Stored at the Fabricator’s or Manufacturer’s Storage

Facilities
Partial payment made under the requirements of this paragraph will be the
delivered cost of structural steel and concrete structural members, minus freight
charges, as verified from invoices furnished by the Contractor. However, such partial
payment will not exceed 70% of the contract unit price as set out in the Schedule of
Pay Items for structural steel or concrete structural members. Under this requirement,
40 all invoices shall show the location of where the material is being stored. Prior to
authorizing partial payment, verification will be obtained that all required inspection
has been made, and the members are acceptable and they are acceptably stored.

111.04 Dowel Bar Assemblies

Partial payment made under the requirements herein will be the delivered cost of
the dowel bar assemblies stored within the project limits or at a storage facility
adjacent to the project site. Basis of payment for the dowel bar assemblies shall be the
paid invoices furnished by the Contractor. Prior to authorizing partial payment,
verification will be obtained that the dowel bars have been tested and are acceptable.
50
111.05 Granular Base, Subbase Materials, and Aggregates for HMA and
Concrete Pavements
Partial payment made under the requirement of this paragraph will be made upon
presentation of paid invoices or certified copies of the cost for the production of such
materials. The partial payment shall not exceed 30% of the unit price bid for the base
or subbase material item as set out in the Schedule of Pay Items. The invoice or
certified copies of the cost shall include an estimated quantity of the materials stored
for partial payment. The estimated quantity of materials will be verified before
payment.
60
The approved storage site shall be within the project limits, at the Contractor’s
adjacent storage facility, or at a production site where the designated materials are
either assigned to, or owned by the Contractor.

125
 111.06

Materials stored under this requirement shall be kept separate from other
production and shall not be used except on the assigned contract, unless otherwise
approved in writing.

Testing shall be provided as directed, during production. Prior to authorizing

70 partial payment, verification will be obtained that the materials have been tested and
are acceptable.

111.06 Bridge Expansion Joints

(a) Type SS
Partial payment will be the delivered cost of the expansion joint SS, as verified
by invoices, except it will not exceed 75% of the contract unit price for expansion joint
SS. Prior to authorizing partial payment, verification will be obtained that all required
inspections have been made and the joint is acceptable.
80
(b) Type M
Partial payment will be the delivered cost of the expansion joint M, as verified by
invoices, except it will not exceed 75% of the contract unit price for expansion joint
M. Prior to authorizing partial payment, verification will be obtained that all required
inspections have been made and the joint is acceptable.

111.07 Structural Supports for Signals, Signs, and Luminaires

Partial payment will be the delivered cost of the materials, as verified by the
invoices, except it will not exceed 50% of the contract unit price for the structural
90 support which is stored within the project limits or at an approved storage facility
adjacent to the project site. Prior to authorizing partial payment, verification will be
obtained that the material has been tested and is acceptable.

111.08 Precast Concrete Median Barrier

Partial payment for precast concrete median barrier as stockpiled material will be
the delivered cost of the materials, including freight, as verified by invoices furnished
by the Contractor. Such partial payment will not exceed 50% of the contract unit price
for the median barrier. The concrete barrier shall be stored within the project limits or
at an approved storage facility adjacent to the project in order for stockpiled payment
100 to be favorably considered.

111.09 Concrete Face Panels and Ground Reinforcement for MSE Walls
Partial payment for concrete face panels and ground reinforcement for MSE walls
as stockpiled material will be the delivered cost of the concrete face panels and ground
reinforcement, including freight, as verified by invoices furnished by the Contractor.
Partial payment will not exceed 75% of the contract unit price for concrete face panels.
Concrete face panels and ground reinforcement shall be stored within the project limits
or at an approved storage location. Prior to authorizing partial payment, verification
will be obtained that the concrete face panels are in accordance with 901.10 and the
110 ground reinforcement is in accordance with 910.07(b).

126
 111.12

111.10 Additional Requirements

Partial payment will not be allowed on an estimate for materials of less than
$10,000 in value.

The Department may consider partial payment for stockpiled materials having a
value of over $25,000. Partial payment will be the delivered cost verified by invoices,
except it will not exceed 50% of the contract unit price.

120 All materials when so paid for under this requirement will become the property
of the Department in the event of default on the part of the Contractor. The Department
may use, or cause to be used, such materials in the construction of the work provided
for in the contract.

Although payment may have been made for materials, the Contractor shall be
responsible for loss or damage to the materials. Such materials shall be replaced with
no additional payment.

Approval of partial payment for stockpiled materials will not constitute final
130 acceptance of such materials for use in completing the work. Structural steel members
and reinforcing bars may be subjected to additional inspection and testing prior to final
acceptance and incorporation into the work. All other stockpiled pay items will be
subjected to additional inspection and testing prior to final acceptance and
incorporation into the work.

Partial payments for stockpiled materials that are a portion of the pay item will be
deducted from estimates due the Contractor as the material is incorporated in the work.

111.11 Method of Measurement

140 No measurement will be made. However, the amount will be substantially verified
before authorization for payment.

111.12 Basis of Payment

Stockpiled materials which are authorized for payment in accordance with the
requirements herein will be paid for in accordance with 111.03, 111.04, 111.05,
111.06, 111.07, 111.08, 111.09 and 111.10.

Payment will be made under:

150 Pay Item Pay Unit Symbol

Stockpiled Material, _________________ ................................ LFT

type of material
CYS
EACH
LBS

127
 113.01

SFT
SYS
TON
160 Structural Steel .......................................................................... LS
Structural Members, Concrete ................................................... LS
Structural Expansion Joint, _____ ............................................. LFT
type

SECTION 112 – BLANK

SECTION 113 – PARTNERING OVERHEAD

113.01 Description
All major players for both the Contractor and the Department will be expected to
attend a partnering workshop to develop a statement of goals and monthly follow-up
meetings. Players need to attend the follow-up meetings only when they are active in
the project. This workshop shall be held at a neutral location and may include a
working lunch if the cost is less than $10.00 per person. The workshop should take
place before the preconstruction conference, but shall not take the place of the
10 preconstruction conference.

113.02 Requirements
The requirements for the workshop shall be as follows:

(a) Meeting Room

The size of the room and the number of persons in attendance may vary.

Attendees Approximate
Number
20
City or County Officials, if applicable ...................................... 3
Department Personnel ............................................................... 12
Designers or Design Consultant ................................................ 2
Prime Contractor’s and Subcontractor’s Personnel ................... 13
Utilities, if applicable ................................................................ 6
____
Total Approximate Number in Attendance ............................... 36

(b) Meeting Length

30 The workshop is expected to last a minimum of 5 h. The follow-up meetings are
expected to last approximately 1 to 2 h.

(c) Facilitator
A facilitator shall be provided. Such facilitator shall have expertise in conducting
workshops of this nature. The Contractor shall select the facilitator. The facilitator will
128
 113.04

be subject to approval by the Engineer prior to being contracted for the work. The
facilitator shall conduct the workshop, the first follow-up meeting, every third follow-
up meeting, and a close-out meeting. The other monthly follow-up meetings will be
conducted by the Engineer and Contractor. At the close-out meeting, a statement of
40 successes and failures shall be developed. The facilitator shall compile and publish a
summary of these successes and failures for distribution to all players.

113.03 Method of Measurement

Partnering overhead will not be measured for payment.

113.04 Basis of Payment

Partnering overhead will be paid for at the contract lump sum price for partnering
overhead.

50 Payment will be made under the following:

Pay Item Pay Unit Symbol

Partnering Overhead .................................................................. LS

The cost of the room, facilitator, mailings, video and audio equipment required,
and all other incidentals shall be included in the cost of partnering overhead.

129
THIS PAGE INTENTIONALLY LEFT BLANK

130
 201.03

DIVISION 200 – EARTHWORK

SECTION 201 – CLEARING AND GRUBBING

201.01 Description
This work shall consist of clearing, grubbing, removing, and disposing of all
vegetation and debris, except such objects as are designated to remain or are to be
removed in accordance with other sections of these specifications, within the
construction limits shown on the plans. If no construction limits are shown, the right-
of-way and easement areas will be the construction limits. This work shall include the
preservation from injury or defacement of all vegetation and objects designated to
10 remain. Disposal of material shall be in accordance with 203.08.

CONSTRUCTION REQUIREMENTS

201.02 General
Right-of-way lines and construction limits will be established. Trees, shrubs,
plants, seeded or sodded shoulders, slopes or other things to remain will be designated.
All such designated items and vegetation shall be preserved. All areas outside the
construction limits shall remain in their original condition. All damage to natural
terrain, vegetation, objects designated to remain, or areas outside the construction
20 limits which have subsequently eroded or been damaged, shall be repaired or replaced
in accordance with 621.11. Tree wound dressing required for cut or scarred surfaces
of trees or shrubs selected for retention shall be in accordance with 914.09(c).

201.03 Clearing and Grubbing

Surface objects, trees, stumps, roots, and other protruding obstructions not
designated to remain shall be cleared and grubbed, including mowing as required.
Undisturbed sound stumps, roots, and non-perishable solid objects, which are a
minimum of 3 ft below the final subgrade or slope of embankments, may be left,
provided they are as nearly flush as possible. However, they shall not extend more
30 than 4 in. above the ground line or low water level. Sound stumps may be cut off at
ground level outside the construction limits of cut and embankment areas if approved.

Except in areas to be excavated, stump holes and other holes from which
obstructions are removed shall be backfilled with suitable material and compacted in
accordance with 203.23.

Burning of perishable material shall be done in accordance with applicable laws,

ordinances, rules, and regulations. All necessary permit approvals shall be obtained
prior to burning.
40
Unless burned in accordance with the requirements herein, perishable materials
and debris shall be removed from the right-of-way and disposed of in accordance with
203.08. If allowed, sod may be disposed of within the right-of-way.

131
 201.04

All merchantable timber in the clearing area, which has not been removed from
the right-of-way prior to the beginning of construction, shall become the property of
the Contractor, unless otherwise provided. The value of the timber shall be taken into
account when the bid is prepared.

50 Low hanging branches and unsound or unsightly branches on trees or shrubs

designated to remain shall be removed as directed. Branches of trees extending over
the roadbed shall be trimmed to give a clear height of 20 ft above the roadbed. All
trimming shall be done by skilled workers and in accordance with good tree surgery
practices.

201.04 Scalping
Areas where excavations are to be made, or embankments are to be placed, shall
be scalped to a maximum of 4 in. Scalping shall include the removal of material such
as brush, roots, sod, grass, residue of agricultural crops, sawdust, and decayed
60 vegetable matter from the surface of the ground.

201.05 Hedge Removal

Hedges and shrubs shall be pulled or grubbed in such a manner as to ensure
complete and permanent removal.

201.06 Method of Measurement

When specified as a pay item, measurement of this work will be made by one or
more of the following methods.

70 (a) Area Basis

The work to be measured will be the number of acres and fractions thereof
acceptably cleared and grubbed within the limits shown on the plans or staked for
clearing and grubbing. Areas not shown on the plans or not staked for clearing and
grubbing will not be measured for payment.

(b) Lump Sum Basis

If clearing and grubbing is specified as a lump sum pay item, no measurement of
area will be made.

80 (c) Individual Unit Basis

1. The diameter of trees will be measured at a height of 24 in.

above the ground. Trees of less than 4 in. in diameter will
be classified as brush.

2. Stumps will be measured by determining the average

diameter at the cutoff location.

3. Scalping will be measured by the acre.

90
132
 201.07

4. If the Schedule of Pay Items shows measurement to be on

an individual unit basis, the units will be designated and
measured in accordance with the schedule of sizes as
follows:

Measured Diameter at
Pay Diameter
Height of 24 in.
4 to 8 in. 6 in.
Over 8 to 12 in. 10 in.
Over 12 to 24 in. 18 in.
Over 24 to 36 in. 30 in.
Over 36 to 60 in. 48 in.
Over 60 in. 60 in.

201.07 Basis of Payment

The accepted quantities of clearing and grubbing will be paid for as shown below.

100 (a) Area Basis

The determined quantities will be paid for at the contract unit price per acre
respectively for each of the pay items shown in the Schedule of Pay Items.

(b) Lump Sum Basis

If the Schedule of Pay Items shows a lump sum pay item, the lump sum price will
be paid for all work shown within the construction limits. All clearing the Contractor
is directed to perform outside the construction limits, including clearing for utility
relocation which is for the benefit of the Department, and not simply for the
Contractor’s convenience, will be paid for in accordance with 104.03 or 109.03 unless
110 such clearing is shown on the plans, in the Contract Information book, or is for the
construction of fence or right-of-way markers.

(c) Individual Unit Basis

If individual unit quantities are shown in the Schedule of Pay Items, the accepted
quantities will be paid for at the contract unit prices for the respective pay items.

Payment for tree removal sizes as designated in requirement 4 of 201.06(c), which

are larger than those sizes shown as pay items, will be made on the basis of the largest
size shown in the Schedule of Pay Items except as set out below.
120
Payment will be made under:

Pay Item Pay Unit Symbol

Clearing and Grubbing .............................................................. ACRE

LS
Clearing Right-of-Way .............................................................. LS
Scalping ..................................................................................... ACRE

133
 202.01

________, ________, Remove .................................................. EACH

130 name size

Except as specified in 621, the cost of repair or replacement of terrain, vegetation,

objects designated to remain, or areas outside the construction limits which have been
damaged by the Contractor or have subsequently eroded, shall be included in the cost
of clearing right-of-way.

(d) Clearing Right-of-Way

If the Schedule of Pay Items contains a lump sum pay item for clearing right-of-
way, such pay item shall include the cost of all work described in this section and all
140 of the work performed in accordance with 202 within the construction limits except
for such work set out specifically as pay items or as otherwise provided for herein. All
clearing the Contractor is directed to perform outside the construction limits, including
clearing for utility relocation which is for the benefit of the Department, and not simply
for the Contractor’s convenience, will be paid for in accordance with 104.03 or 109.03
unless such clearing is shown on the plans, in the Contract Information book, or is for
the construction of fence or right-of-way markers.

(e) Exclusions
If the Schedule of Pay Items does not contain an estimated quantity or a lump sum
150 pay item for work described herein except as set out above, such work will not be paid
for directly. The cost thereof shall be included in the cost of other pay items.

SECTION 202 – REMOVAL OF STRUCTURES AND OBSTRUCTIONS

202.01 Description
This work shall consist of the removal, wholly or in part, and satisfactory disposal
of all buildings, fences, structures, old pavement, abandoned pipe lines, abandoned
tanks, and any other obstructions which are not designated or allowed to remain,
except for the obstructions to be removed and disposed of under other items in the
contract. It shall include the salvaging of designated materials and backfilling the
resulting trenches, basements, holes, and pits.
10
CONSTRUCTION REQUIREMENTS

202.02 General Requirements

All buildings and foundations in accordance with 202.06, structures, fences, tanks,
and other obstructions, any portions of which are on the right-of-way shall be razed,
removed, and disposed of, except utilities and those features for which other provisions
have been made for removal. Salvageable material designated by the Department shall
be removed without unnecessary damage in sections or pieces which may be
transported readily and shall be stored at specified places within the project limits or
20 as otherwise designated.

134
 202.02

Materials not designated by the Department as salvageable and removed from the
construction site shall become the property of the Contractor and shall be disposed of
in accordance with 203.08, except for regulated materials, which shall be disposed of
in accordance with 104.06, and bridge painting debris which is subject to 619.

Unsuitable material shall be removed from cisterns, septic tanks, other tanks,
basements, and cavities. The disposition of this material shall be in accordance with
all applicable and current local, State and Federal regulations. Cisterns, septic tanks,
30 other tanks, basements, and cavities shall be backfilled in an approved manner. Those
which cannot be backfilled satisfactorily shall be removed. If the backfill is within the
limits of construction, it shall be completed in accordance with 203.23, unless
otherwise directed. All abandoned wells shall be backfilled in accordance with the
Indiana Code. A copy of the driller’s license shall be furnished prior to commencement
of work.

In accordance with 326 IAC 14-10, the Contractor shall complete and submit a
demolition/renovation notification to IDEM when demolition or renovation of
buildings, houses, canopies, and bridges are part of the contract. This notification shall
40 be submitted regardless of whether asbestos containing material is present. Fees for
this demolition/renovation notification shall be paid to IDEM by the Contractor.

Copies of the demolition/renovation notification form can be obtained from the

IDEM’s website. Questions concerning the completion of the demolition/renovation
notification should be addressed to IDEM’s Office of Air Quality.

Initial notification to IDEM shall be by certified mail, return receipt requested, or

by hand delivery. Verification of this notification shall be provided to the Engineer.
The Contractor shall provide such notification 10 work days prior to the date on which
50 demolition or renovation operations are anticipated to begin. If the Contractor
postpones the beginning date of demolition or renovation operations, IDEM shall be
provided written notice of the new start date, postmarked at least five work days or
delivered at least two work days before these operations begin. Verification of this
notification shall also be provided to the Engineer.

Unless otherwise specified, materials removed from the construction site shall
become the property of the Contractor and proper allowance for their value shall be
taken into account in the bid price of the item involved. Where a house or building has
been removed previously and the existing utilities and drains or sewer connections
60 have not been terminated and sealed, this work shall be performed in accordance with
104.03, or as otherwise provided for in the contract.

Unless inspection has previously been conducted by the Department, and the
findings are shown in the Proposal book, all facilities to be demolished shall be
inspected for the presence of regulated materials as defined in 104.06. Facilities are
defined as all institutional, commercial, residential or industrial structures,
installations, buildings, and all bridges. Inspection and testing for asbestos shall be in

135
 202.03

accordance with 202.07. If inspected by the Department, a copy of the findings will
be included in the Contract Information book.
70
At the direction of the Engineer and in accordance with 104.06(b), appropriate
tests shall be made by the Contractor of all potentially regulated materials found. The
Contractor shall comply with all applicable environmental regulations.

All identified regulated materials shall be reported and removed in accordance

with the procedures specified in 104.06 prior to commencing the demolition of the
facility. Asbestos removal shall be in accordance with the OSHA Asbestos Standard
for Construction Industry, the EPA Asbestos Facts: Demolition and Renovation
Regulations, and 202.07.
80
Except for tank content waste, in accordance with 202.08, the Engineer will
classify regulated materials as one of the following Department categories for the
purpose of disposal requirements and payment.

(a) Type Y Waste

All waste material that may be disposed of in a RCRA approved landfill.

(b) Type Z Waste

All waste material that is prohibited from being disposed of in a RCRA approved
90 landfill.

202.03 Removal of Bridges, Culverts, and Other Drainage Structures

Bridges, culverts, and other drainage structures in use by traffic shall not be
removed in whole or in part until satisfactory arrangements have been made to
accommodate traffic. Any excavation adjacent to the structure or to its approaches
shall be shored adequately to avoid damage to them or to traffic.

When a reinforced concrete arch bridge is to be removed, either in whole or in

part, the work shall include the removal of miscellaneous items within the limits of the
100 structure, which must be removed prior to or in conjunction with the removal of the
structure. These miscellaneous items shall include but shall not be limited to: concrete
and asphalt pavements; concrete and asphalt sidewalks; and fill within the arches
regardless of content.

(a) Complete
Unless otherwise directed, the substructures of existing structures shall be
removed down to the natural stream bottom and those parts outside of the stream shall
be removed down 1 ft below natural ground surface. Where such portions of existing
structures lie wholly or in part within the limits of a new structure, they shall be
110 removed as necessary to accommodate the construction of the proposed structure.
Portions of pre-existing structures that are not visible and not shown on the plans shall
be removed as directed. Payment for such removal will be paid as class X excavation
in accordance with 206.11.

136
 202.03

Unless otherwise specified, structural steel and materials not designated by the
Department to be salvaged shall become the property of the Contractor. It shall be
removed from the site before completion of the work and proper allowance for its
value shall be taken into account in the bid price of the item involved. If the structure
is to remain the property of the Department, steel or wood bridges shall be carefully
120 dismantled without unnecessary damage, steel members shall be match marked, and
all salvaged material shall be stored in accordance with 202.02.

Blasting or other operations necessary for the removal of an existing structure or

obstruction, which may damage new construction, shall be completed prior to placing
the new work.

(b) Portions
Portions of the existing structure shall be removed as shown on the plans.
Reinforcing bars shall be cut off or allowed to extend into the proposed work as
130 required or as otherwise directed. Explosives shall not be used in the removal of
concrete. Where new concrete joins existing concrete masonry, the surface shall be
cleaned satisfactorily before new concrete is placed. Adequate safeguards shall be
provided to prevent materials from falling below the structure when over or adjacent
to traffic; when over bodies of water; as needed to protect life or property; and as
needed to comply with laws, regulations, or other contract requirements. A plan shall
be submitted for approval showing the proposed method of protection.

Pneumatic hammers, up to a maximum of 45 lb may be used for all removal areas

to be patched in the deck and all areas within 24 in. of full depth removal lines.
140 Pneumatic hammers up to 69 lb maximum weight may be used for removal of all
parapet walls having a construction joint separating the wall from the coping and all
partial curb removals. Pneumatic hammers up to 90 lb maximum weight may be used
for all other removals outside these limits. Concrete splitters may be used for partial
concrete removal subject to satisfactory performance. Deck areas that are to be
removed full depth shall be completely separated from adjacent concrete by sawing
before hammers heavier than 45 lb may be used.

Concrete superstructures or deck removal may be accomplished by pneumatic

hammers larger than 90 lb, except directly over structural members that are to remain
150 in place. Partial concrete removal of columns, piers, and abutments may be
accomplished with pneumatic hammers larger than 90 lb, provided that the reinforcing
bars in the portion to be removed are completely separated from the concrete that is to
remain in place. Alternate methods of removal may be considered if requested in
writing.

Hydrodemolition may be allowed for removal of portions of bridge structures as

an alternate method to pneumatic hammers. Hydrodemolition for such removals may
be accomplished either by use of a machine or a handheld device. Hydrodemolition
shall otherwise be in accordance with 722.

137
 202.04

160
Any portion of the structure that is removed, but which was not included within
the limits of the concrete to be removed as shown on the plans or as directed, shall be
replaced with no additional payment. If at any time during the removal process the
tools or methods being used appear to cause any damage to concrete that is to remain,
the work shall cease immediately and shall not resume until the Engineer is assured
the tools or methods used will not cause further damage.

(c) Disposal of Concrete

All concrete from complete or partial removals, which is determined to be
170 acceptable for riprap, shall be used on the project as directed. Concrete which has paint
or other coatings adhering to it or exposed reinforcing bars shall not be used for riprap.
Disposal or placement as riprap will not be paid for directly, but the cost thereof shall
be included in the cost of removal. Disposal of concrete from complete or partial
removals shall be in accordance with 203.08.

202.04 Removal of Pipe and Tile Drains

When indicated in the contract documents or as directed, all pipe and tile drains
shall be removed and reasonable precaution taken to avoid breaking or damaging
them. The pipe or tile shall be stored neatly on the right-of-way, unless it is to be re-
180 laid as a part of the contract. Otherwise, the conditions in accordance with 104.05 shall
apply.

Pipes to be re-laid shall be removed and stored so that there is no loss or damage
to the pipe. Replacement will be required of sections lost from storage or from damage
through negligence or from improper methods in handling. Removal of pipe or drain
tile, any necessary cleaning, removal of headwalls, storage of pipe, and disposal of
removed headwall material and unsuitable pipe will not be paid for directly, the cost
thereof to be included in the various pay items.

190 Sanitary or storm sewers no longer in use shall be removed from under the
roadway and shoulders if so specified on the plans or in the proposal or if so directed.
No payment will be made for this removal if the removal is shown on the plans and no
pay item exists, or if this removal is necessary during the placing of other structures
or during other excavation operations. The removal of pipes that are not shown in the
contract documents and those that are not being replaced at the same location will be
paid for in accordance with 109.05. Disposal of pipe and tile drain material shall be in
accordance with 203.08.

202.05 Removal of PCCP, Sidewalks, Curbs, RCBA, and Reinforced

200 Concrete Moment Slabs
All unreinforced PCCP, sidewalks, curbs, gutters, and other unreinforced concrete
elements designated for removal shall be:

(a) broken into pieces and used for riprap on the project; or

138
 202.06

(b) broken into pieces, the maximum weight of which shall be 150
lb, and incorporated into the work as directed; or

(c) otherwise disposed of in accordance with 202.02.

210
RCBA, reinforced concrete moment slabs, and reinforced concrete elements
designated for removal shall be disposed of in accordance with 202.02.

Pavement removal shall consist of the removal and satisfactory disposal of

RCBA, reinforced concrete moment slabs, reinforced or unreinforced PCCP, PCC
resurface with its base, or the total of any combination of HMA base, intermediate,
and surface course overlaying PCCP, PCC resurface with its base, RCBA, or
reinforced concrete moment slab base. Pavement removal shall include only the
removal and disposal of existing public road, street, and alley pavement as required
220 for the planned construction. Curb removal shall include curb that is separate from the
pavement or removed separately. Integral curb that is removed with the adjacent
pavement shall be paid for as pavement removal. Prior to performing the work of
pavement removal at locations shown on the plans or where directed, cement concrete
pavement to be removed shall be cut with a power driven concrete saw along
designated lines. Sawing shall be such that any portion of the pavement to remain in
place will not be damaged. Any portion that is damaged or removed outside the
designated lines shall be replaced with no additional payment. Sawing of pavement to
be removed will not be paid for directly, but shall be included in the cost of pavement
removal.
230
202.06 Removal of Houses and Buildings
This item consists of the satisfactory demolition, removal, backfilling, and
disposal of all houses and buildings at locations shown on the plans or where directed.
The houses and buildings shall be demolished and removed down to a point 1 ft below
the original ground level or the subgrade elevation, whichever is lower. All
accumulated debris in existing basements shall be removed and disposed of. Prior to
starting demolition operations, or when directed, all existing utilities shall be
terminated and all floor drains shall be sealed in a satisfactory manner. Temporary
fence in accordance with 107.14 may be required where specified or directed.
240 Basements or depressions left by demolition shall be backfilled with B borrow and
compacted in accordance with 203.23. No additional payment will be made for
temporary fence, the cost thereof to be included in the lump sum price for removal at
the location. Temporary fence shall remain the property of the Contractor.

The removal of houses and buildings shall be arranged and prosecuted such that
all Department maintained highways, and all local roads, streets, and alleys within the
project limits shall remain open to normal traffic at all times unless otherwise directed.

Demolition and removal of any individual house or building shall not be started
250 without written authorization. Compensation will be paid only for houses and

139
 202.07

buildings which are actually removed from the right-of-way as authorized. Removed
materials shall be disposed of in accordance with 104.05 and 104.06.

In the event the houses and buildings listed for removal from a designated parcel
are not in existence at the time of submission of the bid, the lump sum bid for that item
shall be indicated at zero dollars and cents.

202.07 Inspection and Removal of Asbestos

The Contractor shall comply with all applicable environmental regulations
260 including but not limited to those as follows:

(a) In accordance with 202.02 and 326 IAC 14-10, a

demolition/renovation notification is to be submitted to IDEM
10 work days prior to the start of demolition or renovation
operations. During the 10 day period, the IDEM may make a
determination of the existence of asbestos materials. Local
governmental agencies may have additional regulations that
must be followed. The Contractor shall contact the IDEM’s
Office of Air Quality to determine what local agencies have
270 regulations.

(b) 326 IAC 18-3 which requires the inspector conducting the
required inspection to be certified by the IDEM. An accredited
asbestos project supervisor shall be required to be present at all
asbestos removal projects in accordance with 326 IAC 14-10
and 18-1.

(c) Federal Asbestos National Emission Standard for Hazardous

Air Pollutants.
280
(d) Structurally Unsound and in Danger of Imminent Collapse
Building Regulations, in accordance with 326 IAC 14-10-1(b).

202.08 Removal of Underground Storage Tanks Containing Petroleum

Products or Other Hazardous Chemicals
Removal of underground storage tanks shall consist of the proper excavation;
removal of the tank; removal and disposal of liquids, sludges, and other materials in
the tanks; backfilling, and permanent closure of underground storage tanks located as
shown on the plans or as identified by the Engineer.
290
This work shall be performed in accordance with the requirements as follows:

(a) Technical Standards and Corrective Action Requirements for

Owners and Operations of Underground Storage Tanks, UST,
Code of Federal Regulations, Title 40, Part 280 (40 CFR 280),
Subparts F and G;

140
 202.08

(b) American Petroleum Institute Recommended Practice 1604,

“Removal and Disposal of Used Underground Petroleum
300 Storage Tanks”;

(c) American Petroleum Institute Publication 2015, “Cleaning

Petroleum Storage Tanks”;

(d) RCRA and the Indiana Environmental Management Act;

(e) UST Notification, Reporting and Closure Requirements as

prepared by the IDEM Underground Storage Tank Branch;

310 (f) safety regulations issued by OSHA;

(g) Indiana Fire Prevention Code, Flammable and Combustible

Liquids, Article 79, 675 IAC 22;

(h) all applicable Federal and State requirements for certification of

underground storage tank removal contractors; and

(i) local fire codes.

320 An individual who has been certified for underground storage tank closure or
removal, as appropriate, through the State Fire Marshall shall be present at all times
for tank closure or removal. Evidence of such certification shall be given to the
Engineer prior to starting work.

The removal and disposal of all regulated materials in or around the tanks shall
be in accordance with 104.06.

The Contractor shall have the responsibilities as follows:

330 (a) obtain a review of available tank information from the

Engineer;

(b) unless the Department has already done so, provide notification
of tank removal operations to appropriate authorities.
Notification shall be provided as required to the IDEM, Office
of the State Fire Marshall and local fire department in
accordance with (a) through (i) above. Notification shall be
provided to IDEM at least 30 days prior to closure or removal
of regulated tanks in the form of the completed Notification for
340 Underground Storage Tanks Form, and at least 14 days prior to
removal or closure to the State Fire Marshall and the local fire
department. At least 14 days prior notice, by telephone, shall be
given to the IDEM Underground Storage Tank Branch of

141
 202.08

intended closure or removal date. Such forms are available from

the Indiana Department of Environmental Management;

(c) allow the Engineer to visually inspect tanks after removal;

(d) allow the Engineer to visually inspect the excavation zone for
350 contaminated soils;
(e) obtain from the Engineer the limits of excavation for each tank
to be removed;

(f) allow the Engineer to verify all documentation for remediation;

(g) sample and classify the tank contents, if access is available, or

confirm tank contents by sampling and testing;

(h) submit a site operation plan for the contaminated area to the
360 Engineer for review and approval before beginning removal
operations;

(i) provide and maintain pedestrian safety fencing;

(j) remove all liquids and sludges from tanks;

(k) clean tanks and connected piping, including feed lines and drain
lines, of contents;

370 (l) remove tanks from the ground;

(m) dispose of all tank content wastes in accordance with the

directions provided by the Engineer in 104.06;

(n) render tanks useless or dismantle tanks and transport to scrap

dealer or landfill;

(o) implement the site operation plan for the contaminated area as
directed in accordance with 104.06;
380
(p) backfill excavations in an approved manner. Backfill shall be B
borrow in accordance with 211;

(q) maintain accurate records of all operations. Submit reports,

including a completed Notification for UST and an UST System
Closure Site Assessment Report, to IDEM’s UST Branch within
30 days after closure. Two copies of these forms shall be
provided to the Engineer with verification that the documents
were submitted to IDEM;

142
 202.09

390
(r) obtain disposal approvals for the hauling and disposal of all tank
content waste materials from the site; and

(s) if the soil or groundwater surrounding the tank shows evidence

of contamination, the hole shall be covered to prevent
contamination of rainwater until remediation is complete.

The Engineer will classify the tank contents as one of the following liquid wastes
for purposes of disposal requirements and payment.
400
(a) Type A Waste
Type A waste will consist of direct discharge wastewater which may be
discharged to a sanitary sewer system with or without treatment, upon receipt of
required permits.

(b) Type B Waste

Type B waste will consist of low flash wastewater which shall be treated off-site
at a treatment facility prior to disposal.

410 (c) Type C Waste

Type C waste will consist of petroleum or other chemical liquid and sludge wastes
which are regulated materials under current EPA, U.S. Department of Transportation,
or IDEM regulations. Such waste shall be disposed of at a RCRA approved facility.

202.09 Remediation of Contaminated Soil and Groundwater

This work shall consist of remediation. All work shall be performed in accordance
with all applicable Federal, State, and local requirements, and 104.06.

Prior to commencing work, the Contractor shall provide evidence satisfactory to

420 the Engineer that the firm and personnel which are performing the remediation are
properly trained or certified as required. The Contractor shall have the equipment for
the proper remediation of regulated materials. The Contractor shall be familiar with
the required procedures and practices governing such work.

The Contractor shall have the responsibilities as follows:

(a) notify the appropriate authorities regarding remedial operations

and provide verification to the Engineer;

430 (b) take samples and conduct tests as approved by the Department
to determine extent of the contamination;

(c) develop a remediation plan and obtain approval for the plan
from the Department and the proper authorities;

(d) remediate the site upon plan approval;

143
 202.10

(e) verify that remediation has been completed by conducting the

appropriate sampling or testing;
440
(f) backfill excavations and restore ground lines as directed, in
accordance with 211;

(g) maintain accurate and complete records of all operations; and

(h) submit reports to the Engineer and the proper authorities as

requested for proper cleanup documentation.

202.10 Remediation of Other Regulated Materials

450 This work shall consist of the remediation of regulated materials not otherwise
described herein. This work shall include all necessary excavation, backfilling of
resultant excavations, and other handling or storage required.

All work shall otherwise be performed in accordance with all applicable Federal,
State, and local requirements, 104.06, and 202.09.

202.11 Transportation and Disposal of Regulated Materials

This work shall consist of determining locations for disposal, treatment, or
recycling of regulated materials removed from the project site. This work shall also
460 consist of loading regulated materials into a vehicle or transport container and the
movement of such material from the project site to a state or EPA permitted disposal
site, storage treatment, or recycling facility by appropriately trained and licensed
personnel.

The Contractor shall have the responsibilities as follows:

(a) determine the location for disposal, treatment, or recycling of

regulated materials removed from the project site; obtain
written approval of the site; arrange with the approved site for
470 the acceptance of the materials; and obtain the Engineer’s
written approval for the use of the site prior to transporting the
materials;

(b) ensure that all packing containers or tank vehicles are in

accordance with the applicable Federal, State, and local
requirements;

(c) prepare a shipping paper or manifest, as required by Federal and

State requirements, for signature of the Engineer or designated
480 Contractor representative;

(d) ensure that the shipping paper or manifest is carried in the

vehicle;
144
 202.14

(e) ensure that all required placards are properly displayed on the
vehicle;

(f) ensure prompt movement of the vehicle to the disposal site; and

490 (g) return one copy of the signed shipping or manifest documents
to the Engineer.

202.12 Blank

202.13 Method of Measurement

If the contract stipulates that payment will be made for removal of obstructions or
of houses and buildings, or for clearing right-of-way on a lump sum basis, the pay
items for such removals will include all structures and obstructions encountered within
the right-of-way in accordance with the requirements herein. No measurement will be
500 made. If it is specified that payment will be made for the removal of specific
obstructions on a unit basis, measurement will be made by the unit specified in the
Schedule of Pay Items. Material used to backfill excavated areas as directed will be
measured by the cubic yard.

If the contract stipulates that payment will be made for removal, transportation,
or disposal of regulated materials on a unit basis, measurement will be made by the
unit stipulated in the Schedule of Pay Items. However, removal of regulated asbestos,
if found, will be measured by the square foot.

510 Underground storage tank removal will be measured per each within the size
groupings of under 3,000 gal., from 3,000 through 6,000 gal., over 6,000 through
10,000 gal., or over 10,000 gal. Testing for regulated materials will be measured per
each for the type and number of tests required.

The length of pipe removed will be measured by the linear foot, computed by
multiplying the number of commercial lengths removed by the nominal laying length,
or by measuring in place prior to removal, if practicable.

Removal of present structure or portions thereof will not be measured for

520 payment.

Pavement removal will be measured by the square yard of the area removed.

202.14 Basis of Payment

The accepted quantities of removal of structures and obstruction within the
construction limits will be paid for at a contract lump sum price. All structures or
obstructions the Contractor is directed to remove outside the construction limits,
including clearing for utility relocation which is for the benefit of the Department, and
not simply for the Contractor’s convenience, will be paid for in accordance with
530 104.03 or 109.03 unless such clearing is shown on the plans or in the Contract
145
 202.14

Information book. Such price shall be full compensation for removing and disposing
of obstructions in accordance with requirements herein. Regulated materials shall be
subject to 104.06. If no contract price is listed in the Schedule of Pay Items for a pay
item set out in this specification, no direct payment will be made for work necessary
to comply with the requirements for such pay item, except as set out herein. The cost
thereof shall be included in the cost of other pay items. If unknown regulated materials
are discovered during the life of the contract, payment for all work relating to removal,
testing, transportation, or disposal of such materials will be in accordance with 104.03.

540 Specific obstructions, including pipe stipulated for removal and disposal, which
are shown as pay items, will be paid for at the contract unit price per the unit specified
in the Schedule of Pay Items.

Removal of houses and buildings will be paid for at the contract lump sum price
for houses and buildings, of the parcel number shown in the Schedule of Pay Items,
remove.

Testing for regulated materials will be paid for at the contract unit price per each
for the type and number of tests required. Testing shall include collecting of samples
550 and all necessary laboratory procedures.

Payment for removal of contaminated soils will be based on the actual cubic yards
removed, or by the number of 55 gal. drums filled with the contaminated soil.

B borrow required for backfilling basements or depressions left by demolition will

not be paid for separately but will be included in the cost of the removal item. B borrow
required for backfilling of removed contaminated soils or tank will be paid for in
accordance with 211.10.

560 Underground storage tank removal will be paid for at the contract unit price per
each tank within the size groupings of under 3,000 gal., from 3,000 through 6,000 gal.,
over 6,000 through 10,000 gal., or over 10,000 gal. Underground storage tank liquid
waste disposal will be paid for based on the type of waste and the actual number of
gal. of liquid and sludge removed.

Transportation, disposal, and removal of regulated materials will be paid for based
on the type of regulated material and the pay unit shown in the Schedule of Pay Items.
If such pay unit is specified as drum, the term drum will mean the contents of a 55 gal.
drum.
570
Clearing right-of-way within the construction limits will be paid for in accordance
with 201.07 and shall include the cost of all work described herein except for that
which is set out specifically as pay items, or work which is described in 104.06,
202.08, 202.09, 202.10, or 202.11. All clearing the Contractor is directed to perform
outside the construction limits, including clearing for utility relocation which is for the
benefit of the Department, and not simply for the Contractor’s convenience, will be

146
 202.14

paid for in accordance with 104.03 or 109.03 unless such clearing is shown on the
plans, in the Contract Information book, or is for the construction of fence or right-of-
way markers.
580
Removal of present structure will be paid for at the contract lump sum price for
present structure, for the structure number specified, remove. Removal of present
structure portions will be paid for at the contract lump sum price for present structure,
for the structure number specified, remove portions.

When directed, portions of the present structure contiguous to the areas shown on
the plans or non-contiguous portions of the same character as the planned removal
shall be removed. Such additional portland cement concrete acceptably removed will
be paid for as measured in its original position, at twice the contract unit price per
590 cubic yard for class A concrete in superstructures, class A concrete in substructures,
class C concrete in superstructures, or $652.00 per cubic yard, whichever is lowest.

Pavement removal will be paid for at the contract unit price per square yard.

If there is no pay item for pavement removal and such is encountered, payment
will be made for each square yard removed. Such pavement removal shall apply only
to portland cement concrete pavement or base. A unit price for this work will be
established based on thickness, quantity, and removal process. Such unit price will be
generated prior to the work being performed. If portland cement concrete pavement
600 has an asphalt overlay, its removal will be considered as incidental, for which no direct
payment will be made.

Before the Contractor can be paid for any item related to an UST removal in
accordance with 202, a detailed explanation of how costs were calculated for those
items shown in the Schedule of Pay Items that are related to the UST removal shall be
submitted to the Engineer. Such documentation shall include, but is not limited to, a
portion of the mobilization and demobilization, a portion of the field office, a portion
of the B borrow for backfill of the UST excavation, a portion of the surface removal
over the UST, including sawing, and soil borings and laboratory analysis under the
610 testing for waste item. The explanation shall show the type of pavement removed.
Contaminated soil removal shall be broken down into equipment cost, labor, and
mobilization of equipment used. Transportation of the regulated materials shall be
broken down into loading, hauling, and mileage costs.

Payment will be made under:

Pay Item Pay Unit Symbol

Contaminated Soil, Remove ...................................................... CYS

620 Houses and Buildings, Parcel No. _____, Remove ................... LS
Pavement Removal .................................................................... SYS
Present Structure, Str. No. _____, Remove Portion .................. LS
Present Structure, Str. No. _____, Remove ............................... LS
147
 202.14

____________, Remove ............................................................ EACH

specific work LFT
SYS
Regulated Asbestos Containing Materials, Remove.................. SFT
Regulated Materials, Dispose, _____ ........................................ GAL.
type CYS
630 TON
DRUM
EACH
Regulated Materials, Remove, _____........................................ GAL.
type CYS
TON
DRUM
EACH
Regulated Materials, Transport, _____ ..................................... GAL.
type CYS
640 TON
DRUM
EACH
Structures and Obstructions, Remove........................................ LS
Testing for Asbestos .................................................................. EACH
Testing for Wastes, _____ ......................................................... EACH
type
Underground Storage Tank, Liquid Waste Disposal, _____ ..... GAL.
type
Underground Storage Tank, Remove and Dispose,
650 Under 3,000 Gallons Capacity ............................................ EACH
Underground Storage Tank, Remove and Dispose,
3,000 through 6,000 Gallons Capacity ............................... EACH
Underground Storage Tank, Remove and Dispose,
6,000 through 10,000 Gallons Capacity ............................. EACH
Underground Storage Tank, Remove and Dispose,
Over 10,000 Gallons Capacity ............................................ EACH

The cost of removal and disposal of buildings, foundations, debris and unsuitable
material, guide posts, delineator posts, temporary road material, existing asphalt
660 patches, the filling of abandoned wells; terminating utilities; sealing floor drains where
necessary; breaking basement floors; furnishing and erecting all barricades, fences,
and other safety measures necessary for adequate protection of the sites; and backfill
of basements or depressions left by demolition shall be included in the cost of the pay
items of this section. All fence posts and concrete footings shall be completely
removed and the resulting holes backfilled accordingly.

If no contract price is listed in the Schedule of Pay Items for work set out herein,
no direct payment will be made for compliance with the requirements for such work,

148
 202.14

except as set out herein. The cost thereof shall be included in the cost of other pay
670 items.

If the houses and buildings listed for removal from a designated parcel are not in
existence at the time of the letting, no payment will be made for removal work on such
parcel.

The cost of removing the tanks and all pipe from the ground, removal and disposal
of all miscellaneous parts associated with the tank such as concrete pads or holding
devices, filing of all required notifications, preparation and implementation of a site
operation plan, excavation of all materials necessary in order to remove the tank,
680 compliance with closure requirements, all necessary pedestrian safety fencing,
cleaning and draining of tanks and pipes, dismantling or transport, and all required
record keeping or reports shall be included in the cost of underground storage tanks,
remove and dispose. However, disposal of waste contents and removal of
contaminated soil will be paid for separately. No payment will be made for work not
performed in accordance with the specifications or not required by the contract.

The cost of all on-site or off-site storage of the materials shall be included in the
cost of transportation.

690 All disposal fees and recycling or treatment costs required for regulated materials
found within the project limits shall be included in the cost of regulated materials,
dispose. If regulated materials are treated on site and not disposed of at an approved
location, payment will be in accordance with 104.03.

The cost of removal of all regulated asbestos-containing materials and all safety
procedures shall be included in the cost of regulated asbestos containing materials,
remove.

The cost of packaging regulated materials, excavation, restoring ground lines, and
700 maintaining and filing required documents and reports shall be included in the cost of
the pay items.

The cost of removal of regulated asbestos-containing materials shall include only

the removal of material identified in the contract or by the Engineer as regulated
asbestos-containing material. Regulated asbestos-containing materials include the
following:

(a) friable asbestos-containing material;

710 (b) Category I non-friable asbestos-containing material that has

become friable or will be subjected to sanding, grinding,
cutting, abrading, or burning;

(c) transite-like material; and

149
 203.01

(d) other Category II non-friable asbestos-containing material that

has a high probability of becoming or has become crumbled,
pulverized, or reduced to powder by the forces expected to act
on the material in the course of normal demolition operations.
720
Unless directed by the contract or the Engineer, the cost of asbestos removal shall
not include the removal of Category I or II non-friable asbestos-containing material
that is not friable or does not have a high probability of becoming friable but which
becomes friable because the Contractor uses demolition methods that cause such
materials to become regulated. Such cost shall be included in the cost of other pay
items.

The cost of all labor, equipment, materials, and documentation required for
complying with the applicable laws, regulations and procedures, including but not
730 limited to, licenses, permits, other legal fees, or disposal charges shall be included in
the cost of the pay items. No payment will be made for work which is not performed
in accordance with the specifications or that which is not required by the contract.

The cost of removal of specific work shall include the removal and disposal of
such obstructions, the necessary excavation required, salvage of materials removed,
their custody, preservation, storage on the right-of-way, and disposal as provided
herein. All damage to existing facilities caused by the Contractor’s operations or
equipment shall be satisfactorily replaced or repaired with no additional payment.

740 If it is necessary to package the contaminated soil in a container, the cost of the
container and all cost related to packaging shall be included in the cost of removal.
The cost of all excavation pertaining to contaminated soil, removal of all soil within
the limits established by the Engineer, restoring ground lines, maintaining required
records and filing of reports shall be included in the cost of contaminated soil, remove.
No payment will be made for work beyond the limits established by the Engineer,
work not performed in accordance with the specifications, or work not required by the
contract unless in accordance with 104.03.

The cost of all handling of the product, removal of the product from the tank,
750 disposal, all required packaging, and transportation shall be included in the cost of
underground storage tank, liquid waste disposal.

All necessary cleanup of spills caused by the Contractor will not be paid for.

SECTION 203 – EXCAVATION AND EMBANKMENT

203.01 Description
This work shall consist of embankment construction and excavation, hauling, and
disposal or compaction of all material not being removed under some other item which

150
 203.07

is encountered within the limits of the work and also from intersecting entrance
approaches beyond the right-of-way limits necessary for the construction of the
roadway in accordance with 105.03. All excavation will be classified as hereinafter
described.
10
203.02 Common Excavation
Common excavation shall consist of all excavation not included as rock
excavation or excavation which is otherwise classified and paid for, including asphalt
type pavement. Coal ash encountered within the project limits shall be used in
embankments under the same conditions as borrow in accordance with 203.08.2. If
coal ash is encountered within the project limits, appropriate measures as described in
203.23.1 shall be used to prevent movement of coal ash from the project.

203.03 Rock Excavation

20 Rock excavation shall consist of igneous, metamorphic, and sedimentary rock or
other sound mineral matter which cannot be readily excavated by the use of a crawler
mounted hydraulic excavator of not less than 40,000 lbs gross operating weight
equipped with a general purpose excavator bucket of not less than 1 cu yd capacity, in
satisfactory running condition and operated in accordance with the manufacturers
recommended operating instructions. Rock excavation shall also include all boulders
and other detached stones each having a volume of 1/2 cu yd or more.

203.04 Unclassified Excavation

Unclassified excavation shall consist of the excavation and disposal of all
30 materials of whatever character encountered in the work.

203.05 Peat Excavation

Peat excavation shall consist of the necessary excavation and satisfactory disposal
of peat, muck, marl, or any other similar unsuitable material in peat deposits, together
with any overlaying material, except pavement, which is not used in embankment
construction, except as otherwise provided in 203.16.

203.06 Waterway Excavation

Waterway excavation shall consist of the necessary excavation and satisfactory
40 disposal of all material resulting from excavation for clearing waterways, making
channel changes, or both when such are itemized in the Proposal book, but shall not
include class Y excavation, or excavation made for a structure in accordance with 206.
If not otherwise specified, waterways shall be cleared for the entire distance within the
right-of-way lines.

203.07 Class Y Excavation

Class Y excavation shall consist of material encountered within the limits of
waterway excavation which can be classified as rock in accordance with 203.03, or
material which consists of conglomerate, concrete, masonry, or any similar material
50 which is not part of an existing structure shown on the plans. Material as defined in
203.02 will not be considered as class Y excavation.

151
 203.08

203.08 Borrow or Disposal

Borrow shall consist of approved material required for the construction of
embankments or for other portions of the work and shall be obtained from accepted
locations and sources outside the right-of-way. Borrow material shall be free of
substances that will form deleterious deposits, or produce toxic concentrations or
combinations that may be harmful to human, animal, plant or aquatic life, or otherwise
impair the designated uses of a stream or area. Unless otherwise designated in the
60 contract, arrangements shall be made for obtaining borrow. Borrow, as designated
herein, shall not include material excavated beyond the right-of-way limits at
intersecting public roads, private and commercial drive approaches and material
furnished as B borrow.

Disposal of material, other than regulated material and bridge painting debris,
from within the right-of-way shall only be allowed at accepted locations. Disposal of
regulated material shall be in accordance with 104.06. Disposal of bridge painting
debris shall be in accordance with 619.

70 Proposed borrow and disposal sites shall be accepted by the Engineer prior to the
start of any borrow or disposal operations at the site. For each proposed site, an IC-
203 Request for Acceptance of Borrow or Disposal Site form, available on the
Department's website, shall be submitted to the Engineer a minimum of 14 days prior
to the Contractor’s planned start of operations at the site. All requests for acceptance
of a borrow or disposal site shall be in accordance with 203.08(a).

Acceptance of any proposed borrow or disposal site by the Engineer shall not
relieve the Contractor of the responsibility to utilize an appropriate site and to comply
with all applicable local, State and Federal laws and regulations.
80
The Contractor shall provide the Engineer a minimum of 14 days notice prior to
opening borrow areas in order to obtain original cross sections, measurements, and
borrow material samples prior to borrow area use.

No extension of completion time will be granted due to any delays by the

Contractor in securing acceptance of borrow and disposal sites.

(a) Borrow and Disposal Site Requirements

Any proposed borrow or disposal site submitted for acceptance shall be presented
90 as, and meet the requirements of one of the following site definitions.

1. Solid Waste Site

A Solid Waste Site shall be defined as a solid waste facility, in accordance with
329 IAC 10-2-176, with a current IDEM operating number.

A request for acceptance of a Solid Waste Site shall include the following:

152
 203.08

a. Name and contact information of the facility operator.

100 b. Address of the facility.

c. The IDEM operating number.

d. The expiration date of the IDEM operating permit.

2. Established Site
An Established Site shall be defined as an established location, other than as
defined in 203.08(a)1, proposed for borrow or disposal activity that is disturbed or
developed for public, municipal, governmental, commercial, industrial, construction
110 or any other similar or related activity. The Established Site shall be operating under
permits required by local, State and Federal laws for the activities proposed by the
Contractor.

A request for acceptance of an Established Site shall include the following:

a. Name and contact information of the site owner.

b. Address of the site.

120 c. Copy of a right-of-entry obtained from the property

owner. Rights-of-entry shall include rights for access
by Department personnel to the site.

d. Aerial view site plan with the location of the borrow or

disposal areas delineated.

e. Location of all proposed stormwater management

features for the delineated borrow or disposal area.

130 f. List of the documented permits, permit numbers and

permit expiration dates for all permits under which the
site operates.

g. Documentation that a wetlands delineation and an

archaeological field survey, with record check, have
been performed by qualified professionals shall be
provided when borrow or disposal activities are
identified for areas of the proposed site that remain
undeveloped or undisturbed.
140
Any required wetlands delineation and archaeological
field surveys, with record check, shall be limited to

153
 203.08

those undeveloped and undisturbed areas identified for

borrow or disposal that are greater than 0.1 acres.

3. General Site
A General Site shall be defined as a location, other than as defined in 203.08(a)1
and 203.08(a)2, that has not been disturbed or developed for public, municipal,
governmental, commercial, industrial, construction, or other similar or related activity.
150 A General Site shall include private, residential, agricultural fields and pastures, or any
other similar or related locations. General Sites shall require additional documentation
for acceptance.

A request for acceptance of a General Site shall include the following:

a. Name and contact information of the property owner.

b. Address or location of the site.

160 c. Copy of a right-of-entry obtained from the property

owner. Rights-of-entry shall include rights for access
by Department personnel to the site.

d. Site location plan, site dimensions, adjacent property

and right-of-way lines, all demarcated jurisdictional
wetlands or isolated wetlands, all demarcated
archeological sites, existing and proposed finished
contours and proposed finished slope grades.

170 e. Site operations plan detailing the operations proposed

for the site, what equipment will be utilized, how the
site will be accessed and any other information relevant
to the operation of the site.

f. Copy of the Rule 5 Notice of Intent, if required in

accordance with 327 IAC 15-5.

g. Stormwater management plan for the site including the

stormwater features to be incorporated and the
180 sequencing of the measures with respect to the
operations plan for the site.

h. Documentation signed by a wetlands professional

verifying that the site has been inspected for the
presence of both wetlands and isolated wetlands and, if
any are present, specifying the area to be demarcated as
jurisdictional or isolated wetlands.

154
 203.08

i. Documentation of the archeological field survey, with

190 record check, signed by a qualified archeologist
including the limits and border of any archeological site
discovered.

j. Copies of all other permits obtained by the Contractor

to perform operations at the site.

k. Documentation, in the form of a signed and notarized

certification from the property owner, that the proposed
site is not currently an active remediation or corrective
200 action site operating under an IDEM or EPA cleanup
program, and that there are no environmental liens,
easements, deed restrictions, or environmental
restrictive covenants against the proposed site location.
If environmental liens, easements, deed restrictions, or
environmental restrictive covenants exist for the
proposed site location, the Contractor shall provide
copies of the restriction and written approval from the
regulatory agencies having an interest in, or jurisdiction
over the proposed site approving use of the site for the
210 borrow or disposal operations.

When a General Site is identified for borrow or disposal, the Contractor shall
obtain all permits required by local, State and Federal laws prior to the start of any
operations at the site.

All proposed General Sites shall have an inspection of areas impacted by the
borrow or disposal operations conducted by a qualified wetland professional approved
by the Department to determine if wetlands are present on the site. A list of approved
wetland professionals is maintained on the Department's website. The wetlands
220 inspection shall be in accordance with the Federal Manual for Identifying and
Delineating Jurisdictional Wetlands. The inspection shall also determine if isolated
wetlands as defined by IDEM are present. The Contractor shall demarcate the
boundary of all wetlands identified within the proposed borrow or disposal site in a
method acceptable to the Engineer.

Proposed General Sites shall have a qualified archaeologist perform a field

survey, with record check, to determine if any significant archeological sites exist
within the proposed site. The Indiana Department of Natural Resources Division of
Historic Preservation and Archeology maintains a roster of qualified archeological
230 consultants. If any archaeological sites are identified, the archaeologist shall establish
the limits of the site along with a reasonable border. The Contractor shall demarcate
the border of all identified archeological sites within the proposed borrow or disposal
site in a method acceptable to the Engineer.

155
 203.08

(b) Additional Requirements

Identified archeological sites shall not be disturbed unless the site is cleared by
established procedures and written authorization to enter the site has been obtained
from the Department’s Cultural Recourses office. Archaeological artifacts
encountered during operations shall be addressed in accordance with 107.10.
240
No excavation shall occur and no material shall be disposed of within the
boundaries of the demarcated wetlands and archeological areas unless the operations
are in compliance with all required permits and these specifications.

The Contractor shall install all temporary stormwater management control

measures at accepted borrow and disposal locations designated as Established Sites
and General Sites prior to the start of any earth disturbing activity. The Contractor
shall develop and construct all mitigation measures necessary to fulfill the
requirements of all permits obtained by the Contractor for operation of a borrow and
250 disposal site.

No excavation shall occur or no material shall be disposed of within the

boundaries of the demarcated wetlands and archeological areas unless the operations
are in compliance with all required permits and these specifications.

No extension of completion time will be granted due to any delays by the

Contractor in securing approval of borrow and disposal sites.

Unless written permission is granted, there shall be no excavation in a borrow area

260 below the elevation of the adjacent properties within 150 ft of the nearest right-of-way
line of an existing highway, county road, or city street; the nearest right-of-way line
of a proposed highway, county road, or city street; or adjacent property lines. If the
properties adjacent to the borrow area are privately owned, the setback limit of 150 ft
may be lessened if written approval or permission is granted by the owner of the
adjacent property, the excavation is in accordance with local zoning laws and
requirements, and if lessening the limit is in the best interest of the State. Such
minimum distance shall not be closer than 50 ft to an adjacent property line. All
excavated slopes of a borrow area shall not be steeper than 3:1 down to 2 ft below the
ground water elevation. All excavated slopes 2 ft below the ground water elevation
270 shall not be steeper than 2:1.

Top soil from the borrow or disposal area shall be stockpiled for use in restoring
the disturbed area. A minimum encasement of 6 in. shall be placed on the 3:1 or flatter
slopes. Final restoration of borrow or waste disposal areas shall include grading,
seeding, or other necessary treatments that will blend the area into the surrounding
landscape. Restored areas within 150 ft of the nearest right-of-way line shall be well
drained. Areas beyond 150 ft shall be drained unless the landowner desires other
treatment of the borrow area. Construction of borrow or disposal areas shall be in
accordance with existing laws, regulations, and ordinances. Under no conditions shall

156
 203.08.2

280 borrow sites detract from the appearance of the natural topographical features or
increase the potential hazard to a vehicle that has inadvertently left the highway.

If granulated slag, dunes sand, or other granular material which is not suitable for
the growth of vegetation is used, such material shall not be placed within 1 ft of the
required finished surfaces of shoulders and fill slopes. Additional material required to
complete the embankment, such as sandy loam, sandy clay loam, clay loam, clay, or
other materials suitable for the growth of vegetation and free from clods, debris, and
stones, shall be furnished at the contract price for borrow.

290 Additional fill material may be secured from within the permanent or temporary
right-of-way in lieu of borrow or B borrow either from vertical or horizontal
extensions, or both, beyond the lines and elevations of roadway and drainage
excavation as shown on the contract plans when authorized in writing. If additional
material has been obtained without written approval, the material will be classified
either as to source or use, to the best advantage of the Department.

203.08.1 Linear Grading

Linear grading shall consist of:

300 (a) earth wedging at the outside edge of a shoulder once the
pavement has been resurfaced, widened, or replaced;

(b) earth wedging behind guardrail to obtain the required earth

backup for the posts;

(c) median earth filling required for paving and placement of

concrete median barrier.

These types of earthwork will not require benching.

310
203.08.2 Coal Ash
Borrow may also consist of coal ash.

Coal ash is defined as either fly ash, bottom ash, or a mixture of both. Fly ash is
further defined as coal ash with 70% or less passing the No. 200 (75 µm) sieve. Bottom
ash is further defined as coal ash with 20% or less passing the No. 200 (75 µm) sieve
and 10% or less retained on the No. 10 (2.0 mm) sieve.

Boron levels in coal ash shall be less than 5 ppm as determined using the Indiana
320 Neutral Leachate Testing, INLT, methodology.

The Contractor shall provide a copy of an IDEM waste classification certification

for Type III or Type IV material prior to use. The IDEM certification shall identify the
size and geographical location of the coal ash stockpile.

157
 203.09

The Contractor shall also provide a type A certification in accordance with 916
prior to use of coal ash. The type A certification shall include the following:

1. Name of the laboratory performing the tests.

330 2. Location and owner of the stockpile.
3. Date the samples were obtained.
4. Date the samples were tested.
5. Stockpile sampling locations including depth and available
historical testing results.
6. Gradation in accordance with AASHTO T 88.
7. Atterberg limits in accordance with AASHTO T 89 and T 90.
8. Standard Proctor in accordance with AASHTO T 99.
9. Level of boron.

340 All tests shall be performed by a laboratory from the Department’s list of
Approved Geotechnical Laboratories. Tests shall be submitted to the Engineer and to
the Geotechnical Services Section for approval at least five business days prior to use.

If coal ash is obtained from a commercial source, such as a power plant, the
Contractor shall also provide a letter from the source allowing access by Department
personnel for the purpose of inspecting the processes used to produce the coal ash
stockpile and for sampling the stockpile for testing by the Department.

CONSTRUCTION REQUIREMENTS
350
203.09 General Requirements
The excavation and embankments for the roadway, intersections, and entrances
shall be finished to reasonably smooth and uniform surfaces. Excavated materials shall
not be wasted without permission. Excavation operations shall be conducted so that
material outside the limits of slopes will not be disturbed. Prior to beginning
excavation, grading, or embankment operations in any area, all necessary clearing and
grubbing in that area shall have been performed in accordance with 201.

The Contractor shall stabilize an area if disturbed ground is anticipated to be left

360 bare and unworked for seven consecutive calendar days or if directed. The stormwater
management control features shall be installed in accordance with 205 or as otherwise
directed. The area of the exposed materials shall be limited by the Contractor’s
capacity to adequately maintain permanent and temporary stormwater management
control features.

Soils containing organic material greater than 6% by dry weight, or soils with a
maximum dry density of less than 90 pcf shall not be incorporated in the embankment.
Organic content will be determined in accordance with AASHTO T 267, and
maximum dry density will be determined in accordance with AASHTO T 99.
370
Frozen materials, stumps, roots, all or parts of trees, brush, weeds, sod, or other
perishable materials shall not be incorporated in the embankment. Rocks greater than
158
 203.09

3 in. in any dimension shall not be left within 18 in. of the finished subgrade. The
original ground surface, or the surface of any lift in place shall not be frozen and shall
be free of snow, ice, or mud.

All vegetation, all spongy, yielding, soft, and unstable materials, which are
encountered, shall be removed as shown on the plans or as directed. Removed
materials may only be used in embankment construction if they are constructed in
380 accordance with 203.23.

After clearing of the embankment area and prior to embankment placement, all
pronounced depressions left in the original ground shall be filled with suitable material
and compacted in accordance with 203. Proofrolling of the natural ground surface shall
be performed in accordance with 203.26 within all areas where new fill shall be placed.

If the original ground cannot be compacted to the required strength because of

soft or unstable soils, the use of stabilizing materials consisting of coarse aggregate
No. 5 encapsulated in geotextile, in accordance with 214.03(a), or soil drying with a
390 chemical modifier in accordance with 217 shall be used as directed. The coarse
aggregate materials used for stabilization shall be 1 to 2 ft thick and shall allow the
encapsulated material in the embankment to drain.

When free water is encountered, backfilling shall be accomplished using B

borrow, in accordance with 211.02, to an elevation at least 2 ft above the free water
level. Compaction of the B borrow placed above the free water level shall be
accomplished using heavy vibratory equipment.

The use of hydraulic methods to construct embankments will be allowed only

400 when authorized in writing. Only B borrow shall be placed below the free water level.
Backfill at structures shall be in accordance with 211.04.

The embankment shall be kept drained at all times by keeping the center higher
than the sides and uniformly graded.

Each embankment lift shall extend transversely over the entire area and shall be
kept smooth. When fill materials are deposited in large masses onto the embankment,
the materials shall be spread out in uniform lifts. Rock or shale used for embankment
construction shall be in accordance with 203.20.
410
When grading operations are performed in non-daylight hours, artificial lighting
shall be provided and maintained, to enable the construction and inspection of the
operations.

When the embankment soils are granular, silty loam, sandy loam, silts, or when
the plasticity index of the material is less than 8, the embankment shall be encased
with materials consisting of silty clay loam, clay loam, sandy clay loam, or silty clay
of 12 in. minimum depth measured perpendicular to the face of the slope. The

159
 203.10

plasticity index for these materials shall be equal to or greater than 8 and the organic
420 content shall not exceed 6%. The surface of any necessary encasement shall meet the
finished slope limits shown on the plans or as directed.

All slopes, which are to be graded and not immediately stabilized with stormwater
management control measures, shall be roughened, as described herein, until
stormwater management control measures are placed. The soil slopes shall be
roughened to create a series of ridges and depressions parallel to the contour making
grooves at least 1 in. deep and not more than 15 in. apart. Slopes shall be stabilized in
accordance with 205. Roughening shall take place each day after work is performed
on the slopes, or as directed to re-establish the roughening.
430
Sufficient quantities of excavated materials suitable for the growth of vegetation
shall be preserved from within the planned excavation area and used on constructed
cut, fill, and shoulder slopes to help develop the growth of vegetation. Materials
suitable for vegetative growth shall be at least 6 in. deep or as indicated within the
contract documents and shall be measured perpendicular to the face of the slope.
Unless otherwise provided, no additional compensation will be allowed for this work
except payment will be made for the class of excavation involved for authorized
undercutting of back slopes. Encasement of rock embankment and cut slopes will not
be required unless otherwise directed.
440
Material suitable for the growth of vegetation shall be in accordance with 914.01
prior to placement. The material placed on backslopes of cut sections shall be placed
in accordance with 203.21.

If sufficient excavation materials suitable for the growth of vegetation and used
on constructed cut, fill, and shoulder slopes are not available, borrow or other material
suitable for vegetative growth shall be furnished. The sources of all borrow material
shall be in accordance with 203.08 and 914.01. Payment for borrow will be made in
accordance with 203.28. If the contract does not contain a pay item for borrow, a
450 change order will be executed for payment of borrow. Suitable portions of common
excavation may be preserved or borrow material may be furnished for encasement
provided all suitable excavation is used constructively.

203.10 Disposal of Excavated Material except Waterway and Peat

Excavation
Excavation material shall be used for the construction of embankments, shoulders,
special fill, or other places as may be specified or directed, depending on the nature of
the material. Excavated material that is suitable for embankment construction, that is
not required for maintenance of traffic, shall be placed in the embankment before
460 placing any borrow material, unless otherwise authorized in writing.

If more material is excavated from within required cut slopelines than is needed
to construct embankments or special fills, the excess may be used to widen
embankments, flatten fill slopes, or be used otherwise as directed. All excess

160
 203.14

excavated material that cannot be used constructively within the project limits shall be
disposed of off the right-of-way in accordance with 203.08.

Excavation obtained from the right-of-way and planned to be used in fills may be
wasted and replaced with borrow with no additional payment only after written
470 permission is obtained. All required samples of the borrow or the excavation materials
involved shall be furnished with no additional payment.

203.11 Disposal of Waterway Excavation

Unless otherwise provided, material resulting from waterway excavation shall be
used, if suitable, in embankment, special fill, approach embankments, or any
combination of these, as specified or directed.

Any portion of waterway excavation material which is unsuitable for the above
uses, any portion which is suitable but is in excess of that required for such uses, or
480 when locations for such uses are not available, the material shall be disposed of in
accordance with 203.08.

203.12 Disposal of Peat

All material removed as peat excavation, removed or displaced by machine
operation, or displaced by the advancing backfilling material shall be disposed of in
accordance with 203.08.

203.13 Slides
Slides encountered during construction shall be removed as directed and their
490 removal will be paid for as the class or classes of excavation encountered.

If the contract involves paving, the omission or delay of paving operations may
be required at the location of a slide. If proper treatment of a slide has been obtained
prior to completion of the remaining pavement, the gap may be required to be paved,
and payment will be at the contract unit price for pavement.

If proper treatment of a slide has not been obtained prior to completion of the
remaining pavement, the gap left at the slide location shall become an exception to the
contract item for pavement.
500
203.14 Drainage
Ditches shall be interpreted to mean open ditches and channel changes parallel to
and adjacent to the roadbed. Channel changes excavated under the classification of
waterway excavation are not included in this definition.

Lines, grades, and cross sections of ditches shall be as shown on the plans, unless
otherwise established to obtain proper drainage.

Ditches and gutters emptying from cuts onto embankment shall be constructed to
510 avoid eroding the embankment.

161
 203.15

Exploration of underground drainage and sinkholes may be required, and payment

will be hereinafter provided. Should any underground drain be encountered, the
location of which is not shown on the plans, notification shall be made at once.
Drainage shall be explored as directed and, if deemed necessary, taken care of under
applicable provisions of these specifications, or as otherwise directed.

If existing surface drains, tile drains, sewers, or other underground drains, or parts
thereof, are not to be replaced or are not required by the terms of the contract or
520 directed to be changed, whether such drainage facilities are shown on the plans or not,
all such drainage facilities or parts thereof shall be protected, preserved, and
satisfactorily continued in use without change. If in the prosecution of the work such
existing drainage is changed or interrupted, or through negligence such drainage is
interrupted or damaged, satisfactory permanent repairs shall be immediately provided
or adequate temporary drainage facilities shall be maintained until permanent repairs
are made. If temporary facilities are provided, before the work is accepted, such
damage or interrupted drainage facilities shall be restored to the original condition or
to an altered state which is at least equal to their original condition.

530 If slopes or ditches which were graded for a grading contract become eroded or
scoured during the paving contract work, the scoured or eroded areas shall be reshaped
to the original cross section and reseeded or resodded as shown on the plans, all in
accordance with 208 and 621.

When so provided by the plans or special provisions, or when ordered, all tile
drains, sewers, or other underground drains encountered in the prosecution of the
contract shall be repaired, replaced, extended, reconstructed, connected, or otherwise
changed.

540 Unless otherwise provided in the contract, the cost of replacing, restoring, or
connecting an underground drain which is substantially in its original location and
incidental to roadway and drainage excavation, structures, or other drains will not be
paid for directly, but the cost thereof shall be included in the cost of various pay items.

Unless otherwise provided, any necessary drainage change or restoration not

shown on the plans and not due to negligence or operations of the Contractor will be
paid for at the contract unit price or prices thereof. If there is no such contract unit
price or prices, such work shall be done and payment made in accordance with 104.03.

550 203.15 Excavating Rock

If material is encountered during excavation which appears to belong in the
classification of rock excavation in accordance with 203.03, notification shall be made
in writing. Ample time shall be allowed to make such investigation and measurements
that are necessary to determine the class and volume of the material in question.

Exploratory cores shall be taken from the top of the rock to approximately
subgrade elevation as directed. The cores shall be cut with standard diamond core bits

162
 203.15

and series X double tube core barrels to obtain 2 1/8 in. diameter samples. All cores
shall be suitably marked and identified to show the location of the core by station,
560 offset from centerline, elevation of top of rock, depth below top of rock, and percent
recovery within each core. All cores shall be retained. The cores shall be placed in
suitable compartmented wooden boxes in the order in which removed from the boring,
with dividers between core runs. The top and bottom of each run shall be appropriately
marked. The cores shall be transported to a location as directed.

The top of rock elevations shall be determined prior to locating the top of soil cut
slopes where finished rock slopes are planned to be 1:1 or steeper.

Final breakage of rock excavation shall be in accordance with or closely

570 approximate the slope lines shown on the plans unless different slope lines are fixed,
and the Contractor so notified. The final slopes shall be left reasonably smooth and
uniform, and all loose and overhanging rock removed. Unless otherwise specified, no
rock shall finally project more than 1 ft beyond established slopes. If natural seams
intersect an established slope, the excavation may be carried, with permission, along
the face of such seams for the distance approved.

Rock shall be excavated to the required elevation for the full width of the roadbed
as shown on the plans or as directed. Where rock is excavated below the required
elevation, the area shall be backfilled to the subgrade elevation with crushed stone,
580 spalls, subbase material, or other approved granular material, which shall be shaped
and compacted to the required elevation and cross section.

Exploratory drilling, which shall consist of drilling holes for the purpose of
determining the existence of cavities affecting underground drainage and possible
sinkholes in cut sections, may be required at locations as directed. Unless otherwise
directed, the holes shall be drilled on the centerline of the proposed pavement at
approximately 100 ft intervals and shall extend for a depth of 7 ft below the proposed
grade and have a minimum diameter of 1 1/2 in.

590 Where cavities are discovered on centerline, additional holes shall be drilled at
25 ft intervals along the edge of the proposed pavement, and unless otherwise directed,
extend for a depth of 7 ft below the proposed grade. Where any cavity is discovered
or exposed having a minimum cover of less than 5 ft, the cover shall be removed, and
the treatment of such areas shall be in accordance with details in the plans or as
otherwise directed.

The final surface of rock excavation under the roadbed area shall be left so that
drainage between the rock surfaces and any material placed thereon will be
substantially complete. Where seams of clay or other soft material 1 ft or less in
600 thickness are encountered in rock excavation, the volume of such seams will be
considered as rock excavation and paid for as such.

Unless otherwise specified or directed, rock shall be pre-split by drilling and the
use of explosives in such a manner as results in minimum breakage outside neat lines
163
 203.15

of the typical cross section and slope stakes as established. Deposits of commercial
building stone outside the right-of-way shall not be damaged. Holes for pre-splitting
shall be drilled along the established slope stake lines. The holes shall be from 2 to
4 in. in diameter and, unless otherwise directed, be spaced approximately 3 ft apart.
Holes shall be drilled approximately 2 ft below the established grade of the cut, or the
610 predetermined bench elevation, or as directed.

The maximum depth of any pre-split lift shall be 30 ft, unless otherwise directed.
If more than one lift is required, the first line of drill holes shall be set in such a manner
as to allow for a specified offset for each succeeding lift and an offset of 2 ft from the
back of the paved side ditch line. The explosives used and the method of loading
depends on the material to be blasted. These explosives may vary from a single strand
of detonating cord, for blasting unconsolidated formations, to a solid column of
dynamite for massive formations. However, the explosive shall be of a type to
accomplish the pre-splitting with a minimum of breakage outside the excavated area.
620 After the charges are placed, the holes shall be filled with sand or other suitable
granular material.

Except as indicated below, all pre-splitting charges shall be detonated

simultaneously by the use of instantaneous electric blasting caps or by means of a
detonating cord trunkline. The line holes shall be fired before the main excavation is
blasted. Pre-splitting shall be kept well in advance of regular blasting operations.
Primary blasting holes shall be drilled no less than 6 ft from the pre-split face, unless
otherwise directed. If additional charges are required, holes shall be placed at 1/2 the
distance of a full depth hole to a depth such that the bottom of the hole clears the pre-
630 split face approximately 2 ft. The pre-split face shall deviate no more than 6 in. from
the front line of drill holes or more than 12 in. from the back line of drill holes except
where the character of the rock will unavoidably result in some irregularities.

The amount of explosives per shot for instantaneous firing or the amount of
explosives per delay for delay firing shall not be great enough to damage nearby
structures, rock formations, or other property. Where commercial building stone
formations are located in the effective vicinity, adequate seismograph readings shall
be obtained, with no additional payment, as evidence that blasting operations have not
altered existing commercial building stone formations outside the right-of-way limits
640 of the project.

Permission may be granted to use machine methods to establish the finished

slopes in those cuts where machine methods are used to remove roadway excavation,
provided final machine finished slopes are equal or superior to that which would be
obtained by pre-splitting methods.

When or where any direct or indirect damage or injury is done to public or private
property by or on account of any act, omission, neglect, or misconduct in the execution
of the work or in consequence of the non-execution thereof, such property shall be
650 restored, with no additional payment, to a condition similar or equal to that existing

164
 203.16

before such damage or injury was done by repairing, rebuilding, or otherwise restoring
as directed, or such damage or injury shall be made good in an acceptable manner.

No direct payment will be made for pre-splitting, but the cost thereof shall be
included in the pay item of rock excavation or unclassified excavation.

203.16 Peat Deposit Treatment

If construction is specified at a location where a peat deposit is to be treated, the
deposit shall be treated ahead of paving operations to obtain maximum settlement. If
660 settlement has not been obtained when paving operations are at the limits of any peat
deposit treatment, a gap in the pavement shall be left as directed. Gaps not constructed
as part of the project will become an exception to the contract.

Treatment shall be by the following methods:

(a) Treatment of Existing Fills

If the required alignment is on an existing fill over a peat deposit, treatment may
be required by any one or any combination of the following methods:

670 1. removal of the existing fill with or without the removal of

the underlying peat and of the material at the sides of the
existing fill;

2. blasting the peat under the fill;

3. loading the existing fill with additional fill material, and, if

directed, blasting the peat underneath;

4. leaving the existing fill in place and treating the material at

680 the sides either by removing the peat at the sides and
backfilling or by displacement or both;

5. excavating and constructing with lightweight fills.

Determination of the method or methods to be used will be made based on

conclusions from test holes which may be required to be drilled at designated
locations.

(b) Treatment by Removal

690 This method consists of completely removing the objectionable material either as
peat excavation or by machine operation and backfilling to the full toe-width of the
proposed embankment or to such other widths, if so directed depending on the
condition and depth of the material to be removed.

If water is not present, the space previously occupied by the removed material
shall be backfilled with common excavation, borrow, or both, and placed in
accordance with 203.
165
 203.16

If water is present, the backfill shall be with material in accordance with 211.02.
700 Placement of this material shall follow as closely behind the removal of the peat as
possible. It shall be carried across the area from one end to the other by end-dumping
and finally left at the established grade. This grade shall be such that keeps
end-dumping to a minimum, which nominally shall be approximately 2 ft above free
water level. That portion between free water level and this established grade shall be
thoroughly watersoaked to secure maximum compaction.

If additional fill is needed to bring the embankment to its final required grade, it
may be common excavation or borrow. Further placing of the granular material above
the end-dumped material may be authorized. This additional fill shall be placed and
710 compacted in accordance with 203 but shall not be placed for at least 14 days after the
end-dumped material is placed and compacted. This period may be shortened or
lengthened with written approval, depending on the settlement that has been obtained.

(c) Treatment by Displacement

When this method is used, the peat at each end of the deposit shall be removed
completely by excavation to the full width shown on the plans, or to such other width
as may be directed, until a point is reached where the depth of the peat being removed
is greater than 10 ft, or to a greater or lesser depth, as directed.

720 If conditions allow, the upper portions of the remaining peat shall be excavated
across the remainder of the deposit in the same manner as set out above for the ends.
Removal of this upper portion shall begin at one end and proceed to the other end at a
sufficient distance ahead of backfilling operations so displacement of the remaining
peat will not be retarded. If excavation to the required depth is not maintained for the
full width ahead of the backfill or surcharge, additional units shall be used or backfill
operations stopped until the two operations are in balance. If conditions allow,
draglines shall be operated from mats in front of the advancing excavation. If blasting
is required to aid displacement, it shall be completed as extra work in accordance with
104.03.
730
Backfilling shall be in accordance with 203.16(b) for end-dumped material
except, when required, a temporary surcharge shall be maintained at the head of the
backfilling. The top of the surcharge shall be constructed and maintained to a width
equal to the full shoulder width of the proposed embankment, or as approved or
directed. The height of the surcharge shall be the same as the depth of the peat being
treated, unless otherwise directed. The original ground shall be the reference elevation
for measuring peat depths and surcharge heights. The top of the surcharge shall be
approximately level and the length on top shall be at least two times the depth of the
peat being treated. The surcharge shall be kept built up and pushed forward with a
740 bulldozer or other approved equipment as the displacement progresses. Machine
methods shall be used to relieve pressure at the advancing toe and sides of the
surcharge. Sufficient hauling units shall be used to maintain the surcharge at the

166
 203.18

required height, width, and length. The machine operation to augment displacement
shall be coordinated with the rate of placing temporary surcharge.

After the granular backfill has been completed across the deposit, any remaining
fill necessary to bring the embankment up to the required final grade shall be in
accordance with 203.16(b) for that portion above the end-dumped material.

750 203.17 Cased Test Holes

As displacement progresses, cased test holes shall be placed at locations as
directed to determine the extent of peat displacement and for use in conjunction with
final measurement. These holes shall extend to the bottom of the deposit. The boring
shall be conducted in such a manner that accurate information may be obtained as to
the nature of the materials through which the test holes are placed. If these test holes
indicate that full displacement has not been obtained, the remaining peat shall be
blasted or additional treatment shall be performed as required.

Unless otherwise specified in writing, cased test holes shall be placed by hydraulic
760 boring. The external casing shall be a minimum of 2 in. in diameter and of such
additional size as to perform the operation satisfactorily. A continuous supply of fresh
water shall be jetted through an internal pipe so that the wash water and loosened
material is carried to the surface between the jet rod and the external casing. Pumps
and other miscellaneous tools and equipment shall be used as required to perform a
satisfactory operation.

203.18 Embankment Construction

Embankment construction shall consist of constructing roadway embankments,
including preparation of the areas upon which they are to be placed; the construction
770 of dikes within or outside the right-of-way; the placing and compacting of approved
material within roadway areas where unsuitable material has been removed; and the
placing and compacting of embankment material in holes, pits, and other depressions
within the roadway area. Only approved materials shall be used in the construction of
embankment backfill. Rocks, broken concrete, or other solid materials shall not be
placed in embankment areas where piling is to be placed or driven.

Recycled concrete pavement may be used in embankment construction. The

recycled material shall meet the requirements of B borrow in accordance with 211.02
or rock embankment in accordance with 203.20.
780
The recycled concrete pavement may only be placed below the pavement
underdrains and shall be constructed in accordance with 203.23. The recycled concrete
pavement shall not be used within 2 ft of the water table. Proofrolling in accordance
with 203.26 shall be performed to cover the whole grade for every 5 ft of fill. Any rut
greater than 1/2 in. shall be corrected as directed.

A geotextile in accordance with 918.02 shall be placed prior to the placement of

other material when the material is finer than recycled material. A minimum 18 in.

167
 203.19

encasement suitable for vegetation growth shall be constructed in accordance with

790 203.09.

203.19 Embankment Over and Around Structures

Fill shall not be placed against any new masonry abutment, wingwall, retaining
wall, or culvert, or over any culvert, bridge, or arch until approved. Applicable
provisions of 702.23 shall be met.

Filling around culverts, bents, and piers, and fill below the natural ground surface
at abutments, wings, and retaining walls shall be deposited on both sides to
approximately the same elevation at the same time. Piers or bents shall not be displaced
800 and shall be checked for proper location as the work progresses. Corrective measures
shall be made if necessary. Filling at arch structures shall be carried up in horizontal
layers, symmetrically from haunch to crown, and simultaneously over and against all
piers, abutments, and arch rings.

Wedging action of filling material against structures shall be prevented. If

directed, back slopes of excavation shall be destroyed by stepping or serrating.

The embankments around the end bents shall be constructed to approximate

subgrade elevation for a distance of no less than 75 ft. This work shall be done before
810 piling in the end bents are driven, and before the end bent or abutment is constructed.
Compaction shall be in accordance with 203.23. After the embankments are
completed, the embankments shall be excavated to construct the end bents and berms.
Before driving piles, pilot holes to receive the piling shall be predrilled through the
embankment in accordance with 701.09(a). After the piles have been driven, the space
between the pile and the predrilled hole shall be backfilled with granular material as
directed. If the embankment in the area of the end bents is to consist of sand, gravel,
or other permeable material in which a predrilled hole would not remain open, the
piling shall be driven before the embankment is constructed. No direct payment will
be made for excavation of the embankment at the end bents or abutments, or for
820 predrilling, backfilling holes, or excavating fill; those costs shall be included in the
cost of other pay items.

203.20 Rock and Shale Embankment

Utilization of these materials in embankment construction shall be in accordance
with the following.

(a) Rock Embankment

Where rock is used for embankment, no large stones shall be allowed to nest but
shall be distributed over the area to avoid pockets. Voids shall be filled carefully with
830 small stones. The final 2 ft of the embankment just below the subgrade elevation shall
be composed of suitable material placed in layers not exceeding 8 in. loose
measurement and compacted to the required density. Shale or shale-like materials shall
not be incorporated in the upper 2 ft of the embankment.

168
 203.20

Where the depth of an embankment exceeds 5 ft and is to consist entirely of rock,

the rock shall be deposited in lifts not to exceed the top size of the material being
placed, but in no event exceeding 4 ft. The rock for any particular lift shall be deposited
on and pushed over the end of the lift being constructed by means of bulldozers or
other approved equipment. Depositing of rock over the end of any lift from hauling
840 equipment will not be allowed. If the voids of the last lift are not closed sufficiently,
they shall be choked with small broken stone or other suitable material and compacted
as directed. A geotextile in accordance with 918.02(a), Type 2A shall be placed
between the rock and the soil.

Where the depth of embankment is 5 ft or less, or where the material being placed
does not consist entirely of rock, the material shall be placed in lifts not to exceed the
top size of the rock being placed but not exceeding 2 ft. Each layer shall be choked
thoroughly with broken stone or other suitable material and be compacted to the
required density or as directed. A geotextile in accordance with 918.02(a), Type 2A
850 shall be placed between the rock and the soil.

Where a rock fill is to be placed over a structure, the structure shall first be covered
with 2 to 4 ft of earth or other approved material, and properly compacted before the
rock is placed. This covering shall be placed in accordance with 203.19.

Shale shall not be incorporated as rock embankment unless written permission is

obtained.

(b) Shale, Shale and Soft Rock Mixtures, or Soft Rock

860 When these materials are encountered and are to be used for embankment
construction, the compaction shall be accomplished with an approved vibratory
tamping-foot roller in conjunction with a static tamping-foot roller. The minimum
weight for the static tamping-foot roller shall be 30 t. The minimum total compactive
effort for the vibratory tamping-foot roller shall be 27.5 t. Total compactive effort is
defined as that portion of the static weight acting upon the unsprung compaction drum
added to the centrifugal force provided by that drum. If the manufacturer’s charts do
not list the static weight acting on the compaction drum, the roller shall be
satisfactorily weighed, the weight shall be added to the centrifugal force, and the roller
rated in accordance with the Construction Industry Manufacturers Association, CIMA.
870 Each tamping foot on the static roller shall project from the drum a minimum of 6 in.
Each tamping-foot on the vibratory tamping-foot roller shall project from the drum a
minimum of 4 in. The surface area of the end of each foot on both tamping-foot rollers
shall be no less than 5 1/2 sq in.

Shale, shale and soft rock mixtures, or soft rock shall be placed in 8 in. maximum
loose lifts. Strength and moisture control for compacted soils shall be in accordance
with 203.23 or the density shall be at least 95% of maximum dry density with moisture
control in accordance with 203.23. Excavation and blasting procedures shall
accommodate the selective placement of these materials and avoid intermixing rock.
880 Rock shall be placed in accordance with 203.20(a).

169
 203.21

Water shall be applied to the shale in the cut to accelerate the slaking action and
again prior to disking and compaction to facilitate the compaction. The water shall be
distributed by an approved method which provides uniform application of the required
quantity of water. The water shall be uniformly incorporated throughout the entire lift
by a multiple gang disk with a minimum disk wheel diameter of 24 in.

Unless otherwise approved in writing, each embankment lift shall receive a

minimum of three passes with the static roller and a minimum of two passes with the
890 vibratory roller. The material shall be bladed before using the vibratory tamping-foot
roller. A pass shall be in accordance with 402.15. The rollers shall not exceed 3 mph
during these passes. The number of passes will be adjusted upward if necessary to
meet the requirements of 203.23. No additional compensation will be allowed for
additional passes as specified herein, the cost of which shall be included in the cost of
the pay items.

Water required to facilitate the slaking and compaction of the shale or soft rock
will be measured in accordance with 203.27(h) and paid for in accordance with 203.28.
No payment will be allowed for any water required for compaction of material
900 furnished as borrow.

(c) Shale and Thinly Layered Limestone

In Dearborn, Decatur, Fayette, Franklin, Jefferson, Ohio, Ripley, Rush,
Switzerland, Union, and Wayne Counties specifically, or in other areas where
relatively thin layered shale and rock are encountered, their use will be allowed in the
construction of embankment, if the following provisions, in addition to those stated in
203.20(b), are observed.

1. The slopes shall be encased with a minimum of 10 ft of

910 relatively impervious, non-shale, non-erodable material.

2. The maximum size of limestone in the mixture shall be 6

in. in thickness and 1.5 ft in any other dimension.

3. The minimum number of passes with static roller and the

vibratory tamping-foot roller shall be six static and two
vibratory.

If the material is found to be too intermixed with limestone fragments to enable

920 field density tests as required in this section, this requirement may be waived by
written permission. As an alternate to this requirement, proofrolling shall be performed
after every four lifts, and the moisture content will be controlled on clayey soils in
accordance with 203.23.

203.21 Embankment on Hillsides or Slopes

Before an embankment is placed on natural soil slopes or existing fill slopes of
4:1 or flatter, the existing ground surfaces shall be plowed or deeply scarified or, if the
170
 203.22

nature of the ground indicates greater precautions should be taken for integrating the
proposed fill materials with the existing slopes, benches shall be cut into the existing
930 slopes before fill placement is started. All such precautionary work shall be done as
directed. No direct payment will be made for plowing or scarifying, the cost thereof to
be included in the various pay items of the contract. Before an embankment is placed
on natural soil slopes or existing fill slopes steeper than 4:1, benches a minimum of 10
ft wide, unless otherwise specified, shall be cut into the slopes prior to the placement
of embankment fill. If benches are cut, the excavation involved will be paid for at the
contract unit price per cubic yard for the class or classes of excavation encountered.

203.22 Embankment Over Existing Roadbeds

If embankment for new pavement is to be placed over an area where a rigid
940 pavement or any pavement having a concrete base is in place, or in other cases when
required, the upper surface of which is 1 ft or less below the subgrade elevation of the
proposed new pavement, the existing old pavement, including any concrete base, shall
be removed. The method of removal, disposal, and basis of payment shall be in
accordance with 202.05 and 202.14.

If embankment for new pavement is to be placed over an area where an existing

rigid pavement is in place, the upper surface of which is more than 1 ft but less than 3
ft below the subgrade elevation of the proposed new pavement, or in other cases when
required, the existing pavement shall be broken. Pavement shall be broken so the area
950 of any individual unbroken slab does not exceed 1 sq yd.

If embankment for new pavement is to be placed over an area where an asphalt

filled brick-type or an asphalt-type surface on a concrete base is in place, and such
existing surface is more than 1 ft but less than 3 ft below the subgrade elevation of the
proposed new pavement, or in other cases when required, the brick and cushion
material, or the asphalt courses, shall be removed and the concrete base broken.
Removal of the surfacing material, breaking the base, disposal of removed material,
and basis of payment shall be in accordance with 202.05 and 202.14.

960 If embankment for new pavement is to be placed over an area where a

flexible-type pavement is in place, the top of which is at the approximate elevation of,
or is 1 ft or less below the required subgrade elevation of the proposed new pavement,
the existing pavement shall be loosened to the depth directed, but no less than 1 ft.
This loosened material shall be spread uniformly over the full width of the subgrade
plus 1 ft on each side and compacted. No direct payment will be made for this
loosening, spreading, and compacting, the cost thereof to be included in the various
pay items of the contract.

If embankment for new pavement is to be placed over an existing macadam, the

970 surface of which is more than 1 ft but less than 3 ft below the subgrade elevation of
the proposed new pavement, the existing macadam shall be loosened to a depth
sufficient to prevent possible trapping of water above the existing surface. No direct

171
 203.23

payment will be made for this loosening, the cost thereof to be included in the various
pay items of the contract.

Where the existing roadbed is too narrow, except as otherwise herein provided,
new pavement shall not be placed partly on old and partly on new embankment. If the
fill supporting an existing roadbed is 1 ft or more in depth, and is too narrow to carry
the entire width of the proposed new pavement, the existing width of roadbed shall be
980 taken down to include the new roadbed width and rebuilt from the lowest elevation of
the disturbed old roadbed to the required new width. This rebuilding shall be in
accordance with these specifications for constructing embankment and as directed. For
the necessary tearing down of the existing embankment, payment will be made at the
contract unit price per cubic yard for the class or classes of excavation encountered.

If an embankment is to be widened, due precautions shall be taken to ensure a

firm foundation. After all sod and other perishable material has been removed, the
existing shoulders shall be plowed down 2 ft out from the existing pavement. This
material shall be used for widening. Benches, a minimum of 4 ft wide, shall be cut into
990 the slope of the old embankment, unless otherwise directed. The materials from
plowing down the shoulders and benching the slopes shall be deposited, spread, and
compacted as set out herein for embankment, after which any remaining required
embankment shall be finished with additional material, deposited and compacted in
like manner. No direct payment will be made for benching, plowing, spreading, and
compacting, the cost thereof to be included in the various pay items of the contract.

203.23 Embankment other than Rock, with Strength or Density Control

The compaction will be determined by dynamic cone penetrometer, DCP, testing
in accordance with ITM 509 and the moisture content in accordance with ITM 506.
1000 Soil classification will be performed in accordance with the ITM 512 and the following
DCP blow counts will be used for compaction control:

172
 203.23

Acceptable Acceptable Acceptable

Optimum
Maximum Minimum Minimum Minimum
Moisture
Textural Dry DCP value DCP value DCP value for
Content
Classification Density for 6 in. for 12 in. 6 or 12 in.
Range
(pcf) for 95% for 95% for 100%
(%)
compaction compaction compaction
CLAY SOILS
Clay < 105 19 - 24 6 *
Clay 105 - 110 16 - 18 7 *
Clay 111 - 114 14 - 15 8 *
SILTY SOILS
Silty 115 - 116 9 *
13 - 14
Silty 117 - 120 11 *
SANDY SOILS
Sandy 121 - 125 12 *
8 - 12
Sandy > 125 15 *
GRANULAR SOILS - STRUCTURE BACKFILL and A-1, A-2, A-3 SOILS
No. 30 6 9
No. 4 7 10
1/2 in. 11 14
1 in. 16 19
Note: * Test section required in accordance with ITM 513.

Unless otherwise specified, all material directed to be compacted in accordance

with 203.23 shall meet the acceptable minimum DCP value for 95% compaction.
Subgrade shall meet the acceptable minimum DCP value for 100% compaction when
required.

As an alternate, all embankments shall be compacted to at least 95% of their

1010 maximum dry density and all subgrade shall be compacted to at least 100% of their
maximum dry density. In situ density will be determined in accordance with AASHTO
T 191 and the moisture content as specified.

For clay, silty, and sandy soils compacted to 100% of their maximum dry density,
a test section is required in accordance with ITM 513 for DCP testing.

Clay soils shall be constructed and tested with DCP in 6 in. lifts, whereas silty,
sandy, and granular soils shall be constructed in 6 in. lifts and tested with DCP for 12
in.
1020
The moisture compaction range for all soil types shall be as follows:
173
 203.23.1

Soil Type Moisture Compaction Range

Clay (< 105 lb/cu ft) -2 to +2% of optimum moisture content
Clay (105 - 114 lb/cu ft) -2 to +1% of optimum moisture content
Silty and Sandy (> 114 lb/cu ft) -3% to optimum moisture content
Granular 5 to 8%

DCP testing will be performed in accordance with the Frequency Manual at

random locations determined in accordance with ITM 802.

Moisture testing will be performed in accordance with the Frequency Manual.

If the embankment material is too wet or too dry, either the material shall be
1030 aerated to remove excess moisture or watered and disked to increase the moisture
content, until in either case the moisture content is within the specified range.
Sufficient moisture tests will be made to ensure that this range is maintained
throughout the embankment.

The embankment material shall be placed in uniform level layers, left properly
shaped as set out above, and compacted with approved compacting equipment.
Compacting equipment shall include at least one 3-wheel roller or other approved
compacting equipment capable of providing a smooth and even surface on the
embankment as directed.
1040
Each lift shall be disked or treated by some other mechanical means which shall
ensure the breaking up of any existing lumps and clods.

The loose depth of each lift shall be such that the required compaction can be
obtained, but in no case shall it exceed 8 in. Where a tamping roller is used, the loose
depth of lift shall not exceed the length of the tamper feet. The surface area of the end
of each foot of the tamping roller shall be no less than 5 1/2 sq in.

203.23.1 Coal Ash Embankment

1050 When used as borrow, coal ash shall be placed in the embankment, compacted,
and encased upon delivery to the project unless stockpiled at an approved location and
in an approved manner.

The Contractor shall include appropriate measures to prevent the movement of

coal ash from the embankment area. These measures include, but are not limited to
controlling stormwater runoff and fugitive dust. The top of coal ash embankments
shall be temporarily encased if embankment construction will be delayed for more
than seven days or if weather conditions warrant encasement. Control measures shall
be amended into the SWQCP in accordance with 205.
1060
Coal ash shall not be mixed with other embankment materials within a given lift
of the embankment.

174
 203.23.1

Coal ash shall not be placed in any of the following locations:

1. Below existing ground.

2. Within a 100 ft horizontal distance of a stream, river, lake,
reservoir, wetland, karst feature or any protected
environmental area.
1070 3. Within a 150 ft horizontal distance of a well, spring, pond
or other ground source of water.
4. MSE wall backfill.
5. As encasement material.
6. Within the limits of subgrade treatment.
7. Directly in contact with any permanent metallic
construction materials.

The loose depth of each lift of coal ash shall not exceed 8 in. Compaction of each
lift shall begin at the outer edge and progress towards the center of the embankment
1080 using a maximum 10 t roller.

The moisture content shall be controlled within -2 and +2 percentage points of the
optimum moisture content determined in accordance with AASHTO T 99.
Compaction will be determined by DCP testing in accordance with ITM 509. The DCP
criteria for compaction acceptance shall be as follows:

1. A minimum blow count of 7 for a 6 in. compacted lift for

fly ash.
2. A minimum blow count of 16 for a 12 in. compacted depth
1090 of bottom ash consisting of two compacted 6 in. lifts.

The Contractor shall coordinate with the Department’s Office of Geotechnical

Services to determine the minimum blow count for a mixture of fly ash and bottom
ash.

Lateral underdrains shall be installed at the bottom of coal ash embankments.

Lateral underdrains shall be trenched into the embankment after it has reached an
elevation at least 2 ft above existing ground. The bottom of the trench shall be at the
top of existing ground with adjustment made for slope of the drain. The trench shall
1100 be located within 2 ft of the toe of slope. The trench shall be backfilled with the coal
ash material used for the embankment, mechanically compacted to meet the
compaction requirements herein. Lateral underdrains shall be 6 in. diameter Type 4
pipe in accordance with 715.02(d) and shall be enclosed in geotextile for underdrains
in accordance with 918.02. Lateral underdrains shall be spaced a maximum of 100 ft
longitudinally along the centerline of the embankment, shall outlet into the roadside
ditch on each side of the embankment, shall extend a minimum of 8 ft horizontally
into the embankment, and shall be sloped at a minimum of 0.2%.

175
 203.24

Underdrain outlet protectors in accordance with 718.06 shall be installed at the

1110 outlet end of each lateral underdrain.

Coal ash shall be encased on all sides with cohesive soil. The cohesive soil shall
be a silty loam, sandy clay, silty clay, sandy clay loam, clay, or a silty clay loam in
accordance with 903.02. All cohesive soils shall have a minimum clay content of 10%.

Encasement shall be as follows:

Total Finished Encasement

Embankment Height (measured horizontally)
Less than 10 ft 2 ft
10 ft to 20 ft 3 ft
Greater than 20 ft 4 ft

Encasement material shall be placed and compacted concurrently with the coal
1120 ash lifts.

The top of the coal ash embankment shall be encased with a minimum of 1 ft of
cohesive soil beneath the bottom of subgrade.

203.24 Method of Making Strength, Stiffness and Density Tests

The strength of compacted soils will be determined by DCP in accordance with
ITM 509 and the stiffness of aggregates will be determined by the Light Weight
Deflectometer, LWD, in accordance with ITM 508. The percent of compaction shall
be based on the maximum dry densities unless otherwise specified or directed. Field
1130 compaction tests will be performed in accordance with 203.23 and the required
compaction obtained before additional material is placed.

(a) Laboratory
The DCP criteria will be established on representative soils by performing ASTM
D 1140, AASHTO T 88, AASHTO T 89, AASHTO T 90, and AASHTO T 99 using
Method A for soils and Method C for granular materials.

(b) Field
The soil strength of compacted soils or compacted chemically modified soils will
1140 be determined by DCP in accordance with ITM 509 and the stiffness of chemically
modified soils or aggregates will be determined by LWD in accordance with ITM 508.
The moisture content will be determined in accordance with ITM 506.

The field density determination shall be made in accordance with AASHTO T 191
or ITM 512 except as follows:

1. If AASHTO T 191 is used, the sand used for the test shall
be silica sand in accordance with the gradation as follows:

176
 203.24

1150 Passing the No. 20 (850 µm) sieve - 98 to 100%

Passing the No. 40 (425 µm) sieve - 0 to 35%
Passing the No. 70 (212 µm) sieve - 0 to 2%

Sand such as Wedron Silica Sand No. 4075 or Ottawa

2.8 Blasting Sand has been found to be acceptable.

2. If particles larger than those that can pass through a No. 4

(4.75 mm) sieve for soil and a 3/4 in. (19 mm) sieve for
granular material are encountered, corrections shall be
1160 made so that the density obtained is for the minus No. 4
(4.75 mm) or 3/4 in. (19 mm) only. After the densities are
determined, the degree of compaction shall be computed
by the following formula:

In Place Density, pcf

Percent Compaction = x 100
Maximum Density, pcf

3. Other approved types of field density tests may be used for

control purposes after density values corresponding to
those obtained by either of the methods set out above have
1170 been established.

4. All references to soils in these methods of tests shall be

interpreted to mean either or both soil and granular
materials.

The compaction of chemically modified soils and coarse aggregates will be

determined by LWD testing in accordance with ITM 508. The moisture content will
be determined in accordance with AASHTO T 255 or ITM 506. The compaction
procedures shall be in accordance with 203.23, 215, 301, 302, and 303. Compaction
1180 of aggregate shall not occur if the moisture content of the aggregate is greater than
6.0%.

The maximum allowable deflection will be determined from a test section or will
be specified. Acceptance testing with a LWD will be in accordance with ITM 508. The
optimum moisture content and gradation will be determined by performing AASHTO
T 99 Method C, AASHTO T 11, and AASHTO T 27 on representative samples of the
aggregates.

The moisture content of the aggregate shall be between 4% and the optimum
1190 moisture content when the aggregate is delivered to the project. Water shall not be
added to the aggregate on the grade. Samples for moisture content testing will be taken
on the grade from the first truck of the day. The frequency of the moisture content test
for aggregates will be a minimum of one test for each day of aggregate placement.

177
 203.25

The maximum allowable deflection for chemically modified soils and aggregate
over chemically modified soils shall be in accordance with the following:

Maximum Allowable
Material Type
Deflection (mm)
Lime Modified Soil 0.30
Cement Modified Soil 0.27
Aggregate over Lime Modified Soil 0.30
Aggregate over Cement Modified Soil 0.27
Table 1

1200 Test sections shall be constructed in accordance with ITM 514 in the presence of
a representative of the Office of Geotechnical Services for other materials not included
in Table 1 to determine the maximum allowable deflection.

Acceptance of the compaction of chemically modified soils or aggregate will be

determined by averaging three LWD tests obtained at a random station determined in
accordance with ITM 802, for each 1,500 ft length of chemically modified soil for
each two-lane pavement section, or for each 800 t of compacted aggregate. Where the
construction area is 8 ft wide or more, the location of the three tests will be at 2 ft from
each edge of the construction area and at 1/2 of the width of the construction area.
1210 Where the construction area is less than 8 ft wide, the location of the three LWD tests
will be spaced at 1/2 of the width of the construction area and spaced 5 ft apart in the
longitudinal direction. The average deflection shall be equal to or less than the
maximum allowable deflection allowed in Table 1 or determined by the test section.

If the average deflection is not equal to or less than the maximum allowable
deflection for aggregates, a sample of the aggregate shall be obtained in accordance
with AASHTO T 2 and a moisture content test shall be performed in accordance with
AASHTO T 255 to determine if the moisture content is within the acceptable limits.
If the moisture content is not within the acceptable limits, additional LWD tests may
1220 be taken at the same locations after 24 h if the moisture content is within the acceptable
limits at the time of testing. The aggregate will be accepted if the LWD tests are equal
to or less than the maximum allowable deflection.

203.25 Embankment Without Stiffness Control

When aggregate is used for embankment construction and it is not possible to
perform stiffness testing in accordance with ITM 508 or strength testing in accordance
with ITM 509, such material shall be compacted with several passes of crawler-tread
equipment or with approved vibratory equipment, or both. The equipment weight shall
be at least 10 t. The materials shall be placed in lifts not to exceed 9 in. loose
1230 measurements, or as directed by the Engineer. Each lift shall be compacted with a
minimum of five passes. The tread areas shall overlap enough on each trip so that the
entire embankment is compacted uniformly. When the embankment reaches 24 in.
below the proposed subgrade elevation, proofrolling shall be performed in accordance
with 203.26. Proofrolling shall also be performed at every 5 ft of fill placed. Any defect

178
 203.27

shall be corrected as directed. Upon acceptance, a layer of geotextile in accordance

with 918.02(a) Type 2B, shall be placed and the remaining embankment shall be
constructed with No. 53 aggregate in accordance with 301.

At locations inaccessible to the above compacting equipment, the required

1240 compaction shall be obtained with approved mechanical tamps or vibrators, in which
case the depth of lifts, loose measurement, shall not exceed 4 in.

203.26 Proofrolling
When proofrolling is specified, the work shall be performed with an on-highway
dump truck with a minimum tire pressure of 90 psi.

Proofrolling for original ground or embankment construction shall be performed

using a dump truck weighing at least 15 t. Proofrolling for subgrade preparation shall
be performed using a dump truck weighing at least 33 t. All proofrolled surfaces shall
1250 be covered completely with a single pass. Operating speed of the proofrolling truck
shall not exceed 2 mph.

Deflections or rutting in excess of 1/2 in. shall require remediation of the surface
as directed. Deflection or rutting in excess of 3 in. shall require corrective remediation
measures and the Office of Geotechnical Services will be contacted. Proofrolling shall
be performed after remediation measures on embankment or subgrade prior to the
placement of additional material. There shall be one or two complete coverages as
directed. Roller marks, irregularities, or failures shall be corrected.

1260 203.27 Method of Measurement

(a) Contract Quantity

The quantities of excavation for which payment will be made will be those shown
in the Schedule of Pay Items for the pay items, provided the project is constructed to
the lines and grades shown on the plans.

Unless otherwise specified, the project limits will be considered as one balance.
If earthwork balances are shown on the plans, they are for information only.

1270 When the plans have been altered or when disagreement exists as to the accuracy
of the plan quantities in any balance, or the contract quantity, either party shall have
the right to request and cause the quantities involved to be measured in accordance
with measured quantities. When the quantities are measured for payment, the original
plan cross sections plotted on the plans shall be used as original field cross sections.
Additional original cross sections may be interpolated at points where necessary to
determine the quantities more accurately. If the Contractor has acceptable engineered
data that indicates an excavation quantity that is in error by more than 2%, then
additional measurements will be performed on the areas in question and payment will
be made for actual quantities.
1280

179
 203.27

(b) Measured Quantities

When payment is specified on a volume basis, all accepted excavation and borrow
will be measured in its original position by cross sectioning the area excavated, which
measurements will include over-breakage or slides in common excavation and
unclassified excavation, not attributable to carelessness, and authorized excavation of
rock, shale, peat, or other unsuitable material. Volumes will be computed from cross
section measurements by the average end area method.

Measurement for payment will not include material excavated beyond authorized
1290 cross sections. Where material is excavated beyond authorized cross sections and
wasted without authority, the material so wasted will be measured and deducted from
the excavation quantities. Unless otherwise authorized, the amount of waste to be
deducted, when common excavation, rock excavation, unclassified excavation,
borrow, or other excavation has been wasted along embankments or elsewhere without
authority shall be that portion of the embankment or fill which is outside a 1/4 to 1
slope in excess of that shown on the plans, and all portions outside a line from the
shoulder point to a point 4 ft, measured horizontally, outside the theoretical toe of the
slope. In determining waste, no tolerance in widths of shoulders will be allowed unless
additional widths are authorized in writing before shoulders are finally constructed.
1300
Measurements will be made for unsuitable materials actually excavated and
removed to obtain proper compaction in cut sections and in foundations for fill
sections.

Where it is impracticable to measure material by the cross section method due to

the erratic location of isolated deposits, acceptable methods involving three-
dimensional measurements may be used to measure the material in its original
position.

1310 The cubic yards of peat excavated will be determined by cross sections, as
described above, with the final cross sections taken after complete excavation and
before placing granular backfill, if peat is removed by excavation. When removal by
displacement is necessary, final cross sections will be derived from cased test holes
through the completed granular treatment in accordance with 203.17. Such test holes
shall be located at intervals which clearly define the bottom of the treatment between
lateral limits. Pay quantities of peat excavation will be limited to the volume of peat
lying between vertical lines as shown on the plans for lateral limits.

Cased test holes and exploratory drilling will be measured by the linear foot; B
1320 borrow by the cubic yard, in accordance with 211.09. However, measurement to neat
lines will not apply unless specifically designated. Breaking pavement will be
measured by the square yard in place before breaking.

(c) Measurement on a Linear Basis

Linear grading will be measured by the linear foot. Measurement will be made
once along each survey centerline for all linear grading completed on the line.

180
 203.27

Deductions will be made for bridges. Classes of excavation, except for required
borrow, involved in linear grading will not be measured.

1330 (d) Measurement of Excavation Items on a Weight Basis

A pay item for excavation may be specified to be measured and paid for on a
weight basis. When a weight basis is specified, the material will be weighed in
accordance with 109.01(b).

(e) Measurement of Embankments

When specified, embankments constructed will be measured in accordance with
the terms set forth.

When embankment is specified as a separate pay item, the volume so constructed

1340 will be measured in place in accordance with 203.27(b). However, no measurement
will be made for excavation or borrow, except as noted herein. The volume shall be
computed in cubic yards from the dimensions of the embankment cross sections and
to the depth below completed grade to which this method of construction applies. No
shrinkage factor shall be used in computing the embankment volume. Measurements
will be made for unsuitable materials actually excavated and removed to obtain proper
compaction in cut sections and in foundations of fill sections in accordance with
203.27(b). B borrow from off the right-of-way placed within embankment areas will
be measured in accordance with 211.09.

1350 (f) Measurement of Borrow

Borrow will be measured by the cubic yard. Except as otherwise provided herein,
borrow will be cross sectioned in its original position before excavation is started,
again after it is completed, and the volume computed by the average end area method.
No material shall be excavated as borrow until unsuitable material, vegetation, and
other perishable matter have been removed and cross sections taken over the cleared
area. None of this removed unacceptable material shall be move back into the pit
before final sections are taken.

If borrow is obtained from a source where it is impracticable to measure the

1360 material in its original position, such material will be measured after being placed in
embankment with no allowance made for a compaction factor. The borrow may be
measured in truck beds in accordance with 211.09 for contracts having a proposal
quantity less than 500 cu yd. If such source is contemplated, approval shall be obtained
in writing before this part of the work is started. For quantities less than 5,000 cu yd,
the material may be weighed in accordance with 109.01(b) and converted from pounds
shown on the weigh tickets to cubic yards using a factor of 3,000 lb/cu yd.

If borrow is specified outside the limits of B borrow and if the requirements of the
work do not otherwise prohibit, material in accordance with these specifications for B
1370 borrow, may be furnished and placed at the contract unit price for borrow, in which
case measurement will be in accordance with 211.09. Measurement of borrow in
accordance with 211.09 will be limited to nominal quantities outside the limits of

181
 203.28

structure backfill. The quantity of borrow measured for payment will not exceed the
theoretical quantity of B borrow furnished.

(g) Measurement of Embankment Foundation Soils Treatment

Mechanical treatment of embankment foundation soils will be measured by the
square yard. Chemical treatment of embankment foundation soils will be measured in
accordance with 217.
1380
(h) Measurement of Water for Shale, Shale and Soft Rock Mixtures, or
Soft Rock
When payment for water for shale is specified in the contract, the water for shale
used will be measured by the 1,000 gal. by means of calibrated tanks or distributors,
or by means of accurate water meters. When water for shale is not specified as a pay
item in the contract, the water for shale that is used will not be measured directly. Such
measurement will be included in that required for other pay items.

(i) Lump Sum

1390 If the pay unit for a pay item for excavation is lump sum, no measurement will be
made.

(j) Measurement of Exploratory Cores

Exploratory cores will be measured by the linear foot of rock core.

(k) Measurement of Coal Ash

If coal ash is used as borrow, it will be measured in accordance with 203.27(f).

If coal ash is encountered during excavation, it will be measured as common

1400 excavation in accordance with 203.27.

203.28 Basis of Payment

The accepted quantities of excavation and embankment will be paid for at the
contract price per unit of measurement for each of the pay items listed below which is
included in the Schedule of Pay Items. Common excavation and unclassified
excavation will be paid for on the unit basis of contract quantities in accordance with
203.27(a), without any quantity limit, unless otherwise shown in the Schedule of Pay
Items. Combined quantities of borrow, common and unclassified excavation not
exceeding 15,000 cu yd will be paid for on the basis of contract quantities in
1410 accordance with 203.27(a) with no adjustment to plan shrinkage factor. Except as
noted above, borrow, as well as all other excavation, will be paid for on the basis of
measured quantities in accordance with 203.27(b), unless otherwise shown in the
Schedule of Pay Items. Linear grading will be paid for at the contract unit price per
linear foot.

If the class of excavation is linear grading, additional borrow and the excavation
of and disposal of unsuitable material not included as pay items will be paid for as
follows:

182
 203.28

1420 If the total quantity exceeds 5,000 cu yd at a given location, it will be paid for at
$8.00 per cu yd. If the total quantity exceeds 1,000 cu yd, but does not exceed 5,000
cu yd at a given location, it will be paid for at $12.00 per cu yd. If the total quantity
does not exceed 1,000 cu yd at a given location, it will be paid for at $15.00 per cu yd.

Linear grading includes only such grading within the construction limits. All
grading the Contractor is directed to perform outside the construction limits, except
for the Contractor’s convenience, will be paid for in accordance with 104.03 or 109.03
unless such grading is shown on the plans or in the Contract Information book.

1430 Existing concrete building foundations, concrete walls, concrete columns, or

concrete steps not visible and not shown on the plans within the limits of the planned
excavation will be paid for at 10 times the contract unit price per cubic yard for
common or unclassified excavation, whichever is set out as a pay item. Unless a waste
area is established within the contract limits, the minimum pay for this work will be
$80.00 per cu yd.

Excavation and disposal of unsuitable material will be paid for at the contract unit
price for the class of excavation involved. If no such pay item is included in the
contract and embankment is included as a pay item, the excavation and disposal will
1440 be paid for at the contract unit price for embankment, unless otherwise directed.

If there is no pay item for rock excavation and such is encountered, it will be paid
for at $125.00 per cu yd for quantities less than or equal to 100 cu yd. For quantities
greater than 100 cu yd pay will be determined in accordance with 104.03.

If there is no pay item for common excavation and if such is encountered, it will
be paid for at the contract unit price per cubic yard for borrow.

If the contract includes a pay item for waterway excavation, and if class Y
1450 excavation is encountered and there is no pay item for such, the class Y excavation
will be paid for at 10 times the contract unit price per cubic yard for waterway
excavation, or $100.00 per cu yd, whichever is greater.

If the contract does not include a pay item for waterway excavation and such is
encountered, pay will be determined in accordance with 104.03.

If excavation is necessary to investigate or to seal sinkholes, or to explore

underground drainage, the accepted quantity involved at each location will be paid for
as follows. The first 10 cu yd or fraction thereof will be paid for at 10 times the contract
1460 unit price for the class of excavation encountered. The next 40 cu yd or fraction thereof
will be paid for at seven times the contract unit price for the class of excavation
involved. Additional quantities will be paid for at three times the contract unit price
per cubic yard for the class of excavation involved.

183
 203.28

Material overlying the peat deposits which is excavated and used in embankment
will be considered as common excavation and will be paid for as such. Excavation for
standard side ditches or other side ditches which are constructed through peat areas at
locations shown on the plans, or where directed, will be paid for at the contract unit
price per cubic yard for common excavation.
1470
Mechanical treatment of embankment foundation soils will be paid for by the
square yard as embankment foundation soils treatment.

Cased test holes and exploratory drilling will be paid for at the contract unit price
per linear foot.

If there is no pay item for borrow, the costs of identifying the borrow areas, the
archeological investigation, all required permits, and the opening and closing of the
borrow area will be included in a change order developed in accordance with 109.05
1480 and paid for as borrow area.

If the contract documents do not identify excess excavation or require removal of

any items from the site, the cost of identifying a disposal area, archeological
investigation, all required permits, and the opening and closing of the disposal area
will be included in a change order developed in accordance with 109.05 and paid for
as disposal area.

If a type of excavation for which no pay item exists is required and the new type
of excavation requires the Contractor to use equipment not otherwise being used on
1490 the contract, all cost involved in determining the type of equipment necessary to
complete the work and making this equipment available for the project will be
included in a change order developed in accordance with 109.05 and paid for as
additional mobilization and demobilization.

If a type of excavation for which no pay item exists is required and the new type
of excavation requires additional traffic control not shown on the plans or results in
traffic control being required for an additional period of time, all cost involved in
providing the additional traffic control will be included in a change order developed
in accordance with 109.05 and paid for as additional maintaining of traffic.
1500
Coal ash used as borrow will be paid for at the contract unit price for borrow.

Excavation of coal ash will be paid for at the contract unit price for common
excavation.

Payment will be made under:

Pay Item Pay Unit Symbol

1510 Borrow ....................................................................................... CYS

184
 203.28

Breaking Pavement.................................................................... SYS

Cased Test Holes ....................................................................... LFT
Embankment .............................................................................. CYS
Embankment Foundation Soils Treatment ................................ SYS
Excavation, Common ................................................................ CYS
Excavation, Peat ........................................................................ CYS
Excavation, Rock....................................................................... CYS
Excavation, Unclassified ........................................................... CYS
Excavation, Waterway ............................................................... CYS
1520 Excavation, Y ............................................................................ CYS
Exploratory Cores...................................................................... LFT
Exploratory Drilling .................................................................. LFT
Linear Grading .......................................................................... LFT
Water for Shale .......................................................................... kGAL.

If embankment is specified as a pay item, borrow and common excavation, unless

otherwise specified, will not be paid for directly. The costs thereof shall be included
in the cost of embankment. Such price shall be full compensation for preparation of
the natural ground on which the embankment is to be placed and excavating, hauling,
1530 placing, spreading, and compaction of materials in accordance with 203.23. The costs
of labor, equipment, tools, and necessary incidentals shall be included in the cost of
embankment. The cubic yards of suitable material used in the embankment excavated
from the right-of-way and paid for under a specific pay item will not be deducted from
the embankment quantities. The quantity of material to be paid for as B borrow and
placed within the embankment area as specified will be deducted from the quantity of
embankment.

The costs of excavating, backfilling, disposal of surplus material, labor,

equipment, tools, and necessary incidentals necessary shall be included in the cost of
1540 excavation required to seal sinkholes or explore underground damage.

The costs of all excavated or displaced peat, regardless of depth, peat disposal,
temporary surcharge, machine operation, and machine availability shall be included in
the cost of peat excavation. However, the Department may provide temporary right-
of-way for peat disposal when so specified.

Cost for providing additional lighting for grading operations shall be included in
the cost of other pay items in this section.

1550 No payment will be made for the construction or restoration of borrow or disposal
sites.

No payment will be made for the inspection of disposal and borrow areas for
wetland identification, obtaining of permits, the development and construction of all
mitigation measures, or the fulfillment of permit requirements.

185
 204.01

The cost of boring the holes, casings and fittings, labor, equipment, tools, and all
necessary incidentals shall be included in the cost of cased test holes or exploratory
drilling.
1560
The cost of reshaping scoured or eroded areas shall be included in the cost of other
pay items.

The cost of surface roughening shall be included in the cost of other pay items.

The cost of identification of borrow areas, archeological investigations, and

changes to construction operations caused by the identification of an archeological site
shall be included in the cost of borrow, unless otherwise agreed to in writing.

1570 The cost of all classes of excavation, except required borrow, within the limits of
linear grading shall be included in the cost of linear grading.

The cost of geotextiles shall be included in the cost of other pay items.

The costs for the use of coal ash in embankment construction, including, but not
limited to testing of the material, encasement, additional erosion and sediment control
measures, lateral underdrains and all incidentals shall be included in the cost of other
pay items in this section.

SECTION 204 – GEOTECHNICAL INSTRUMENTATION

204.01 Description
This work shall consist of providing, installing and maintaining of geotechnical
instrumentation including settlement plates, settlement stakes, lateral stakes and
standpipe piezometers as directed and in accordance with 105.03.

MATERIALS

10 204.02 Materials
Materials shall be in accordance with the following:

B Borrow ................................................................................... 211.02

Coarse Aggregate, Class D or Higher, Size No. 53. .................. 904
Structure Backfill, Size No. 30 ................................................. 904
Ottawa Sand* ....................................................................... AASHTO T 252
* Ottawa Sand shall have a minimum permeability of 25 ft/day.

Bentonite chips shall consist of commercially processed angular fragments of

20 pure bentonite, without additives.

186
 204.03

Bentonite-cement grout shall consist of a mixture with the ratio of 25 lb of

bentonite with 94 lb of Portland Cement, type I in accordance with 901.01(b) and a 30
gal. of water.

CONSTRUCTION REQUIREMENTS

204.03 Settlement Plates

Settlement plates consist of 1/2 in. by 3 ft by 3 ft steel plate equipped with sections
30 of 3/4 in. pipe and 2 in. galvanized threaded pipe and couplings to act as a cover or
guard.

(a) Installation Requirements

Each settlement plate shall be placed on a horizontal plane consisting of a
compacted leveling layer of B borrow, whose surface is not less than 1 ft below the
elevation of the adjacent area. The first section of pipe shall then be installed by
welding to the settlement plate. The bottom elevation of the settlement plate will be
recorded. The area is backfilled with B borrow and thoroughly compacted. The
couplings shall be tack welded and the top elevation of the first pipe section will be
40 recorded before starting the first lift of grading operations.

The pipe sections for the settlement plates shall be 3/4 in. steel pipe, 4 ft long and
threaded on both ends with proper fittings so that such pipe sections can be extended
vertically from the center of the plates up through the new embankment as it increases
in height during grading operations. A cover pipe 2 in. shall be slipped over and
centered on the standpipe, and not welded to plates. The 3/4 in. steel and cover pipes
shall extend a minimum of 2 ft or more above the grade of the new embankments at
all times during grading operations and monitoring period.

50 Settlement stakes and lateral stakes, if required, shall be installed as shown on the
plans or as directed by the Engineer. The stakes shall be 3/4 in. by 4 ft steel rods and
shall be driven at least 12 in. into the ground. These stakes shall be set firmly in a
vertical position and initial readings will be taken.

B borrow shall be used as compaction material around the settlement plates and
pipes and shall be placed in accordance with the applicable requirements of 211.

(b) Instrument Readings and Settlement Period

During the construction of the embankment, elevation readings will be taken on
60 all settlement plate extension pipes and settlement stakes at the end of each seven-day
period, or more frequently if required. After the embankment is constructed to
subgrade elevation, additional readings will be taken every seven days until the
settlement rate per week is 1/4 in. or less for four consecutive weeks. The monitoring
period may be reduced as directed by the Department’s Geotechnical Section.

If the results of any readings indicate that the new embankment has settlement
greater than 1/4 in., the monitoring period will be extended until the settlement
requirements are met.
187
 204.04

70 Settlement stakes will be used to measure the vertical movement, in conjunction

with settlement plates if specified. Settlement stakes and settlement plates will be
monitored at the same time and interval. Measurements will be made to the nearest
1/4 in. Settlement data will be sent electronically to the Department’s Geotechnical
Section within one day of the readings for approval.

Lateral stakes will be used to monitor horizontal movement of the ground or new
fill. If lateral movement is noticed during the construction of the fill, the work will be
suspended and corrective measures taken as directed. Measurements will be made to
the nearest 1/4 in.
80
Settlement plates, extension pipes, cover pipes, and stakes shall be protected
during construction operations and during the monitoring period.

204.04 Standpipe Piezometers

The standpipe piezometers shall be installed by a Department approved
Geotechnical Consultant prior to placing the first lift of embankment. Piezometer
consists of a 1/2 in. leak proof, flush-coupled Schedule 80 PVC pipe or ABS standpipe
extending to the surface of the embankment with an attached polyethylene tip in
accordance with AASHTO T 252.
90
(a) Installation Requirements
A separate water-monitoring borehole shall be installed outside the influence of
the fill as shown on the plans. This shall be a minimum 2 in. diameter borehole, cased
with slotted pipes, drilled to a recommended depth and location or as directed by the
Engineer, to establish ground water elevation prior to piezometer installation.

The installation of the standpipe piezometer shall precede placement of any

embankment by at least two weeks to allow time for testing of the installation. The
piezometer shall be maintained and protected during the embankment construction.
100 The hollow stem auger shall be advanced to an approximate depth of 6 in. below the
recommended piezometer tip elevation. Augers shall be cleaned and washed inside for
their full length, until the wash water runs clear.

The auger shall be withdrawn 6 in. by means of jacking or other steady pull
operations. The hole shall be filled to the bottom with saturated Ottawa sand and
tamped with an annular tamping hammer. The elevation shall be measured and
provided to the Engineer.

The tip shall be attached to the standpipe and tested for free flow of water. The
110 bottom end of the tip shall be plugged and soaked in water if a porous stone tip is used.
The tip and standpipe shall be filled with clean water. The tip shall be lowered into the
auger until it rests on the top of the sand placed and the elevation of the tip should be
documented. Excess head shall be maintained in the standpipe during lowering to
ensure that a small amount of water flows out of the tip.

188
 204.04

The auger shall then be pulled or jacked a distance equal to the length of the tip
in increments of 6 in. The hole shall be filled with water saturated Ottawa sand at each
increment. This layer of sand shall not be tamped in order to avoid damage to the tip.

120 The auger shall be raised 12 in. and the hole filled with saturated Ottawa sand in
6 in. increments until the backfilling reaches a minimum of 6 in. below the elevation
of the strata change or as directed by the Engineer. In locations where there is no strata
change, the Ottawa sand shall be placed a minimum of 12 in. above the top of the tip.

The augers shall then be raised and the hole sealed with bentonite chips in
accordance with AASHTO T 252 which shall be placed in 6 in. lifts. The top of the
seal shall be a minimum of 6 in. above the strata break. A weighted line shall be used
to ensure the bentonite seal is in place. The remainder of the hole shall then be
backfilled with bentonite-cement grout as the augers are withdrawn. The riser pipe
130 shall be kept in tension and shall be centered in the auger while backfilling. Depths for
various stages shall be recorded on the Engineers’ logs.

If the piezometer location is not in an area of proposed fill, a protective metal

cover, about 3 ft long shall be installed at the top with about 2 ft below the surface and
12 in. above the surface. A 6 in. circular pad of course aggregate; 6 in. thick shall be
filled around the cover. A lockable cap shall be securely attached onto the protective
metal cover.

If the piezometer location is in an area of proposed fill, a PVC casing shall be

140 used around the piezometer standpipe in order to protect the pipes during embankment
construction. B borrow shall be placed and compacted around the casing without
disturbing the casing.

The casing and standpipe shall be extended as the fill is placed, by adding extra
lengths not to exceed 5 ft. The top of the standpipe shall be at least 12 in. above the
grade of the new fill. Each time the casing and standpipe are extended, the casing shall
be filled with structure backfill. The last extension of pipe shall be of such length that
it extends 12 in. above grade. It shall be filled with structure backfill to within 9 in. of
the top of the casing. A 6 in. circular pad of coarse aggregate, 6 in. thick shall be filled
150 around the pipes. A lockable cap shall be securely attached onto the protective cover.

When the standpipe is completed it shall be checked for obstructions by dropping

a weighted line through the pipe. The standpipe shall then be filled with water and
periodic readings made of the water level until the ground water level is stabilized.
Hydrostatic time lag required for equalization will be provided by the Geotechnical
report. If required, the standpipe shall be flushed and retested at the direction of the
Engineer. Ground water readings shall be provided to the Engineer.

Standpipe piezometers, and cover pipes shall be protected during construction

160 operations and during the monitoring of the fill. In the event of damage, fill
construction shall be suspended in this area until the piezometer is restored.

189
 204.05

(b) Readings and Maintenance of Piezometer

The Engineer will conduct and record all observations and measurements required
to determine natural ground water elevations and pore pressures induced by
embankment construction. Monitoring intervals will be once every day for the first
seven days, once every other day for the next eight, and then, once every three days
through the end of construction of the fill. The elevation of the natural ground water
existing at the time of installation, prior to placement of any fill, will be used as a
170 reference to determine baseline pore pressures. Ground water and pore pressure test
results will be made available to the Contractor.

The pore pressure measurement in conjunction with settlement data will be sent
electronically to the Department’s Geotechnical Section within one day of the readings
for approval. If it is determined that pore-water pressures have not sufficiently
dissipated, fill placement shall be suspended, and the monitoring period extended as
directed.

If monitoring is to be continued after paving in a traffic accessible area, then the

180 pipe shall be cut off 6 in. below the finished grade and a handhole in accordance with
807.09, shall be installed for monitoring access. When the evaluation is completed, the
water monitoring borehole and piezometers shall be backfilled with bentonite-cement
grout.

204.05 Method of Measurement

Settlement plates, settlement stakes, lateral stakes, standpipe piezometers, and
water monitoring boreholes will be measured by the number of units installed.

204.06 Basis of Payment

190 Settlement plates, settlement stakes, lateral stakes, standpipe piezometers, and
water monitoring boreholes will be paid for at the contract unit price per each.

Payment will be made under:

Pay Item Pay Unit Symbol

Settlement Plate ......................................................................... EACH

Stake, Lateral ............................................................................. EACH
Stake, Settlement ....................................................................... EACH
200 Standpipe Piezometer ................................................................ EACH
Water Monitoring Borehole ...................................................... EACH

The cost of furnishing, installing, and maintaining settlement plates, extension

pipes, cover pipes, B borrow, structure backfill, coarse aggregate and all necessary
incidentals shall be included in the cost of settlement plates.

The cost of backfilling water monitoring boreholes will be included in cost of

water monitoring boreholes.
190
 205.03

210 The cost of handholes, protective covers, bentonite chips, bentonite-cement grout,
Ottawa sand, tips, casing, drilling, tubing or PVC pipe, backfilling and measurements
will be included in the cost of standpipe piezometers.

No additional compensation will be made for any costs incurred related to the
repair of settlement plates, pipes, settlement stakes, lateral stakes or standpipe
piezometers as the result of damage by the Contractor.

SECTION 205 – STORMWATER MANAGEMENT

205.01 Description
This work shall consist of furnishing, installing, inspecting, maintaining, and
removing stormwater management measures in accordance with the Department’s
Design SWPPP, the submitted and accepted SWQCP developed by the Contractor,
and 105.03.

MATERIALS
10
205.02 Materials
Materials shall be in accordance with the following:

Coarse Aggregate, Class F or Higher .......................... 904

Fertilizer ...................................................................... 914.03
Filter Sock ................................................................... 914.09(h)
Geotextile .................................................................... 918.02
Grass Seed, Temporary ............................................... 914.02
Manufactured Surface Protection Products ................. 205.04(c)
20 Metal End Sections ...................................................... 908.06
Mulch .......................................................................... 914.05(a)
Pipe Drains .................................................................. 715.02(d)
Plastic Net ................................................................... 914.09(g)
Revetment Riprap ........................................................ 904*
Stakes .......................................................................... 914.09(b)
Staples ......................................................................... 914.09(f)
Top Soil ....................................................................... 914.01
Water ........................................................................... 914.09(a)
* The minimum depth does not apply. Straw bales shall not weigh
30 less than 35 lb. Bales shall be bound with wire or nylon twine.

CONSTRUCTION REQUIREMENTS

205.03 General Requirements

The Contractor shall locate, install, inspect, maintain, and remove stormwater
management control BMPs for earth disturbing activity areas, and develop a SWQCP
in accordance with 327 IAC 15-5. The Contractor’s SWQCP shall be a required
191
 205.03

contract specific component to the Department’s Design SWPPP. The submitted and
accepted Contractor’s SWQCP and the Department’s Design SWPPP shall work in
40 coordination with each other to complete the requirements of 327 IAC 15-5.

(a) Stormwater Quality Control Plan Development

The Contractor’s SWQCP shall be developed by a professional engineer who
holds a current CPESC or CPESC In-Training certification or approved equivalent.
The SWQCP developer shall be familiar with the project site and be able to develop
the SWQCP in accordance with the site conditions. In the event of conflict between
requirements, pollution control laws, rules, or regulations of other Federal, State or
local agencies, the Contractor’s SWQCP shall adhere to the more restrictive laws,
rules, or regulations. The SWQCP developer shall issue clarifications, correct errors
50 and omissions, and revise the SWQCP as required. The Contractor’s SWQCP shall be
stamped by the SWQCP developer as defined above.

The Contractor shall develop the project SWQCP for all applicable stormwater
management measures in accordance with 327 IAC 15-5, Chapter 205 of the Indiana
Department of Transportation Design Manual, the IDEM “Indiana Storm Water
Quality Manual”, ITM 803, and all other applicable contract documents.

The Contractor’s SWQCP shall incorporate all narrative information, plan sheets,
and implementation information necessary for stormwater management utilized for
60 the project. The SWQCP shall include any revisions to the Department’s Design
SWPPP and the plans to comply with all known permit requirements applicable to the
construction phase of the project included in the NOI, 401 and 404 permits, and all
other permits as well as those required by the Contractor in accordance with 107.01
and 205.03(c).

A copy of the Contractor’s offsite operations permits for items such as offsite
stockpiles, borrow sites, waste sites, or storage areas shall be submitted to the Engineer
prior to operations at those sites.

70 Electronic files of any plan sheets and narratives shall be provided in .pdf format.

The Contractor may elect to prepare and submit the SWQCP in multiple phases.
The first phase of the SWQCP shall show the location, installation, and maintenance
of stormwater management BMPs for the existing topography of the project during
clearing activities and prior to earth disturbing activities for the remaining
construction. The first phase of the SWQCP shall be submitted prior to subsequent
phases. Additional phases shall show the progression from the existing topography to
the final grade and shall be submitted for review prior to earth disturbing activity for
that phase. Each phase of the SWQCP shall be modified to meet existing field
80 conditions as needed.

If a governmental agency or a local governmental authority finds a violation of

NPDES or any other surface water permits provided in the bid documents, or any

192
 205.03

BMPs are incomplete, or the Contractor’s SWQCP is incomplete, full responsibility

shall be borne by the Contractor to make corrections. In addition, if an assessment,
damage judgment or finding, agreed order, fine, or any other expense for a violation
of the contract requirements is leveled against the Department, the Contractor shall
reimburse the State for that amount within 30 days. The Contractor agrees to
indemnify and hold harmless the Department and will reimburse the Department for
90 any assessments, damage judgments or finding, fine, penalty, or other expense relating
to this portion of the contract. The Department may withhold the amount owed from
the Contractor’s subsequent pay estimates. Delays caused by stop work orders from
regulatory agencies, suspension of work orders from the Department, or any other
delays caused by inadequate submittals or implementation will be considered Non-
Excusable Delays in accordance with 108.08(c).

(b) Stormwater Quality Manager

The Contractor shall designate one person as the contract SWQM. The designated
individual shall be trained as a level 1 or level 2 SWQM as indicated within the
100 contract documents. The SWQM training level shall meet or exceed the level required
within the contract documents.

1. Level 1 SWQM
A level 1 SWQM shall have successfully completed the Department’s
Construction Stormwater Training course and hold a current training verification
document for that course.

2. Level 2 SWQM
A level 2 SWQM shall meet the requirements of 205.03(b)1, and hold a current
110 certification as a CESSWI, or a CESSWI In-Training, or a CISEC, or a CISEC In-
Training, or a CPESC, or a CPESC In-Training, or an approved equivalent.

The SWQM shall be responsible for ensuring that the Contractor’s SWQCP has
been submitted for review prior to implementation. The SWQM shall also be in
responsible charge of the implementation of the Contractor’s SWQCP.
Implementation of the SWQCP includes installation, maintenance, and removal of all
stormwater management measures. The SWQM shall also be in responsible charge of
the weekly and post-event inspections. The inspections shall be documented
electronically using the Stormwater, Erosion, and Sediment Control Inspection Report
120 which is available on the Department’s website or provided by the Engineer.

The SWQM shall attend the pre-construction conference and at least one contract
scheduling meeting per calendar month. The SQWM shall accompany personnel from
IDEM or other governmental agencies, as required, during site visits by those
agencies. The name of the SWQM shall be furnished to the Engineer at, or prior to,
the pre-construction conference. If the designated individual is replaced during the
contract, the replacement shall be designated, and notification given to the Engineer
within 24 hours.

193
 205.03

130 (c) Stormwater Quality Control Plan Content

The Contractor’s developed SWQCP shall include the processes and procedures
of how the Contractor intends to meet the requirements as outlined in this section and
in accordance with ITM 803, Contractor Quality Control Plan for Stormwater.

Any individual phase of the SWQCP shall be submitted to the Engineer for review
a minimum of 14 calendar days prior to commencing earth disturbing activities for
that phase. Upon receipt, the Engineer will perform a review of the submitted phase
of the SWQCP within 14 calendar days for acceptance.

140 At a minimum, the SWQCP shall include the following:

1. Description of the site.

2. Locations of all proposed top soil stockpiles.

3. Locations of all proposed equipment storage areas, fueling

locations, construction trailers, batch plants, and
designated concrete truck washout areas.

150 4. Proposed construction sequence and phasing of stormwater

management measures including plans for installation,
inspection, maintenance, and removal of BMPs.

5. Locations and design flow from offsite areas that drain

onto project limits. The SWQCP design shall include
BMPs properly sized and placed to accommodate runoff
from outside of the project limits and the drainage quantity
from within the project limits.

160 6. Locations of all construction entrances where vehicles and

equipment will enter and exit the site.

7. Material handling and spill prevention plan. A plan for the

collection, storage, and disposal of concrete washout waste
water shall be in accordance with 205.03(d).

8. Statements that the stormwater management measures for

the project shall, at a minimum, be inspected on a weekly
basis and within 24 h of every 1/2 in. rain event.
170
9. Provisions to ensure that pollutants such as fuels,
lubricants, asphalt, sewage, wash water, or waste from
concrete mixing operations, and other harmful materials
shall not be discharged into existing bodies of water.

194
 205.03

10. Provisions to ensure that all applicable regulations and

statutes relating to the prevention and abatement of
pollution shall be complied with in the performance of the
contract.
180
11. Statements that all appropriate stormwater management
items shall be in place prior to disturbing the project site.

When Waters of the United States are located within the project limits the
following shall also be addressed in the SWQCP:

1. A method for delineating the boundaries of the Waters of

the United States as shown on the plans.

190 2. A method for conducting work located in or adjacent to

bodies of water, and how the work in those locations shall
be conducted in compliance with all conditions within the
project 401, and 404 permits.

(d) Temporary Stormwater Management Features

Temporary stormwater management measures shall be placed as soon as
practicable. Perimeter protection and sediment traps shall be installed prior to
beginning earth disturbing activities. Pipe end sections and anchors shall be installed
when the structure is installed. If the pipe end sections or anchors cannot be placed at
200 the same time, temporary riprap splashpads shall be placed at the outlets of the pipes
until end sections or anchors can be installed.

Adjustments of the stormwater management measures shall be made to satisfy

field conditions and shall be subject to the Engineer’s approval. Adjustments made to
meet field conditions shall be made as soon as practicable and shall be maintained as
necessary.

The Contractor shall provide a stable construction entrance at the points where
construction traffic will enter onto an existing road. Where there is insufficient space
210 for a stable construction entrance, other measures shall be taken to prevent the tracking
of sediment onto the pavement. These temporary entrances shall be the responsibility
of the Contractor to completely install, maintain, and remove.

Within the SWQCP, the Contractor shall provide a written plan for the collection,
storage, and disposal of concrete washout waste water that is adequate for the size of
the concrete pour, the environmental conditions of the job site, and in accordance with
327 IAC 15-5-7(2) and 327 IAC 15-13-17(2)(F). A secondary washout container shall
be on site and be part of the material handling and spill prevention plan. Straw bale
washout pits will not be allowed. Concrete washout waste water may either be recycled
220 back into the truck, washed out into a lined roll off container or a lined in-ground pit
of adequate size, or an approved manufactured product, or taken back to a batch plant.

195
 205.04

Lining shall consist of a minimum of one sheet of 10 mil plastic, be continuous with
no over lapping, and shall be free of leaks.

Concrete waste water liquid shall be fully evaporated prior to the planned capacity
of the washout container capacity being exceeded. Otherwise the waste water shall be
pumped out into a secondary lined container or into a tanker and taken to an approved
disposal facility. Concrete waste water shall not be allowed to leak onto the ground,
run into storm drains, or into any body of water. Where washout waste water leaks
230 onto the ground, all contaminated soils shall be excavated and disposed of in
accordance with 202.08 except that all costs associated with excavation and disposal
shall be the responsibility of the Contractor.

The installation of stormwater management measures shall include those

necessary or required by permits at off-site locations such as borrow and disposal
areas, field office sites, batch plants, locations where the Contractor’s vehicles enter
and leave public roads, and other locations where work pertaining to the contract is
occurring. The Contractor’s SWQM shall be responsible for the installation,
inspection, and maintenance of these measures.
240
The Contractor shall employ dust control measures in accordance with 107.08(b).

(e) Permanent Stormwater Management Features

Permanent stormwater management measures shall be incorporated into the work
at the earliest practicable time.

205.04 Temporary Surface Stabilization

Non-vegetated areas shall be temporary stabilized if the area remains inactive for
more than seven days. The area will be considered inactive when no meaningful work
250 toward accomplishing a pay item has been performed at a site of disturbed soil.
Stabilization methods shall be as shown in the SWQCP.

(a) Seed
Temporary seeding shall be placed on disturbed areas that are expected to be
inactive for more than seven days, or as agreed to by the Contractor and the Engineer.
Seed shall be placed either by drilling in, spraying in a water mixture, or by use of a
mechanical method which places the seed in direct contact with the soil. Where
inaccessible to mechanical equipment, or where the area to be seeded is small, a hand
operated cyclone seeder or other approved equipment may be used. Seed shall not be
260 covered more than 1/2 in. Seed may be distributed by a drill seeder, cyclone seeder,
hand or other approved equipment which allows for even distribution of the seed. If as
a result of a rain event, the prepared seed bed becomes rutted, crusted or eroded, or
depressions exist, the soil shall be reworked until it is smooth. Reworked areas shall
be re-seeded. All seeded areas shall be mulched within 24 h after seeding.

Temporary seed shall be used for surface stabilization and temporary ground
cover. Temporary cover mixtures shall be placed and be subject to seasonal limitations

196
 205.04

as defined herein. This mixture is not intended to be used as a permanent seed mixture.
This mixture shall not be used to satisfy the requirements of the warranty bond.
270
The mix shall be spray mulched where the slope is steeper than 3:1. From June 16
through August 31, mulching alone shall be used to stabilize the soil.

1. Spring Mix
Spring mix shall be used from January 1 through June 15. This mixture shall be
applied at the rate of 150 lb/ac. The mix shall consist of oats.

2. Fall Mix
Fall mix shall be used from September 1 through December 31. This mixture shall
280 be applied at the rate of 150 lb/ac. This mix shall consist of winter wheat.

Unless otherwise indicated in the SWQCP, fertilizer shall be spread uniformly

over the area to be seeded and shall be applied at 1/2 the rate shown in 621.05(a).
Fertilizer shall only be applied during the active growing season March through
November.

(b) Mulch
Mulch shall be applied uniformly in a continuous blanket at the rate of 2.5 t/ac. If
seeded, mulch shall be placed within 24 h after seeding. The percent of moisture in the
290 mulch shall be determined in accordance with 621.14(c).

Mulch shall be punched into the soil so that it is partially covered. The punching
operation shall be performed longitudinally to the slope. The tools used for punching
purposes shall be disks that are notched and have a minimum diameter of 16 in. The
disks shall be flat or uncupped. Disks shall be placed a minimum of 8 in. apart. Shaft
or axle sections of disks shall not exceed 8 ft in length.

The disk for punching shall be constructed so that weight may be added or
hydraulic force may be used to push puncher into the ground. An even distribution of
300 mulch shall be incorporated into the soil.

On a slope of 3:1 or steeper but flatter than 2:1, or where specified, temporary
mulch stabilization shall also be used. Unless otherwise specified, the following types
may be used.

1. Type A
The mulch shall be held in place by means of commercially produced water borne
mulch binder product. The product shall be manufactured and used in accordance with
all applicable State and Federal regulations. Such product shall be applied in
310 accordance with the manufacturer’s written instructions. A copy of the written
instructions shall be supplied to the Engineer prior to the seeding work. The product
shall include a coverage indicator to facilitate visual inspection for evenness of
application. If the mulch fails to stay in place, the Contractor shall repair all damaged
areas.
197
 205.04

2. Type B
The mulch shall be held in place with binder twine fastened down with wooden
pegs not less than 6 in. long spaced 4 ft apart. The twine shall be placed parallel to and
also at 60° to the pavement edge in both directions. The distance between the
320 intersections of the diagonal strands measured along the strands shall be 12 ft. The
strand parallel to the pavement shall cross the diagonal strands at their intersections to
form equilateral triangles of 12 ft on a side.

3. Type C
The mulch shall be held in place with a polymeric plastic net. The plastic net shall
be unrolled such that it lays out flat, evenly, and smoothly, without stretching the
material. The plastic net shall be held in place by means of staples. The staples shall
be driven at a 90° angle to the plane of the soil slope. Staples shall be spaced not more
than 4 ft apart with rows alternately spaced. The plastic net shall be secured along the
330 top and bottom of the soil slope with staples spaced not more than 1 ft on center. The
ends and edges of the plastic net shall be overlapped approximately 4 in. and stapled.
Overlaps running parallel to the slope shall be stapled 1 ft on center and overlaps
running perpendicular to the slope shall be stapled at least 3 ft on center. The plastic
net shall be placed with the length running from top of slope to toe of slope, or the
plastic net shall be placed with the length running horizontally or parallel to the
contour.

On a slope of 2:1 or steeper, or where specified, a manufactured surface protection

product shall be used.
340
(c) Manufactured Surface Protection Products
Prior to placing a manufactured surface protection product, the area to be covered
shall be free of all rocks or clods of over 1 1/2 in. in diameter, and all sticks or other
foreign material, which prevent the close contact of the blanket with the seed bed.

After the area has been properly shaped, fertilized, and seeded, the manufactured
surface protection product shall be laid out flat, evenly, and smoothly, without
stretching the material.

350 Manufactured surface protection products may be used for covering an area that
has not been seeded. Soil cover shall not be used to cover seeded areas.

1. Excelsior Blanket
An excelsior blanket may be used as mulch for seeding where seeding is specified
or where erosion control blanket is specified. Excelsior blankets shall be placed within
24 h after seeding operations have been completed. Excelsior blankets shall be
installed in accordance with the manufacturer’s recommendation.

2. Straw Blanket
360 A straw blanket may be used as mulch for seeding where mulched seeding is
specified or where erosion control blanket is specified. Straw blankets shall be placed
198
 205.05

within 24 h after seeding. The straw blanket shall be unrolled over the designated area
so that the plastic mesh is on top and the straw fibers are snugly and uniformly in
contact with the soil surface. The rolls shall be butted together and stapled in place.
The staples shall be driven through the blanket at a 90° angle to the plane of the ground
surface. Each staple shall anchor the plastic mesh. The staples shall be spaced in
accordance with the manufacturer’s recommendations.

For placement on a slope, the straw blankets shall be placed with the length
370 running from the top of slope to the toe of slope and shall extend a minimum of 3 ft
over the crown of the slope. The blanket shall be stapled in accordance with the
manufacturer’s recommendations.

For placement in ditch lines, the straw blanket shall be unrolled parallel to the
centerline of the ditch. The blanket shall be placed so that there are no longitudinal
seams within 24 in. of the bottom centerline of the ditch. In a ditch line, the blanket
shall be stapled in accordance with the manufacturer’s recommendations with a
minimum of six staples across the upstream end of each roll.

380 3. Rolled Erosion Control Products

The Contractor shall use degradable RECPs including netting, open weave textile,
and erosion control blankets.

Seed shall be applied in accordance with 621 unless soil infilling is required.

If soil infilling is required, RECP shall be first installed and then seed applied and
brushed or raked 1/4 to 3/4 in. of topsoil into voids in the RECP filling the full product
thickness. Staples of at least 6 in. in length shall be used to secure the RECP. The
RECP shall be unrolled parallel to the primary direction of flow and placed in direct
390 contact with the soil surface. RECP shall not bridge over surface inconsistencies.
Edges of adjacent RECP shall be overlapped by 2 to 4 in. Staples shall be placed to
prevent seam separation in accordance with the manufacturer’s recommendations.

4. Geotextile
Disturbed soil shall be covered with geotextile. The covering shall be placed over
the exposed soil in a shingle like fashion with a 2 ft minimum overlap covering all
loose or disturbed soil. The geotextile, if new, shall be in accordance with 918.02. The
geotextile used for soil covering need not be new but shall not have holes or unrepaired
rips or tears. All repairs shall be made in accordance with the manufacturer’s
400 recommendation.

205.05 Concentrated Flow Protection

(a) Check Dam

Check dams and modified check dams shall be constructed as shown on the plans.
Geotextile for check dams shall be in accordance with 616 unless otherwise specified.

199
 205.05

Temporary revetment riprap shall be in accordance with 616. No. 5 and No. 8 filter
stone shall be in accordance with 904.

410 (b) Check Dam, Traversable

Traversable check dams shall be composed of straw bales, 8 in. minimum
diameter fiber rolls, or 8 in. minimum diameter socks filled with straw, ground wood
chips, shredded bark, or other approved material for site specific conditions. Rolls and
socks may be stacked in a triangle pattern as shown on the plans. Check dams shall be
staked as shown on the plans or as specified by the manufacturer. Check dams shall
be configured to eliminate gaps between sections. Straw bales shall be placed such
that the bindings are parallel to and not in contact with the ground.

(c) Diversion Interceptors

420 Grading for diversion interceptors shall be in accordance with 203 with the
exception that compaction requirements will not apply. The Contractor shall identify
the construction areas which shall utilize diversion type A or B. Slope drains shall be
provided at the low points of the diversion interceptor. Perimeter diversion, type C
shall be installed prior to earth moving activities and shall be immediately stabilized.
Type A or B shall be stabilized if anticipated to be left in place for more than seven
calendar days.

(d) Sediment Traps

Sediment traps shall be constructed with revetment riprap, filter stone and
430 geotextile.

(e) Sediment Basins

Embankment construction shall be in accordance with 203. Temporary revetment
riprap used for overflow protection shall be in accordance with 904, unless otherwise
indicated in the SWQCP. Sediment basins shall be constructed as shown on the plans,
or as specified in the SWQCP. Sediment basins shall be designed to provide a
minimum storage volume to contain the runoff from a 10 year 24 h storm event.

(f) Slope Drains

440 Slope drain pipes shall be lengthened as required due to the construction of the
embankment.

(g) Vegetative Filter Strips

Designated vegetative filter strips shall not be disturbed. Small rills that form shall
be repaired. Fertilizer shall be applied as indicated in the SWQCP.

(h) Splashpads
Splashpads shall be constructed with revetment riprap with geotextile.

450 (i) Inlet Protection

All deck and curb drains shall have sediment control measures when the structure
or road is to be used for hauling operations or adjacent to disturbed areas. Copies of
all current manufacturer’s installation manuals shall be provided prior to installation.
200
 205.07

205.06 Perimeter Protection

(a) Silt Fence

Shipping, handling and storage shall be in accordance with the manufacturer’s
recommendations. The silt fence material shall be in accordance with 918.02(d). The
460 silt fence material will be rejected if it has defects, tears, punctures, flaws,
deterioration, or damage incurred during manufacture, transportation, storage, or
installation. Each roll shall be labeled or tagged to provide product identification.

Joints shall be made from the ends of each section of fence wrapped around a
wood stake and joined together or other method recommended by the manufacturer.
Copies of all current manufacturer manuals shall be provided prior to installation.

(b) Filter Berm

Filter berms shall be constructed of organic mulch, filter sock, or No. 5 and No. 8
470 filter stone.

205.07 Maintenance
Stormwater management measures shall be inspected, at a minimum, once every
seven days and after a 1/2 in. rain event. Inspections shall be documented and records
shall be maintained by the Contractor, to be submitted to the Engineer on the next
business day following the inspection. The temporary protection measures shall be
remedied within 48 h after inspection or as directed. The Contractor shall rebuild or
repair damaged stormwater management measures.

480 If conditions do not allow the Contractor access to the location of the stormwater
management features using normal equipment and maintenance, the Contractor shall
submit to the Engineer an acceptable written alternate schedule, within 48 h, to bring
the stormwater management features back into compliance.

(a) Silt Fence

If the fence fabric tears, starts to decompose, or becomes ineffective, the affected
portion shall be replaced. Deposited sediment shall be removed once it reaches 1/2 the
height of the fence at its lowest point. Once the contributing drainage area has been
stabilized, the Contractor shall remove the fence and sediment deposits, grade the site
490 to blend with the surrounding area, and stabilize the graded area.

(b) Sediment Basin

Sediment shall be removed once it has accumulated to 1/2 the design volume. The
filter stone around the riser pipe shall be replaced if the sediment pool does not drain
within 72 h following a stormwater runoff event.

(c) Filter Berm

Accumulated sediment shall be removed once it reaches 1/4 of the height of the
filter berm. The filter berm shall be inspected to ensure that it is holding its shape and
500 allowing adequate flow. Eroded and damaged areas shall be repaired.
201
 205.08

(d) Inlet Protection

Accumulated sediment shall be removed once identified and after each storm
event. Flushing with water will not be allowed. The sediment shall not be allowed to
re-enter the paved area or storm drains. Curb inlet inserts shall be cleaned in
accordance with the manufacturer’s recommendations.

(e) Sediment Traps

Following each storm event, the Contractor shall repair slope erosion and piping
510 holes as required. Sediment shall be removed once it has accumulated to 1/2 design
volume. The Contractor shall replace the coarse aggregate filter stone if the sediment
pool does not drain within 72 h following a stormwater runoff event.

(f) Concrete Washout

The containment system shall be inspected for leaks, spills, and tears, and shall
be repaired or replaced as necessary. The Contractor shall ensure that each
containment system maintains adequate capacity. Solidified waste concrete shall be
disposed of in accordance with 202.

520 (g) Check Dams

Sediment shall be removed once it reaches 1/2 the height of the check dam.
Sediment shall be removed and disposed of in accordance with 201.03 and 203.08.
The Contractor shall rebuild or repair each damaged check dam to maintain the design
height, cross section, and control function.

205.08 Quality Adjustments

If maintenance deficiencies are not remedied within 48 h after identifying them
in the inspection and in accordance with 205.07, the Contractor may be assessed
damages for failure to maintain the required stormwater management. For each day,
530 during which the following units of stormwater management are in an unsatisfactory
condition, a quality adjustment, in accordance with 109, will be assessed as shown
below, per each unsatisfactory unit.

(a) Silt Fence: $100.00 per each contiguous 100 ft section or

portion thereof.

(b) Check Dam: $100.00 per check dam.

(c) Sediment Basin: $100.00 per basin.

540
(d) Sediment Trap: $100.00 per trap.

(e) Inlet Protection Devices: $100.00 per unit.

(f) Failure to inspect site per 327 IAC 15-5 requirements: $100.00
per required inspection.

202
 205.10

(g) Failure to temporarily stabilize non-vegetated areas: $100.00

per acre or portion thereof.
550
(h) Failure to correct identified deficiencies not defined above:
$100 per day per measure.

Silt fence will be considered unsatisfactory if the fence material has an exposed
cut or tear exceeding 1 ft in length, a seam has separated or the retained sediment
exceeds 1/2 of the height of the fence.

Check dams, sediment basins and sediment traps will be considered unsatisfactory
if they no longer perform their function, or the retained sediment exceeds 1/2 of the
560 design volume.

Inlet protection devices will be considered unsatisfactory if they no longer

perform their function, or the accumulated sediment exceeds 1/2 of the capacity of the
device.

205.09 Removal
Stormwater management measures shall be removed as soon as an area becomes
stable. All stormwater management measures shall be removed prior to application for
the NOT. The Contractor shall remove and dispose of all excess silt accumulations,
570 dress the area, and reestablish vegetation to all bare areas in accordance with the
contract requirements. Use or disposal of stormwater management measures shall be
as specified in the SWQCP.

205.10 Method of Measurement

Temporary silt fence and traversable check dams will be measured by the linear
foot.

Temporary sediment basins, standard metal end sections and temporary inlet
protection will be measured by each unit installed.
580
Temporary revetment riprap check dams, temporary revetment riprap, temporary
sediment traps, splashpads, temporary filter stone, temporary mulch, No. 2 stone for
stable construction entrances, and fertilizer will be measured by the ton.

Temporary mulch stabilization, manufactured surface protection products, and

temporary geotextile will be measured by the square yard.

Temporary seeding will be measured by the pound.

590 Removal of sediment will be measured by the cubic yard.

203
 205.11

Temporary slope drains will be measured by the linear foot. Measurement will be
made for the maximum footage in place at one time, per drain location regardless of
the number of times the material is moved.

Temporary filter berms and filter sock will be measured by the linear foot
complete in place.

Revetment riprap and filter stone used in sediment basins will be measured by the
600 ton.

Excavation for detention ponds, temporary sediment traps and temporary

sediment basins will be measured as common excavation in accordance with 203.27.

Diversion interceptors type A and B, and interceptor ditches will not be measured
for payment. Diversion interceptors type C will be measured by the linear foot.

Mobilization and demobilization for surface stabilization will be measured per

each trip as provided in the submitted and accepted SWQCP.
610
Weekly inspections will be measured by each for inspections conducted after the
contract completion date.

SWQCP Preparation and Implementation Level 1 and Level 2 will not be

measured.

BMPs used at the off-site locations designated in 205.03 and concrete washouts
will not be measured for payment.

620 205.11 Basis of Payment

The accepted quantities of silt fence and traversable check dams will be paid at
the established unit price per linear foot.

Temporary sediment basins, standard metal end sections, and temporary inlet
protection will be paid at the established unit price per each unit installed.

Temporary revetment riprap check dams, temporary revetment riprap, temporary

sediment traps, splashpads, temporary filter stone, temporary mulch, No. 2 stone for
stable construction entrances, and fertilizer will be paid at the established unit price
630 per ton.

Temporary mulch stabilization, manufactured surface protection products, and

temporary geotextile will be paid at the established unit price per square yard.

Temporary seeding will be paid at the established unit price per pound.

Removal of sediment will be paid at the established unit price per cubic yard.

204
 205.11

Temporary slope drains, temporary filter berms, and filter sock will be paid at the
640 established unit price per linear foot.

Revetment riprap and filter stone used in sediment basins will be paid at the
established unit price per ton.

The accepted quantities of excavation for detention ponds, temporary sediment

traps, and temporary sediment basins will be paid for as common excavation in
accordance with 203.28.

Diversion interceptors type C will be paid at the established unit price per linear
650 foot.

Payment for mobilization and demobilization for surface stabilization will be paid
at the established unit price per each and will be made for the initial movement to the
project site, and for each occurrence as indicated in the submitted and accepted
SWQCP, or as directed.

Weekly inspections will be paid at the established unit price per each for
inspections conducted after the contract completion date. No payment will be made
for inspections during the time when liquidated damages in accordance 108.09 are
660 assessed.

The Department will include the pay item Stormwater Management Budget, with
an established dollar amount, in the proposal to pay for BMP work. This established
amount is the Department’s estimate of the total cost of the BMP work required to be
performed for the contract. The established amount shown in the proposal is included
in the total bid amount. The Department will pay for those items installed and listed
with established prices for the quantities installed as indicated in the submitted and
accepted SWQCP. If the BMP work exceeds the Department’s estimated amount, the
additional BMPs shall be explained and submitted as a revision to the SWQCP. The
670 additional work will be reviewed for acceptance in accordance with 104.03 except that
the additional BMP work will be paid at the pre-determined established prices shown.

The Department will pay to replace BMPs that have failed during a rain event at
the unit price shown in 205.11 if those BMPs had been adequately designed based on
the watershed, installed correctly, and maintained as necessary.

The item SWQCP Preparation and Implementation Level 1 will be paid when a
Level 1 SWQM is designated in the contract documents. The item SWQCP
Preparation and Implementation Level 2 will be paid when a Level 2 SWQM is
680 designated in the contract documents. The item SWQCP Preparation and
Implementation Level 1, or Level 2 will be paid as a lump sum. After the SWQCP has
been submitted, 25% of the SWQCP Preparation and Implementation bid price will be
paid. If the SWQCP is submitted in phases, 25% of the SWQCP Preparation and
Implementation bid price will be paid after the first phase of the SWQCP has been

205
 205.11

submitted. The balance will be paid as the plan is implemented over the life of the
contract.

Items shown with an established price will be paid at the prices shown. If any of
the following items are shown in the schedule of pay items the bid item and price will
690 prevail over the established prices shown.

Payment will be made under:

Pay Item Pay Unit Established

Symbol Price

Diversion Interceptor Type C ...................................... LFT .......... $20.00

Fertilizer ...................................................................... TON ......... $725.00
Filter Sock ................................................................... LFT .......... $5.00
700 Manufactured Surface Protection Product ................... SYS .......... $1.25
Mobilization and Demobilization for
Surface Stabilization ............................................ EACH ...... $650.00
No. 2 Stone .................................................................. TON ......... $25.00
Sediment, Remove ....................................................... CYS ......... $20.00
Splashpad .................................................................... TON ......... $55.00
Standard Metal End Section ........................................ EACH ...... $340.00
Stormwater Management Budget ................................ DOL
SWQCP Preparation and Implementation, Level 1 ..... LS
SWQCP Preparation and Implementation, Level 2 ..... LS
710 Temporary Check Dam, Revetment Riprap ................ TON ......... $50.00
Temporary Check Dam, Traversable........................... LFT .......... $15.00
Temporary Filter Berm ................................................ LFT .......... $15.00
Temporary Filter Stone................................................ TON ......... $40.00
Temporary Geotextile .................................................. SYS .......... $2.50
Temporary Inlet Protection.......................................... EACH ...... $100.00
Temporary Mulch Stabilization ................................... SYS .......... $0.25
Temporary Mulch ........................................................ TON ......... $400.00
Temporary Revetment Riprap ..................................... TON ......... $50.00
Temporary Sediment Basin ......................................... EACH ...... $3,000.00
720 Temporary Sediment Trap ........................................... TON ......... $40.00
Temporary Seed .......................................................... LBS .......... $2.50
Temporary Silt Fence .................................................. LFT .......... $2.00
Temporary Slope Drain ............................................... LFT .......... $20.00
Weekly Inspection ....................................................... EACH ...... $400.00

The cost associated with revisions to permits shall be included in the cost of
SWQCP Preparation and Implementation.

The cost for trenching, backfilling, posts, fencing, and all necessary incidentals
730 shall be included in the cost of the pay item for temporary silt fence.

206
 205.11

The cost for stakes, trenching, backfilling, posts, and all necessary incidentals
shall be included in the cost of the pay item for temporary check dams, traversable.

The payment for temporary sediment basin shall include all costs involved with
construction of the basin except for excavation, revetment riprap, and filter stone.

The payment for temporary sediment trap shall include all costs involved with
construction of the trap except for excavation.
740
Temporary entrances utilized by the Contractor for borrow and waste areas will
not be paid for directly.

The costs for diversion interceptor types A and B and interceptor ditches shall be
included in the cost of the earth moving items.

The cost for anchors and all incidentals necessary to perform the work shall be
included in the cost of the pay item for temporary slope drains.

750 The cost of materials, installation, inspection, maintenance, and removal of

stormwater management measures at off-site locations designated in 205.03 will not
be measured for payment.

The payment for BMPs in this section shall include materials, installation,
maintenance, removal and proper disposal, except for the removal of sediment.

The cost associated with sediment removal and temporary filter stone replacement
due to BMP maintenance shall be included in the cost of the pay item for sediment
removal.
760
The cost of constructing, maintaining, and removal of the construction entrance,
other than those constructed by the Contractor for borrow and waste sites, shall be
included in the cost of No. 2 stone. No direct payment will be made for construction
entrances for borrow and waste sites.

The cost associated with concrete washout shall not be paid for directly, but shall
be included in the costs of the concrete pay items.

The costs associated with the weekly and post-event inspections and all other
770 inspections conducted prior to the original contract completion date shall be included
in the costs of the other pay items of this section.

Adjustments to the contract payment with respect to stormwater management will

be included in a quality adjustment in accordance with 109.05.1.

207
 206.01

SECTION 206 – STRUCTURE EXCAVATION

206.01 Description
This work shall consist of the excavation and backfill or disposal of all materials
required for the construction of foundations for substructures of bridges, culverts, and
retaining walls; and for the furnishing and subsequent removal of all necessary
materials and equipment for and the construction of cribs, cofferdams, caissons, and
similar items, together with their dewatering. The work shall be in accordance with
105.03.
10
All excavation for structures below the designed slope or subgrade line as shown
on the plans shall be included under this item.

Unless otherwise specified, structure excavation shall include all pumping,

bailing, draining, sheeting, bracing, and incidentals required for proper execution of
the work.

206.02 Class X Excavation

20 (a) General Excavation

If one or more of the following materials is encountered within the limits of
foundation excavating, such shall be defined as class X excavation.

1. solid rock, hard ledge rock, slate, hard shale, or

conglomerate, any of which is actually removed by
blasting or use of pneumatic or equivalent tools and which
could not reasonably be removed by any other method;

2. loose stones or boulders more than 1/2 cu yd in volume;

30
3. concrete, masonry, or other similar materials which are
parts of an old structure not shown on the plans;

4. timber grillages, old foundation piling, buried logs, stumps,

or similar materials which extend beyond the limits of
excavation so that they must be cut off. Such obstructions
shall be removed back to cofferdam limits and the portions
so removed within cofferdam limits will be considered as
class X.
40
Material commonly known as hardpan will not be considered as class X. If
material is encountered during excavation which seems to be in accordance with that
defined herein as class X, notification shall be made in writing, and ample time shall
be allowed to make necessary investigations and measurements to determine the class
and volume of the material in question.

208
 206.05

(b) Excavation for Foundation of Traffic Support Structures

If class X material as defined in 206.02(a) is encountered within the limits of
foundation excavation for traffic support structures, overhead sign structure
50 foundations, strain pole, or high mast lighting foundations, the foundation shall be
located as directed.

If class X material in accordance with 206.02(a)1 is encountered at foundations

for overhead sign structures, strain poles, signal cantilever structures, high mast
lighting poles, and ITS towers, the material shall be excavated to allow the foundation
to be embedded as shown on the plans or as directed.

If class X material in accordance with 206.02(a)1 is encountered at foundations

for wide flange sign supports, signal pedestals, conventional light poles, the material
60 shall be excavated to allow the foundation to be embedded a distance that is equal to
1/2 of the remaining depth of the foundation before the material was encountered or
to a minimum 3 ft depth, whichever is greater.

If class X material in accordance with 206.02(a)2, 206.02(a)3, or 206.02(a)4 is

encountered, the material shall be removed to the total depth of the foundation as
shown on the plans.

206.03 Wet Excavation

Wet excavation shall be defined as that portion of foundation excavation, except
70 class X, which is below a horizontal plane designated on the plans as the upper limit
of wet excavation and above the bottom of the footing as shown on the plans. If wet
excavation is a pay quantity and the elevation of the upper limit of wet excavation is
not shown on the plans, an elevation of 1 ft above the elevation of low water level as
shown on the plans shall be used as such limit.

206.04 Dry Excavation

Dry excavation shall be defined as that portion of foundation excavation, except
class X, which is above the upper limit of wet excavation.

80 206.05 Foundation Excavation, Unclassified

If the Schedule of Pay Items provides a pay quantity of foundation excavation,
unclassified, and none for wet excavation or dry excavation, then foundation
excavation, unclassified shall include all work described as wet excavation and dry
excavation, regardless of whether or not water is encountered, but shall not include
class X. Even though designated herein as foundation excavation, unclassified, it shall
be regarded in these specifications as a class of excavation.

If no upper limit of foundation excavation, unclassified is shown on the plans, it

shall be at the original ground except where waterway excavation, common
90 excavation, or other classified excavation overlaps the area of foundation excavation
and is a pay item. The upper limit of foundation excavation, unclassified shall be the
lower limit of the overlapping classified material.

209
 206.06

CONSTRUCTION REQUIREMENTS

206.06 General Requirements

The drainage requirements of 203.14 shall apply to excavation for structures and,
in addition, adequate outlets shall be provided as shown on the plans or as directed, if
within the limits of the excavation.
100
All excavation shall be adequately shored to avoid damage to the structure, its
approaches, adjacent roadway, embankments, tracks, buildings, or other property.

Footing excavation shall, in general, conform with the outlines of footings as

shown on the plans, or as revised, and shall be of sufficient size to enable construction
of the footings to their full required dimensions. If an existing structure is being
extended, the old footings shall be adequately protected. Boulders, logs, or other
unforeseen obstacles encountered shall be removed.

110 The elevations of bottoms of footings as shown on the plans shall be considered
approximate. The final elevations shall depend on conditions encountered during
excavation, at which time other elevations may be ordered in writing if necessary to
secure satisfactory foundations.

Where existing foundation material would not support the contemplated load
safely, the plans may require, or it may be directed that foundation piles be driven in
the footing area. This piling shall be furnished, driven, and paid for in accordance with
701.

120 206.07 Disposal of Excavated Material

Except as otherwise herein provided, material excavated for a structure or its
approaches, including any material excavated beyond the pay limits of foundation
excavation or its specified or approved extensions, shall, if suitable, be used for filling
around the new structure, for spandrel filling, approach embankment, regular
embankment, or for any combination of these, all as specified or directed.

If excavated material is in accordance with 211.02 and if material of this nature is

required at the structure or in its approaches, then this material shall be used as special
fill and placed in accordance with applicable provisions of 211.
130
Surplus or unsuitable material shall not be disposed of in any manner that would
obstruct or pollute the stream or otherwise impair the efficiency or appearance of the
structure. If there are piers in the water, permission may be granted to waste excavated
material adjacent to these piers provided such waste does not obstruct the waterway.
If usable excavated material is wasted without authority, the quantity so wasted will
be deducted from the quantities of common excavation, borrow, or B borrow,
depending on the nature of the waste and its use.

210
 206.08

Disposal of surplus or unsuitable material, including class X excavation, outside

140 the right-of-way shall be in accordance with 201.03 and 203.08.

206.08 Preparation of Foundation Surfaces

Excavation for foundations on rock without piles shall extend a minimum of 2 ft
into solid rock. All rock or other hard material, if to be left in place as a foundation
surface, shall be freed of loose material, cleaned, and cut to a firm surface. The final
surface shall be level, stepped, or serrated as directed. Seams shall be cleaned and
filled with concrete, cement mortar, or grout. These conditions shall prevail when the
foundation masonry is placed.

150 Where the masonry is to rest on a foundation surface other than those described
above, the approximate bottom of the excavation shall not be disturbed. The final
removal of material to the required grade shall be done carefully just prior to placing
the foundation masonry. The final surface shall be left smooth and, unless otherwise
designated, be level.

Notification shall be given after final excavation of each foundation is completed.

No masonry shall be placed until the depth of the excavation and the character of the
foundation material have been approved.

160 Before foundations that do not require piling are poured, sufficient test borings
shall be made to determine the character of the underlying material for a depth of at
least 5 ft below the bottom of the footing. Also, before pilings are driven in foundations
requiring piling, sufficient soundings shall be made to determine the character of the
underlying material for a depth of 10 ft below the bottom of the footing.

Rock at the bottom of spread footings shall be proof tested. Exploratory holes of
2 in. diameter shall be drilled into the foundation base. Holes shall be drilled into
sound rock to a depth of 5 ft or as directed. Three holes shall be drilled into each
foundation base. Observations shall be made at each hole as follows:
170
1. speed of drilling

2. drill pressure

3. dropping or clogging of drill bit

4. loss of drill water, if used

5. probing of the sides of the holes with a right angled chisel

180 point. The chisel shall be formed from a rod of 3/8 or 1/2
in. diameter

6. continuity of bearing material.

211
 206.09

A professional engineer shall supervise the proof testing work. A report for each
hole shall be prepared and submitted for review and approval.

206.09 Cofferdams and Temporary Construction Dikes

Working drawings shall be submitted in accordance with 105.02. They shall show
190 the proposed method of cofferdam construction and other details left open to choice
or not fully shown on the plans.

Working drawings for dikes to be used in lieu of cofferdams or to be used for

access to the work shall be submitted in accordance with 105.02, if such dikes are to
be constructed within the waterway. Approval of such drawings will only be given if
the probability of stream pollution and stream flow restriction is minimal.

Cofferdams shall be constructed for all abutments and piers where water or
unstable soil is encountered or where the soil may become unstable; excessive stream
200 pollution or stream flow restriction might occur with other construction procedures; or
if necessary to support the sides of excavated areas, embankment, adjacent buildings,
tracks, or other premises. In general, they shall be carried down well below bottoms
of footings, shall be well braced, and as nearly watertight as practicable. The interior
dimensions shall be sufficient to provide ample clearance to enable pile driving, the
construction of forms, and clearance for pumping equipment outside the forms.
Cofferdams shall be constructed to protect plastic concrete against damage from a
sudden rising of the stream and to prevent damage to the foundation by erosion.

No timber or bracing that would extend into substructure masonry shall be left in
210 cofferdams except with written permission.

Cofferdams which become tilted or moved laterally during the process of sinking
shall be righted or enlarged to provide ample clearance. Any necessary correction shall
be made with no additional payment.

Except as otherwise provided herein, cofferdams shall be dewatered and sediment

controlled in accordance with 108.04. Pumping will not be allowed for 24 h after
concrete placement, unless otherwise approved.

220 When conditions are encountered under which it is established that no reasonable
pumping will dewater the cofferdam when every practicable effort has been made to
reduce the inflow of water, or other conditions are such that a foundation seal is
necessary, the construction of a concrete foundation seal may be required of such
dimensions as necessary. This seal shall be constructed in accordance with 702.20(f).

Unless otherwise specified, all cofferdam bracing shall be removed and all
sheeting removed or cut off at least 2 ft below the finished ground line, except within
the low-water channel it may either be removed or cut off even with the stream bed.
Removal shall be such that the finished masonry will not be marred or disturbed.
230

212
 206.11

206.10 Method of Measurement

Structure excavation, except wet excavation, will be measured in cubic yards in
its original position below the limits of roadway excavation. Wet excavation will be
the theoretical quantity in accordance with 206.11(b). When structures are to be placed
in embankment sections, the natural ground line, as cross sectioned, will be the
uppermost level of computation unless otherwise specified or shown on the plans.

Class X material encountered and removed during the excavation of foundations

for traffic support structures will be measured to the foundation neat lines as shown
240 on the plans below the surface of class X material.

If the pay unit for any item of excavation in the Schedule of Pay Items is lump
sum, no measurement will be made.

Extended excavation for footings will be measured to include the entire depth
needed for the deeper footing and the entire width needed to comply with OSHA or
IOSHA requirements.

Additional excavation required for a culvert when the culvert is placed at an

250 elevation that is a least 1 ft below the elevation shown on the plans shall be measured
to include the entire width needed to comply with OSHA or IOSHA requirements.

206.11 Basis of Payment

The accepted quantities of structure excavation will be paid for at the contract unit
price per cubic yard or lump sum.

Unless otherwise provided, excavation for bridges will be paid for at the contract
unit price or prices per cubic yard for the respective class or classes involved.

260 If cofferdams are specified as a pay item, they will be paid for at the contract lump
sum price for cofferdams.

If a foundation seal is constructed, it will be paid for in accordance with 702.28.

The quantity of class X excavation to be paid for will be the cubic yards of such
material actually removed from within vertical planes defining the neat lines of the
footings, except where material classified as class X excavation overlays other
material which shall be excavated to cofferdam limits. Such overlying strata will be
paid for to the limits of the material excavated beneath it. Unless otherwise provided,
270 no additional payment will be made for such excavation made outside these limits.

If class X excavation is encountered at locations other than sign foundations,

traffic signal foundations, and highway illumination foundations, and there is no
contract unit price for class X excavation, payment will be made at a unit price per
cubic yard as follows:

213
 206.11

1. $1,000.00 per cu yd if the quantity of class X excavation is

less than or equal to 1 cubic yard per foundation.

280 2. When the quantity of class X excavation is greater than 1

cubic yard per foundation, payment will be made at the
lesser of four times the contract unit price for wet
excavation or 10 times the contract unit price for dry
excavation.

If class X excavation is encountered at locations for sign foundations, traffic

signal foundations, highway illumination, and ITS foundations and there is no contract
unit price for class X excavation, payment will be made as follows:

290 1. $500.00 if the quantity of class X excavation is less than or

equal to 1 cubic yard per foundation.

2. $500.00 per cu yd for all quantities over 1 cubic yard.

In addition to the payment for class X excavation at sign foundations, traffic signal
foundations, highway illumination, and ITS foundations when there is no contract unit
price for class X excavation, a mobilization and demobilization payment for class X
excavation will be paid in the amount of $1,500.00 per occurrence. Multiple
mobilization and demobilization payments will be paid if all project foundation
300 locations are not made available in a reasonable time frame while the equipment is on
the project. The cost of this work will be included in a change order developed in
accordance with 109.05 and paid as class X excavation and a mobilization and
demobilization for class X excavation.

If class X excavation is encountered in foundation excavation unclassified and

there is no pay item shown in the Schedule of Pay Items, payment will be made at
eight times the contract unit price per cubic yard for foundation excavation
unclassified.

310 Except as otherwise provided, the quantity of dry excavation to be paid for will
be the amount of such excavation actually removed from its original position within
vertical planes which are 18 in. outside the neat lines of the footings and parallel
thereto. Regardless of the quantity actually removed, the quantity of wet excavation to
be paid for will be the theoretical volume bounded by the bottom of the footings, the
upper limit of wet excavation, and vertical planes which are 18 in. outside the neat
lines of footings and parallel thereto. Additional payment will not be made for such
excavation outside these limits.

Where it is necessary to carry a footing or a portion of a footing deeper than its

320 elevation shown on the plans, such additional excavation, except a portion thereof
classified as class X which is carried down to a plane which is 4 ft below the bottom
of footing as shown on the plans, will be paid for as extended dry excavation, extended

214
 206.11

wet excavation, or extended foundation excavation unclassified, at a price to be

determined by multiplying the contract unit price for dry excavation, wet excavation,
or foundation excavation, unclassified, respectively by the factors shown below.

1. For footings or portions thereof lowered not more than 1 ft,

the factor will be 2.0.

330 2. For footings or portions thereof lowered more than 1 ft and

not more than 2 ft, the factor will be 2.5.

3. For footings or portions thereof lowered more than 2 ft and

not more than 3 ft, the factor will be 3.5.

4. For footings or portions thereof lowered more than 3 ft and

not more than 4 ft, the factor will be 5.0.

For a footing lowered more than 4 ft below its elevation shown on the plans, all
340 such extended excavation below the bottom of footing elevation shown on the plans
to the revised bottom of footing shall be done as extra work in accordance with 104.03.
Payment will be made in accordance with 109.05.

All backfill material or sub-footing material required whose source is other than
structure excavation will be paid for at the contract unit price for the material being
used or as extra work if no unit price has been established. A change order will be
prepared in accordance with 109.05.

The cost of furnishing all materials and labor associated with proof testing of rock
350 shall be included in the cost of other pay items.

If a borrow area is required and borrow is not specified as a pay item, payment
will be made in accordance with 203.28.

If a waste area is required and the contract documents do not identify excess
excavation or require removal of any items, payment will be made in accordance with
203.28.

Except for sign foundations, traffic signal foundations, and highway illumination
360 foundations, if a type of excavation for which no pay item exists is required and the
new type of excavation requires the Contractor to use equipment not otherwise being
used on the contract, payment will be in accordance with 203.28.

If a type of excavation for which no pay item exists is required and the new type
of excavation requires additional traffic control not shown on the plans or results in
traffic control being required for an additional period of time, payment will be made
in accordance with 203.28.

215
 206.11

Payment will be made under:

370
Pay Item Pay Unit Symbol

Cofferdam.................................................................................. LS
Excavation, Dry ......................................................................... CYS
Excavation, Foundation, Unclassified ....................................... CYS
Excavation, Wet ........................................................................ CYS
Excavation, X ............................................................................ CYS

The cost of placing and compacting of all backfill when the materials used are
380 obtained from excavation, clearing and grubbing required and not paid for under
another pay item, formation of embankments made with material from structure
excavation, and disposal of all surplus or unsuitable excavation, unless otherwise
specified shall be included in the cost of the pay items.

The cost for disposing of surplus or unsuitable excavated materials outside the
right-of-way shall be included in the various pay items in this section.

(a) Culverts
This requirement will not include pipe culverts. Except as otherwise provided
390 herein, excavation for culverts will not be paid for directly. The cost thereof shall be
included in the cost of the class of concrete used therein. The cost of all necessary
removal and satisfactory disposal of all or part of the existing old structure unless its
removal is otherwise provided for, cleaning out an old channel or constructing a new
channel within the right-of-way limits and widening it to the grade of the existing or
proposed new stream bed as shown on the plans or as directed, construction of all
necessary curbs and cofferdams and their subsequent removal, subsoil borings or
soundings below bottom of footings, dewatering, disposal of excavated materials, and
all labor, equipment, tools, and necessary incidentals shall be included in the cost of
this work.
400
If a culvert is lowered, relocated, or material of such nature is encountered that
additional excavation is necessary over and above that required at the originally
planned location, the additional excavation will not be paid for if it is 10 cu yd or less.
Additional excavation in excess of 10 cu yd will be paid for at three times the contract
unit price for the class of excavation involved. However, if the culvert is placed at a
depth that is equal to or greater than 1 ft deeper than the elevation shown on the plans,
the additional excavation in excess of 10 cu yd will be paid at five times the contract
unit price for the class of excavation involved.

410 (b) Bridges

The cost of clearing right-of-way within the project limits; constructing,
dewatering, and removal of cofferdams, if not a pay item; subsoil borings or soundings
below bottoms of footings; final preparation of foundation surfaces; disposal of

216
 206.11

excavated material; and all labor, equipment, tools, and incidentals necessary to the
satisfactory completion of the excavation shall be included in the cost of this work.

The cost of all required working drawings; furnishing, hauling, and placing
necessary materials; construction; maintenance; dewatering; removal of bracing;
removal of or cutting off the sheeting; and labor, equipment, tools, and necessary
420 incidentals shall be included in the cost of cofferdams.

If cofferdams are not specified as a pay item, and if cofferdams are necessary,
their cost shall be included in the cost of excavation or the concrete requiring their use.

If there is no pay item for dry excavation, the cost of this part of the work shall be
included in the cost of the foundation concrete or for other concrete requiring such
excavation. However, where waterway excavation, common excavation, or other
classified excavation overlaps the area of dry foundation excavation, no deduction will
be made in the pay volume of such overlapping classified material. This exception will
430 apply only if dry excavation is not a pay item.

Except as otherwise provided in 206.05, the cost of foundation excavation

unclassified shall include all work and elements of volume, and excavation described
above for wet excavation and dry excavation, regardless of whether or not water is
encountered. The cost of foundation excavation unclassified shall not include the cost
of class X excavation.

The classifications for necessary excavation for a cantilevered wing outside the
limits of foundation excavation shall be the same as those governing the excavation
440 inside such limits. The quantity to be paid for will be that actually removed from its
original position within vertical planes 18 in. outside the neat lines shown on the plans
and parallel thereto and above a plane 1 ft below and parallel to the bottom surface of
the wing.

The classifications for necessary excavation for arch superstructures outside the
limits of foundation excavation or waterway excavation shall be those governing the
excavation inside the limits of foundation excavation or waterway excavation,
depending on the location of the excavation for the arch superstructure. Such
excavation shall be bounded by vertical planes which are 1 ft outside the outside faces
450 of the arch ring and parallel thereto, by a vertical plane passing through the intersection
of the intrados of the arch ring and the original ground line and parallel to the face of
the abutment, and the vertical plane bounding the foundation excavation on the side
adjacent to the arch ring. The lower limit shall be a sloping plane which is 1 ft below
a plane connecting the intersection of the intrados of the arch ring and the original
ground, and the intersection of the intrados of the arch ring with the vertical plane
bounding the foundation excavation.

For U-abutments, the limits of dry excavation to be paid for will be extended to
include all material removed from between the limits of the wing excavation and above

217
 207.01

460 the elevation of the bottom of the lowest tie beam. If the bottom of the lowest tie beam
is below the upper limits of wet excavation, the limits of wet excavation and dry
excavation to be paid for will be extended to include material actually and necessarily
removed from between the limits of the wing excavation.

Where it is necessary to excavate outside the foundation excavation limits for

superstructure or extensions other than those described above, the pay limits will be
extended to include all such excavation, as determined necessary.

If a suitable sump is constructed outside the pay limits as described above, such
470 limits will be extended to include the actual lines of the sump. The additional pay
limits added for the sump will not exceed 4% of the area of the footing involved.

(c) Traffic Structure Supports

The cost of excavation for traffic structure supports, except for class X material
in accordance with 206.02(a)1, shall be included in the cost of the foundation material.

SECTION 207 – SUBGRADE

207.01 Description
This work shall consist of the construction of the subgrade in accordance with
105.03.

MATERIALS

207.02 Materials
10 Materials shall be in accordance with the following:

Chemical Modifiers ....................................... 215.02

Coarse Aggregate, Class D or Higher,
Size No. 5, 8, 43, 53, or 73 ..................... 904
Geogrid, Type IB ........................................... 918.05
Geocell Confining System ............................. 214
Water ............................................................. 913.01

Soils containing greater than 3% by dry weight organic material, or with a

20 maximum dry density of less than 100 pcf, or with liquid limit of greater than 50, or
with a soluble sulfate content greater than 1,000 ppm, will not be allowed within the
specified thickness of the subgrade treatment in cut sections and will not be allowed
within 24 in. of the finished subgrade elevation in fill sections. Density will be
determined in accordance with AASHTO T 99 or ITM 512 and organic content will
be determined in accordance with AASHTO T 267. Liquid limits will be determined
in accordance with AASHTO T 89. Sulfate content will be determined in accordance
with ITM 510.

218
 207.04

CONSTRUCTION REQUIREMENTS
30
207.03 Construction Requirements

(a) Subgrade Construction Methods

The subgrade shall be constructed uniformly transversely across the width of the
pavement including shoulders or curbs unless shown otherwise on the plans, by one
of the following methods:

(a) chemical modification in accordance with 215;

40 (b) aggregate No. 53 in accordance with 301;

(c) geogrid in accordance with 214 placed under aggregate No. 53

in accordance with 301, or

(d) soil compaction to 100% of maximum dry density.

Longitudinally, the treatment may vary depending on the method of construction.

(b) General Requirements

50 All rock greater than 3 in. shall be removed or broken off and placed at least 6 in.
below the specified subgrade. Holes or depressions resulting from the removal of
unsuitable material shall be filled with soils in accordance with 207.02 or B borrow
and compacted in accordance with 203.23.

Coal within the specified thickness of the subgrade shall be excavated if directed,
and disposed of in accordance with 202.02.

During subgrade preparation, adequate drainage shall be provided at all times to

prevent water from standing on the subgrade. The grade and cross section of the
60 subgrade shall be finished within a tolerance of 1/2 in. from the subgrade elevation
shown on the plans.

Even though the subgrade has been previously accepted, the condition of the
subgrade shall be in accordance with 105.03 and 207.04 at the time paving material is
placed.

Finishing within this tolerance by blading or other mechanical means without the
use of side forms will be allowed. If these methods do not finish within this tolerance,
side forms shall be used.
70
207.04 Subgrade Treatment Types
The subgrade treatment type shall be as specified on the contract plans. If
required, the subgrade foundation shall be corrected as directed by the Engineer prior
to subgrade treatment.

219
 207.04

Type Subgrade Description

I 24 in. of soil compacted in accordance with 203.23
IA [blank]
IB 14 in. chemical soil modification
IC 12 in. coarse aggregate No. 53 in accordance with 301
II 6 in. coarse aggregate No. 53 in accordance with 301
IIA 8 in. chemical soil modification
III In-place compaction in accordance with 203.23
12 in. coarse aggregate No. 53 with Type IB geogrid in
IV
accordance with 214
12 in. coarse aggregate with Geocell confining system
IVA
in accordance with 214
3 in. of subgrade excavated and replaced with 3 in.
V
coarse aggregate No. 53

In areas where shallow utilities are encountered or chemical modification is not

allowed, the Contractor may submit a request to the Engineer to substitute Type IC for
Type IB.
80
Where the strength or density and moisture control option is used, compaction of
embankment areas shall be in accordance with 203.23. In cut and transition areas, the
top lifts shall be removed, and the bottom 6 in. compacted in-place in accordance with
203.23. The excavated material shall then be replaced and compacted in 6 in. lifts in
accordance with 203.23. Removal of the lifts may be waived and only the upper 6 in.
compacted in accordance with 203.23 when it is determined, through testing in
accordance with 203.24, that the lower lifts comply with 203.23.

In sections where rock, shale, sandstone or its mixtures are encountered, these
90 materials shall be undercut 24 in. below the subgrade elevation and replaced with
coarse aggregate No. 53 or No. 73 and compacted in accordance with 301.06.
Geotextiles used shall be in accordance with 918.02. All irregularities and holes shall
be graded with either coarse aggregate No. 53 or No. 73. If an aggregate base is part
of the HMA pavement structure, the 24 in. excavation depth shall be reduced by the
thickness of the aggregate base.

The 3 in. compacted aggregate as part of the subgrade treatment Type V shall be
compacted to 100% prior to the placement of the pavement.

100 When conditions are encountered below the specified subgrade treatment depth
that prevent achieving the specified subgrade compaction, such conditions shall be
corrected in accordance with 203.09, or as directed.

Proofrolling shall be performed in accordance with 203.26. The proof rolling shall
cover the entire subgrade surface. The maximum allowable deflection or rutting in
subgrade shall not be greater than 1/2 in.

220
 208.01

207.05 Method of Measurement

Subgrade treatment will be measured in both cut and fill areas by the square yard
per type. Chemicals for modification, excavation, aggregates, and geogrid materials
110 will not be measured.

The undercutting of rock, where encountered, will be measured in accordance

with 203.27(b).

207.06 Basis of Payment

The accepted quantities of subgrade treatment will be paid for at the contract unit
price per square yard per type, complete in place. In areas where shallow utilities are
encountered or the Contractor elects to use Type IC for Type IB, payment will be made
at the price of Type IB.
120
The undercutting of rock, where encountered, will be paid for in accordance with
203.28.

Payment will be made under:

Pay Item Pay Unit Symbol

Subgrade Treatment, Type _____ ............................................. SYS

130 The cost of subgrade treatments including testing, sampling, aggregates,

chemicals for modification, geogrid, geotextile and geocell confining system, coarse
aggregate for subgrade Type IC, Type II, Type IV, Type IVA, Type V, water, and the
excavation required, shall be included in the cost of the pay item.

The cost of excavation and grading of existing railroad ballast and railroad bed
material shall be included in the cost of subgrade treatment, Type V.

Where conditions exist below the specified subgrade compaction depth that
prevent achieving the specified compaction, payment for correcting such conditions
140 will be made based on the directed method of treatment.

SECTION 208 – FINISHING SHOULDERS, DITCHES, AND SLOPES

208.01 Description
This work shall consist of the final shaping and dressing of shoulders, ditches, and
slopes by hand or machine methods, or both, to the required smoothness in accordance
with these specifications and in reasonably close conformance with the elevations and
cross sections shown on the plans or as directed.

Where divided pavement is constructed, each roadway with its shoulders, ditches,
10 and slopes will be considered a separate roadway.

221
 208.02

CONSTRUCTION REQUIREMENTS

208.02 Finishing Shoulders

Unless otherwise provided, shoulders shall be constructed of earth or other
approved material which contains no sod, weeds, sticks, roots, or other perishable
matter. The inside edges shall be built up slightly above the finished surface of the
adjoining pavement and compacted thoroughly with a roller weighing no less than 5 t
and with the roller wheel slightly overlapping the pavement. Rolling shall continue
20 until there is no break between the pavement and shoulders, and until the required
cross section is obtained.

If rolling is not practicable on shoulders for approach pavement or other

miscellaneous areas, compaction shall be obtained with mechanical tamps, vibrators,
or other satisfactory means.

Except where permission has been granted to widen shoulders to dispose of

surplus excavation, the outside edges shall be parallel to the pavement edges.

30 Where cuts are widened beyond the typical cross sections shown on the plans in
order to obtain additional material for constructing shoulder widths required or where
fills are widened to dispose of excess excavated material, the shoulders shall be
finished to the widths as finally constructed.

It may be necessary to finish shoulders after the pavement is opened to traffic. As

a matter of safety to traffic, the pavement shall be kept as free as possible from
shoulder material and equipment. The adjacent pavement over which traffic is being
routed shall be cleaned at the close of each work day.

40 208.03 Finishing Ditches

Ditches shall be finished to the lines and grades shown on the plans or as otherwise
laid out. The edges shall be parallel to the pavement unless it is necessary to have the
gradients different from that of the pavement in order to obtain proper drainage, in
which case the edges shall be as determined.

208.04 Finishing Slopes

All cut and fill slopes shall be constructed to the cross sections shown on the plans
or to revised sections where cuts are widened to obtain additional material or fills
widened to utilize excess. Cut and fill slopes shall be finished to the degree ordinarily
50 obtained by a blade grader, scraper, or hand shovel.

208.05 Blank

208.06 Finishing at Contract Drainage Structures

If the contract work is for bridges or culverts or for extensions thereof, the
requirements of this specification shall apply to the right-of-way within the contract
structure limits, unless otherwise specified.

222
 210.01

208.07 Method of Measurement

60 Finishing will not be measured for payment unless otherwise provided.

208.08 Basis of Payment

Finishing shoulders, ditches, and slopes will not be paid for directly. The cost
thereof shall be included in the cost of other pay items.

SECTION 209 – FINISHING EARTH GRADED ROADS

209.01 Description
This work shall consist of leveling, shaping, and otherwise completing an earth
graded road ready for acceptance when the contract is for grading or for grading and
structures, but not when the contract includes paving or surfacing.

209.02 Construction Requirements

After all grading is substantially complete and structures, if any, are finished, the
10 roadbed and cut and fill slopes shall be shaped properly and, where necessary,
compacted.

Shaping and compacting shall be with approved equipment supplemented with

hand methods if necessary. Reasonably smooth surfaces shall be obtained and finished
at least to within ±0.1 ft of the required profile and cross sections shown on the plans
or as directed.

All rock greater than 6 in. encountered shall be removed or broken off at least 6
in. below the subgrade surface. Holes or depressions resulting from the removal of
20 unsuitable material shall be filled with an acceptable material and compacted to
conform with the surrounding subgrade.

Final trimming and cleaning shall be in accordance with 210.

209.03 Method of Measurement

Finishing earth graded roads will not be measured for payment unless otherwise
provided.

209.04 Basis of Payment

30 Finishing earth graded roads will not be paid for directly. The cost thereof shall
be included in the cost of other pay items.

SECTION 210 – FINAL TRIMMING AND CLEANING

210.01 Description
This work shall consist of trimming and cleaning the otherwise completed
highway between right-of-way lines for its entire contract length.

223
 210.02

210.02 Construction Requirements

At the time of acceptance, the following conditions shall prevail for the entire
contract length and also for the full right-of-way width except as hereinafter provided.

10 Debris and rubbish shall be removed and disposed of in accordance with 201.03.

Remaining loose stones and broken masonry meeting the aggregate requirements
for hand laid or grouted riprap shall be stored in neat piles on the right-of-way as
directed.

Weeds, brush, and stumps shall be cut close to the ground. Disposal shall be in
accordance with 201.03 and 203.08.

Cut and fill slopes made or disturbed shall be left reasonably smooth and uniform.
20 Loose and overhanging rock shall be removed.

Floors, roadways, railings, bottom chords, shoes, and seats of bridges shall be
cleaned of rubbish, sand, stone, gravel, and dirt. Waterways shall be left unobstructed.
Culverts and other drainage structures shall be left clean for their entire length.

If the contract is for construction of a new pavement or for grading and structures
only on a right-of-way acquired for divided highway construction, one roadway of
which has been constructed and on which the Department has assumed normal
maintenance, the provisions of this specification shall not apply to the maintained
30 portion except to those areas of such which are disturbed by the operations.

If the contract is for construction of a portion of a divided highway on a right-of-

way on which no previous construction has been done or on a divided highway
right-of-way on which a previous grading-only contract has been completed, then the
provisions of this specification shall apply to the entire right-of-way for the full
contract length.

Unless otherwise set out in the special provisions for a contract which includes
work for patching, widening, resurfacing, surface treating, undersealing, or for a
40 combination of these, or for a contract through which traffic is being maintained during
construction, these requirements will apply only to that portion of the right-of-way
disturbed by the operations.

210.03 Method of Measurement

Final trimming and cleaning will not be measured for payment unless otherwise
provided.

210.04 Basis of Payment

Final trimming and cleaning will not be paid for directly. The cost thereof shall
50 be included in the cost of other pay items.

224
 211.02

SECTION 211 – B BORROW AND STRUCTURE BACKFILL

211.01 Description
This work shall consist of backfilling excavated or displaced peat deposits; filling
up to designated elevations of spaces excavated for structures and not occupied by
permanent work; constructing bridge approach embankment; and filling over
structures and over arches between spandrel walls, all with special material.

MATERIALS
10
211.02 Materials
Materials shall be in accordance with the following:

B Borrow ................................................................................... As Defined*

Flowable Backfill ...................................................................... 213
Geotextile .................................................................................. 918.02
Structure Backfill ...................................................................... 904
* The material used for special filling shall be of acceptable quality, free
from large or frozen lumps, wood, or other extraneous matter and shall
20 be known as B borrow. It shall consist of suitable sand, gravel, crushed
stone, ACBF, GBF, or other approved material. The material shall
contain no more than 10% passing the No. 200 (75 µm) sieve and shall
be otherwise suitably graded. The use of an essentially one-size
material will not be allowed unless approved.

Aggregate for end bent backfill shall be No. 8 or No. 9 crushed stone or ACBF,
class D or higher.

The Contractor has the option of either providing B borrow or structure backfill
30 from an established CAPP source, or supplying the material from another source. The
Contractor has the following options for supplying B borrow or structure backfill from
a local site:

(a) the establishment of a CAPP Producer Yard at the local site in

accordance with 917; or

(b) use a CAPP Certified Aggregate Technician or a consultant on

the Department’s list of approved Geotechnical Consultants For
Gradation Control Testing.
40
For material excavated within the project limits, gradation control testing will be
performed by the Department if the Contractor is directed to use the material as
B borrow or as structure backfill.

The frequency of gradation control testing shall be one test per 2,000 t based on
production samples into a stockpile or by over the scales measurement, with a
minimum of two tests per contract, one in the beginning and one near the mid-point.

225
 211.03

The sampling and testing of these materials shall be in accordance with applicable
requirements of 904 for fine and coarse aggregates. The Contractor shall advise the
50 Engineer in writing of the plan to measure the material.

CONSTRUCTION REQUIREMENTS

211.03 General Requirements

If B borrow or structure backfill is obtained from borrow areas, the items of
obtaining the areas, their locations, depths, drainage, and final finish shall be in
accordance with 203.

Unless otherwise specified, if excavated material complies with 211.02 and if

60 B borrow or structure backfill is required for special filling, the excavated material
shall be used as such. If there is a surplus of this material, such surplus shall be used
in embankment. The provisions of 203.19 shall apply to placing this material at
structures. All surplus in excess of the directed or specified use on the right-of-way
shall be disposed of in accordance with 201.03.

If fill or backfill as described in this specification is within embankment limits,

and if it is not required that the entire fill or backfill be of B borrow and placed as such,
then that portion above the free-water level shall be placed in accordance with
applicable provisions of 203 and compacted to the required density.
70
If borrow is required outside the specified limits of B borrow, material in
accordance with the specifications for B borrow may be furnished at the contract unit
price for borrow; however, the quantity of borrow measured for payment outside the
limits of structure backfill will not exceed the theoretical quantity of B borrow
furnished.

Unless otherwise specified, all spaces excavated for and not occupied by bridge
abutments and piers, if within embankment limits, shall be backfilled to the original
ground line with B borrow, and placed in accordance with 211.04.
80
Where B borrow or structure backfill is required as backfill at culverts, retaining
walls, sewers, manholes, catch basins, and other miscellaneous structures, it shall be
compacted in accordance with 211.04.

Where specified, aggregate for end bent backfill shall be placed behind end bents
and compacted in accordance with 211.04. Prior to placing the aggregate, a geotextile
shall be installed in accordance with 616.11.

211.03.1 Structure Backfill Types

90 The structure backfill type shall be as specified.

Within each of the following structure backfill types, the Contractor shall choose
from the listed options for each type:

226
 211.03.1

(a) Type 1

1. Structure backfill in accordance with 904.05.

2. Non-removable or removable flowable backfill in

100 accordance with 213.

(b) Type 2

1. Crushed stone aggregate or ACBF structure backfill in

accordance with 904.05, except No. 30, No. 4, and 2 in.
nominal size aggregate shall not be used.

2. Non-removable or removable flowable backfill in

accordance with 213.
110
(c) Type 3
Structure backfill in accordance with 904.05, except only nominal size aggregates
1 in., 1/2 in., No. 4 or No. 30, and coarse aggregate No. 5, No. 8, No. 9, No. 11, or No.
12 shall be stone. If ACBF is used, it shall only be used in sizes that meet the size
requirements for coarse aggregate No. 5 or No. 8.

A type A certification in accordance with 916 for the additional structure-backfill

testing described below shall be furnished to the Engineer prior to use. An approved
geotechnical laboratory shall be used to perform the tests.
120
Structure backfill for all retaining walls shall be in accordance with the following
criteria:

Property Criteria Test Method

pH (Note 1) 5 < pH < 10 AASHTO T 289
Organic Content (Note 2) 1% max. AASHTO T 267
Permeability, min. (Note 3) 30 ft/day AASHTO T 215
Notes:
1. One PH test is required for each bench of stone, each source of air-cooled
blast furnace slag, and each source of gravel.
2. One organic content test is required for each source of gravel.
3. One permeability test is required for the smallest aggregate size from each
source. Sizes No. 5, No. 8, and No. 9 do not require a permeability test.

The gradation shall be performed on the material used in the permeability test.
Testing for permeability shall be performed on the sample of the material compacted
to 95% in accordance with AASHTO T 99, Method C or D. All of the tests listed above
shall be performed a minimum of once every 12 months per source.

130 In addition to the criteria above, structure backfill for retaining wall systems
containing metal components in contact with structure backfill shall also be in

227
 211.04

accordance with the following criteria:

Property Criteria Test Method

Chlorides < 100 ppm AASHTO T 291
Sulfates < 200 ppm AASHTO T 290
Resistivity, min. 3,000 Ω-cm AASHTO T 288
Internal friction angle, φ, min. 34° AASHTO T 236* or T 297*
* under consolidated drained conditions

If the minimum resistivity exceeds 5,000 Ω-cm, the requirement for the testing of
chlorides and sulfates will be waived. The resistivity shall be tested at 100% saturation.
All of the tests listed above shall be run a minimum of once every 12 months per
source. The Office of Materials Management will evaluate the material from each
source and determine the appropriate tests to be performed.
140
Testing for φ shall be performed using a sample of the material compacted to 95%
in accordance with AASHTO T 99, Method C or D. Testing for φ will not be required
when using coarse aggregate No. 5, No. 8, or No. 9.

(d) Type 4
Removable flowable backfill in accordance with 213.

(e) Type 5
Non-removable flowable backfill in accordance with 213.
150
211.04 Compaction
B borrow and structure backfill types 1, 2, and 3 shall be compacted with
mechanical tamps or vibrators in accordance with the applicable provisions of 203.23
except as otherwise set out herein.

Aggregate for end bent backfill and coarse aggregate used for structure backfill
shall be deposited in layers not to exceed 12 in. loose measurement. Each layer shall
be mechanically compacted with a compactor having a plate width of 17 in. or larger
that delivers 3,000 to 9,000 lb per blow. Each lift shall be compacted with two passes
160 of the compactor.

211.05 Embankment for Bridges

When special filling is required, the embankment for bridges shall be constructed
using B borrow within the specified limits shown on the plans. All embankment
construction details specifically set out in this specification for embankment for
bridges shall be considered in accordance with the applicable requirements of 203.

At the time B borrow is being placed for approach embankment, a well compacted
watertight dam shall be constructed in level lifts, the details of which are shown on the
170 plans. Except as hereinafter specified for material to be used in constructing the
enclosing dam, and for growing vegetation, and unless otherwise provided, the

228
 211.09

material for constructing bridge approach embankment shall be B borrow compacted

by mechanical methods. If approach embankment or shoulders are constructed of
material not suitable for growing seed or sod, and if one or both of these is required,
then such areas shall, unless otherwise specified, be covered with a layer of clay, loam,
or other approved material. This layer shall be approximately 1 ft thick after being
compacted into place.

211.06 B Borrow Around Bents

180 When specified, B borrow shall be placed around all bents falling within the limits
of the approach grade as shown on the plans. Before placing, the surface of the ground
on which it is to be placed shall be scarified or plowed as directed. The embankment
slope shall be 2:1 on the sides and beneath the structure, and shall be 6:1 from the end
of the bridge down to the average ground line, or it may be required to complete the
approaches back to the existing grade. An enclosing dam and provisions for growing
vegetation shall be constructed in accordance with 211.05.

211.07 Blank

190 211.08 Spandrel Filling

Unless otherwise specified, spandrel fills for arch structures shall be composed of
B borrow. The fill shall be carried up symmetrically in lifts from haunch to crown and
simultaneously over all piers, abutments, and arch rings. Compaction shall be in
accordance with 211.04.

211.09 Method of Measurement

B borrow, structure backfill types 1, 2, or 3, and aggregate for end bent backfill
will be measured by the cubic yard as computed from the neat line limits shown on
the plans. If cubic yards are set out as the pay item for B borrow or structure backfill
200 in the Schedule of Pay Items and if neat line limits are not specified for measurement
of volume for the material, measurement will be made by the cubic yard at the loading
point in truck beds which have been measured, stenciled, and approved. The B borrow
may be weighed and converted to cubic yards by assuming the weight per cubic foot
to be 90% of the maximum wet density in accordance with AASHTO T 99. The
material may be cross sectioned in its original position and again after excavation is
complete, and the volume computed by the average end area method. If B borrow is
used for backfill in areas where unsuitable material is present or peat excavation has
been performed, unless otherwise directed, the B borrow will be cross sectioned, and
the volume will be computed by the average end area method.
210
Structure backfill types 4 or 5 will be measured by the cubic yard as computed
from the neat line limits shown on the plans. If neat line limits are not shown on the
plans, the volume in cubic yards of flowable backfill furnished and placed as structure
backfill type 4 or 5 will be computed from the nominal volume of each batch and a
count of the batches. Unused and wasted flowable backfill will be estimated and
deducted.

229
 211.10

If the material is to be paid for by the ton, it shall be weighed in accordance with
109.01(b).
220
If the material comes from a wet source such as below water or a washing plant,
and weighing is involved in the method of measurement, there shall be a 12 h drainage
period prior to the weighing.

Geotextile will be measured in accordance with 616.12.

211.10 Basis of Payment

The accepted quantities of B borrow will be paid for at the contract unit price per
cubic yard or per ton as specified, complete in place.
230
Structure backfill will be paid for at the contract unit price per cubic yard of the
type specified, provided the material comes from outside the permanent right-of-way.

B borrow material placed outside the neat lines will be paid for as borrow when
such B borrow eliminates required borrow material. Otherwise, no payment will be
made for backfill material placed outside the neat lines.

Aggregate for end bent backfill will be paid for at the contract unit price per cubic
yard, based on the neat line limits shown on the plans.
240
Geotextile will be paid for in accordance with 616.13.

If topsoil, loam, or other suitable material in accordance with 211.05 is used for
expediting the growth of seed or sod, it will be paid for at the contract unit price per
cubic yard for borrow, unless otherwise provided.

Payment will be made under the following:

Pay Item Pay Unit Symbol

250
Aggregate For End Bent Backfill .............................................. CYS
B Borrow ................................................................................... CYS
TON
Structure Backfill, Type _____ ................................................. CYS

No payment will be made under this section for material obtained within the
excavation limits of the project if the Contractor is directed to use the material as
B borrow or structure backfill in a pipe trench, culvert, construction of an embankment
or fill, or if the Contractor uses the material for its own convenience. Material obtained
260 from within the excavation limits of the project and which the Contractor is directed
to use as B borrow or structure backfill for other purposes including replacement of
undercut areas, support for a retaining wall system, and end bent fill will be paid for

230
 212.04

at the contract unit price of $5.00 per cubic yard for B borrow/structure backfill
handling.

The cost of disposal of excavated material shall be included in the cost of the pay
items in this section.

SECTION 212 – STOCKPILED SELECTED MATERIALS

212.01 Description
This work shall consist of excavating selected road material from within the
construction limits and stockpiling it on the right-of-way at designated locations. It
also includes any subsequent removal of the material from the stockpile, if to be used
in the work.

212.02 Materials
10 Any material to be excavated and stockpiled will be specifically named and
described in the special provisions and may include rock, top soil, material in
accordance with 211.02, or any other material selected, any of which may be excavated
as common excavation.

After the selected material is stockpiled it shall be known as stockpiled selected

material and if any of this material is required to be removed from the stockpile and
used in the work, its removal and its incorporation into the work shall be known as
salvaged stockpiled selected material.

20 212.03 Construction Requirements

Selected material shall be excavated from specified areas and stockpiled on the
right-of-way at designated locations. The depth of excavation shall be as directed.

If the material is required to be taken from the stockpile and utilized in the work,
the material so utilized shall be placed in accordance with these specifications as they
apply to the nature of the material and the use to which it is put.

212.04 Method of Measurement

Stockpiled selected material will be measured in the stockpiles by means of cross
30 sections by the cubic yard, computed by the average end area method. The volume
measured as salvaged stockpiled selected material will be the difference in cubic yards
between that of the existing stockpile and that remaining after the material has been
removed from the stockpile and used. Both stockpiles will be measured by means of
cross sections. The volume will be computed by the average end area method.

If stockpiled selected material is obtained from within the excavation pay limits
of new construction, the volume of the material will be deducted from the pay
quantities for excavation as shown on the original cross sections.

231
 212.05

212.05 Basis of Payment

40 The accepted quantities of stockpiled selected material and salvaged stockpiled
selected material will be paid for at the contract unit price per cubic yard, complete in
place.

Payment will be made under:

Pay Item Pay Unit Symbol

Stockpiled Selected Material ..................................................... CYS

Stockpiled Selected Material, Salvaged .................................... CYS
50
The cost of excavation, hauling, removing material from the stockpile, placing
materials, and necessary incidentals shall be included in the cost of the pay items.

SECTION 213 – FLOWABLE BACKFILL

213.01 Description
This work shall consist of placing flowable backfill in trenches for pipe structures,
culverts, utility cuts, other work extending under pavement locations, cavities beneath
slopewalls and other locations in accordance with 105.03.

Flowable backfill will be classified as either removable or non-removable.

10 MATERIALS

213.02 Materials
Materials shall be in accordance with the following:

Concrete Admixtures* ................................... 912.03

Fine Aggregate .............................................. 904.02(a)
Fly Ash .......................................................... 901.02
Portland Cement ............................................ 901.01(b)
Water ............................................................. 913.01
20 * Other admixtures that increase flowability may be used as
approved by the Engineer.

The supplier may elect to use nominal size No. 23 and No. 24 gradations in
accordance with 904.02(h) or may propose the use of alternate gradations. The
alternate gradation and proposed tolerances of material passing each sieve shall be
included in the flowable backfill mix design.

213.03 Flowable Backfill Mix Design

The Contractor shall submit a flowable backfill mix design, FBMD, to the DTE a
30 minimum of seven days prior to the trial batch. The FBMD will be accepted in

232
 213.04

accordance with 213.04. The FBMD shall be submitted in a format acceptable to the
DTE and shall include the following:

(a) a list of all ingredients

(b) the source of all materials
(c) the gradation of the aggregates
(d) the batch weight with the aggregates at the SSD condition
(e) the names of all admixtures
(f) the admixture dosage rates and manufacturer’s recommended range.
40
A FBMD in accordance with these specifications, which has been approved for
use on a previous contract, may be submitted to the DTE for approval. The submittal
shall include copies of test results in accordance with 213.04 and 213.05.

Changes in the FBMD will not be allowed except for adjustments to compensate
for routine moisture fluctuations or a change in sand source in accordance with 213.05
based on the dry flow determined from the trial batch testing. All other changes will
require a new FBMD.

50 213.04 Flowable Backfill Mix Criteria

The FBMD shall produce a workable mixture with the following properties:

(a) Flow Consistency

Flow consistency will be measured in accordance with ASTM D 6103. The
diameter of the spread shall be at least 8 in.

(b) Lightweight Dynamic Cone Penetration Blow Count Number

A lightweight dynamic cone penetration test will be performed in accordance with
ITM 216 after the flowable backfill mix has cured for three days. The average
60 penetration resistance blow count number for removable flowable backfill shall not be
less than 12 or greater than 30. Non-removable flowable backfill mixes shall have an
average penetration resistance blow count greater than 30.

(c) Removability Modulus

The removability modulus, RM, will be determined for the FBMD by the formula
as follows:

.
RM 0.000104 U 1.72N 15.64

70 where:

N14 = average lightweight dynamic cone penetration blow count

after 14 days in accordance with ITM 216.

Uw = dry unit weight, lb/cu ft, of flowable backfill after 14 days in

accordance with ITM 218.

233
 213.05

The RM shall be 1.0 or less for removable flowable backfill.

After all test results have been reviewed for compliance with the specifications, a
80 mixture number will be assigned by the DTE.

213.05 Flowable Backfill Trial Batch

A trial batch shall be produced by the Contractor and will be tested by the
Department to verify that the FBMD meets the flowable backfill mix criteria. The
Department will verify the classification of the mix as either removable or
non-removable from the results of the trial batch. The flowable backfill shall be
batched within the proportioning tolerances of 508.02(b). The Department will
determine the test results and provide them to the Contractor. The trial batch shall be
of sufficient quantity to allow the Department to perform all required tests from the
90 same batch.

The Department will obtain a sample of the fine aggregate and fly ash described
in the FBMD. The Department will test the dry flow in accordance with ITM 217 and
record the results on the FBMD.

If the Contractor requests to change the source of the fine aggregate identified in
an approved FBMD the Contractor shall submit a revised FBMD to the DTE. The
Department will obtain a sample of the new fine aggregate and, if applicable, a sample
of the fly ash as identified in the approved FBMD. Dry flow will be tested in
100 accordance with ITM 217. If the test result is within ±2.0 s of the value shown on the
approved FBMD, the revised FBMD will be approved and a new trial batch will not
be required. Failure to meet the dry flow test requirement will require the Contractor
to submit a new FBMD and perform a new trial batch for approval of the proposed
new fine aggregate.

213.06 Mixing Equipment

The mixing equipment shall be in accordance with the applicable requirements of
702 or 722.

110 CONSTRUCTION REQUIREMENTS

213.07 Placement
The flowable backfill shall not be placed on frozen ground. Flowable backfill shall
be protected from freezing for 72 hr. Flowable backfill shall not be placed into or
through standing water unless approved by the Engineer in writing.

The diameter of the flowable backfill spread shall be at least 8 in. at time of
placement. Water may be adjusted from the FBMD to meet the minimum spread
requirement if the initial measured spread is between 7 and 8 in.
120
If using mixing equipment in accordance with 722, the yield will be checked using
the 1/4 cu yd box method as follows:

234
 213.09

(a) The chute shall be cleaned and the box shall be positioned on a
level surface to receive the discharged flowable backfill.

(b) The mixer shall be operated until the cement or fly ash counter
indicates that 1/4 cu yd of flowable backfill has been yielded.

130 (c) The contents of the box will be consolidated and struck off. If
the box is not full, the gates shall be adjusted and the procedure
shall be repeated until the actual and calculated volumes of
flowable backfill agree.

(d) Yield will be checked on the first load of each truck and every
third load per truck thereafter. Additional yield tests will be
required after making any adjustments.

The flowable backfill shall be brought up uniformly to the fill line as shown on
140 the plans or as directed. When used as structure backfill, flowable backfill shall be
placed uniformly so as not to induce unbalanced loading on any part of a structure.

The flowable backfill shall not be subjected to load or disturbed by construction

activities until a lightweight dynamic cone penetration test has produced a minimum
blow count. The minimum blow count shall be as follows:

Construction Activities with Vibratory Compaction after Backfill ......... 12

Construction Activities without Vibratory Compaction after Backfill .... 7

150 213.08 Method of Measurement

Flowable backfill will be measured by the cubic yard of the type specified as
computed from the neat line limits shown on the plans. If neat line limits are not shown
on the plans, the volume in cubic yards of flowable backfill furnished and placed will
be computed from the nominal volume of each batch and a count of the batches.
Unused and wasted flowable backfill will be estimated and deducted. Drilled holes
will be measured by the number of holes drilled.

213.09 Basis of Payment

The accepted quantities of flowable backfill will be paid for at the contract unit
160 price per cubic yard for the type specified, furnished and placed. Holes drilled in the
pavement will be paid for at the contract unit price per each.

Payment will be made under:

Pay Item Pay Unit Symbol

Drilled Hole for Flowable Backfill ............................................ EACH

Flowable Backfill, Non-Removable .......................................... CYS
Flowable Backfill, Removable .................................................. CYS
170
235
 214.01

SECTION 214 – GEOSYNTHETICS

214.01 Description
This work shall consist of furnishing and installing geosynthetics as shown on the
plans or as directed by the Engineer and in accordance with 105.03.

MATERIALS

214.02 Materials
10 Materials shall be in accordance with the following:

Coarse Aggregate .......................................... 904.03

Geocell Confining System ............................. 918.04
Geogrid .......................................................... 918.05
Geotextile for Pavement and Subgrade ......... 918.02
Notes: Coarse Aggregate No. 2, 5, 43, 53, 73, shall be used only.
ACBF Slag shall not be allowed.

CONSTRUCTION REQUIREMENTS
20
214.03 Foundation Preparation
The embankment foundation shall be cleared and grubbed in accordance with 201
and excavated using lightweight equipment to minimize disturbance of the
embankment foundation surface soils. Construction activities using equipment which
cause pumping and rutting of the embankment foundation soils shall be prevented
where possible and shall otherwise be minimized. Fine grading may be waived where
impractical. When very soft soil is encountered, the embankment foundation shall be
cleared of all trash and rubbish materials without disturbing the vegetation cover or
root mat. The embankment foundation shall be subject to approval prior to placement
30 of geosynthetics. Proofrolling of the embankment foundation will not be required in
accordance with 203.09 when geosynthetics are used in construction of embankment
foundation treatment.

(a) Geotextile as a Drainage Blanket

Geotextile shall be stored in such a manner as to prevent exposure to direct
sunlight and damage by other construction activities. Geotextile shall be placed taut
and transversely after backfilling all wheel tracks. Geotextile shall be overlapped by 3
ft and sewn in accordance with the manufacturer’s guidelines.

40 Coarse aggregate No. 2 or No. 5 shall be placed as directed and encapsulated with
geotextile. Coarse aggregate shall be placed by spreading dumped material over
previously placed material with light equipment in such a manner as to prevent damage
to the geotextile. Dumping of coarse aggregate will be allowed on initial working
platform. The overlap shall be staggered throughout the roadway profile. Coarse
aggregate shall be placed to the full required thickness and compacted before any
loaded trucks are allowed on the blanket. The drainage blanket shall have positive
drainage.
236
 214.03

No vehicles or construction equipment shall be allowed on the geotextile prior to

placement of the coarse aggregate. Damaged geotextile shall be repaired or replaced
50 as directed. Damaged geotextile may be patched by placing a piece of the same
geotextile over the damaged area. The overlap shall be at least 3 ft wide. The remaining
lifts of the embankment shall be in accordance with 203.23.

(b) Geotextile Placement for Pavement, Subgrade, or Embankment

The subgrade or embankment shall be proofrolled in accordance with 203.26 and
any defect or rut shall be repaired as directed prior to the geotextile placement.
Geotextile shall be placed taut, without wrinkles and stretched in tension. Coarse
aggregate shall be placed with a minimum disturbance to grade. Any damage to
geotextile shall be repaired in accordance with 214.03(a). The remaining grade shall
60 be constructed in accordance with 207.

Geotextile shall be covered within three calendar days of placement.

(c) Geogrid Placement in Embankment and Subgrade

The geogrid shall be installed in accordance with the Engineer’s designs or the
manufacturer’s recommendations. The geogrid shall be kept taut during placement of
the initial lift of backfill. Installation shall require the use of stakes, staples, sandbags,
pile of granular fill, or other approved means to hold the geogrid in place during fill
placement operations. Type IA geogrid shall be used for embankment foundation
70 treatment. Type IB geogrid shall be used for subgrade treatment, type IV. When
placing type IA geogrid, any rutting in the granular material shall not exceed 3 in. in
the embankment foundation. The Engineer may increase the lift thickness to obtain
stability of the granular material.

If required by the Engineer, the geogrid material supplier shall provide a qualified
manufacturer’s representative on the contract site at the start of the work to assist the
Contractor. The representative shall also be available during the construction when
required by the Engineer or the Contractor.

80 When type IB geogrid is used, proofrolling shall be performed in accordance with

203.26 prior to placing the type IB geogrid. Deflection or rutting shall not exceed 1 in.
Any defect shall be repaired as directed. The first 6 in. of coarse aggregate No. 53 shall
be spread and compacted with a 10 t roller in static mode. The spreading and
compaction of the aggregate shall be performed so that adequate interlocking of the
aggregate and geogrid is obtained. The second 6 in. of coarse aggregate No. 53 shall
be constructed in accordance with 301.

The geogrid shall be overlapped a minimum of 2 ft side to side and end to end for
type IB. The type IA geogrids shall be overlapped 3 ft in areas where foundation
90 conditions cannot support foot traffic or where 2 ft is found to be inadequate during
fill placement. Overlaps shall be oriented in the direction of fill placement, or shingled,
to prevent advancing fill from lifting any geogrid roll edges. Overlaps shall be further
secured to prevent separation during fill placement. Damaged geogrid shall be

237
 214.04

patched. Patching shall include placement of a minimum of 3 ft of overlapped geogrid

beyond the damaged area. If the damaged portion extends for more than 50% of the
roll in the width direction, the entire width shall be replaced.

Geogrid shall be covered with fill within three calendar days after placement.
Only that amount of geogrid required for pending work shall be placed to minimize
100 exposure of the geogrid.

(d) Geocell Confining System

The Contractor shall construct the grade in accordance with 203. A layer of
geotextile shall be placed in accordance with 214.03(b) and shall be anchored at the
roadway edge when widening or when intersecting an existing roadway. The geocell
confining system, GCS, shall be placed and anchored as shown on the plans, or as
directed. The Contractor shall ensure that the GCS is anchored vertically and the
geocell shall be filled with a minimum of 3 in. of coarse aggregate No. 5, No. 8, or
No. 43. If the Contractor chooses No. 5 or No. 8, geotextile in accordance with
110 918.02(a), Type 1B shall be placed on the GCS before placing No. 53 or No. 73. The
GCS shall be oriented with the smaller cell dimension perpendicular to the roadway.
The remaining GCS shall be filled with No. 53 or No. 73 and at least 9 in. of No. 53
or No. 73 shall be placed on the GCS. The aggregate shall be back dumped and
compacted with a light roller in accordance with 301. No trucks or construction
vehicles shall be allowed on the GCS. A light tracked bulldozer or other equipment
may be used as directed. A 6 in. lift above GCS shall be compacted with low frequency
and amplitude, with a minimum of six passes. The remaining aggregate shall be placed
and compacted lightly at first, then with high amplitude. Efforts shall be made to
ensure that the geotextile and GCS are in tension. The Contractor may propose an
120 alternate means of providing a typical section for the GCS, and shall submit the
proposal to the Engineer for review and approval. The proposal shall be certified by a
professional engineer registered in the State of Indiana.

GCS shall be constructed in accordance with 207 and 214.

214.04 Fill Placement

Construction vehicles shall not be on the geogrid. The placement of the fill shall
proceed forward along the roadway centerline and outward to the embankment edges
and compacted in accordance with 203.23. The Engineer may waive density
130 requirements for the first lift of embankment foundation treatment if the fill is
determined to be too weak to support compaction equipment.

214.05 Method of Measurement

Geotextile for pavement, and subgrade will be measured by the square yard, for
the type specified. Geotextile for coarse aggregate and drainage blankets will be
measured in accordance with 301 and 616, respectively. Geogrid will be measured by
the square yard, for the type specified. The quantity will be computed based on the
total area of geosynthetics shown on the plans. The aggregate used for the embankment
foundation improvement will be measured in accordance with 301.09. The geogrid
140 reinforced subgrade will be measured in accordance with 207.05.
238
 215.02

The GCS and the excavation required to place the GCS will not be measured.

214.06 Basis of Payment

The accepted quantity of geotextile will be paid for at the contract unit price per
square yard per type of geotextile. The accepted quantities of geogrid will be paid for
at the contract unit price per square yard per type of geogrid. The aggregates will be
paid for in accordance with 301.10. The geogrid reinforced subgrade will be paid for
in accordance with 207.06.
150
Payment will be made under:

Pay Item Pay Unit Symbol

Geotextile for Pavement, ______ .............................................. SYS

type
Geotextile for Subgrade, ______ ............................................... SYS
type
Geogrid, _____ .......................................................................... SYS
160 type

The cost of furnishing the materials, manufacturer’s representative, all labor and
equipment required for furnishing and placing the geotextile or geogrid, all work
necessary to establish grades, geogrid splices, overlaps, stakes or pins, supplemental
product test data, and patching or replacement of damaged geotextile or geogrid shall
be included in the cost of this work.

The geocell confining system, anchors, restraint clips, pins, necessary incidentals
required to provide a complete in place system, and the Type IB geotextile if required
170 for the GCS, shall be included in the cost of subgrade treatment in accordance with
207.06.

SECTION 215 – CHEMICAL MODIFICATION OF SOILS

215.01 Description
This work shall consist of the modification of soils by uniformly mixing portland
cement, fly ash, lime or a combination of the materials with soil to aid in strength gain
and achieving the workability of soils having excessive moisture content.

MATERIALS

10 215.02 Materials
Materials shall be in accordance with the following:

Fly Ash .......................................................... 901.02

Lime .............................................................. 913.04(b)
239
 215.03

Portland Cement, Type I................................ 901.01(b)

Water ............................................................. 913.01
Note: Quicklime or portland cement may be used dry or as a slurry.

Soils containing greater than 6% by dry weight calcium/magnesium carbonate, or

20 organic material, or having a maximum dry density of less than 95 pcf, or with a
soluble sulfate content greater than 1,000 ppm shall not be used in the subgrade. The
density shall be determined in accordance with AASHTO T 99, the loss on ignition
shall be determined in accordance with AASHTO T 267, the calcium/magnesium
carbonate shall be determined in accordance with ITM 507, and the sulfate content
shall be determined in accordance with ITM 510.

CONSTRUCTION REQUIREMENTS

215.03 Testing and Mix Design

30 The Contractor shall be responsible for all tests required to determine the chemical
modifier type and optimum chemical modifier content for modification of the soils.
The modifier selection, laboratory testing, and mix design shall be performed by an
approved geotechnical consultant in accordance with the Department’s Design
Procedures for Soil Modification or Stabilization.

The quantities for hydrated lime, quicklime, or portland cement shall be based on
4.0% of the maximum dry density of the soils. The quantities for lime by-products
shall be based on 5.0% of the maximum dry density of the soils. The quantities for fly
ash class C shall be based on 12.0% of the maximum dry density of the soils. Class F
40 fly ash shall not be used except in combination with lime or cement.

If hydrated lime, quick lime, lime by-products or portland cement are used, test
results and the geotechnical consultant recommendations shall be submitted to the
Engineer prior to use. If fly ash or any combination of chemical modifiers are used,
the test results and the geotechnical consultant recommendations shall be submitted to
the Engineer and to the Office of Geotechnical Services for approval at least five
business days prior to use. If the modifier as bid is not appropriate for the soils
encountered, portland cement shall be used. Portland cement, fly ash, lime, and lime
by-products shall be from the Department’s list of approved sources.
50
The quantity of chemical modifier may be adjusted for different soil types.
However, the source or type of chemical modifier shall not be changed during the
progress of the work without approval. A change in source or type shall require a new
mix design.

215.04 Storage and Handling

The chemical modifier shall be stored and handled in accordance with the
manufacturer’s recommendations.

60 215.05 Weather Limitations

The chemical soil modification shall be performed when the soil has a minimum
240
 215.09

temperature of 45°F, measured 4 in. below the surface, and with the air temperature
rising. The chemical modifier shall not be mixed with frozen soils or with soil
containing frost. Chemical soil modification shall only be performed in areas which
are going to be paved during the same construction season.

215.06 Preparation of Soils

The soils shall be prepared in accordance with 207.03. All aggregates which are
larger than approximately 3 in. encountered before or after mixing the soils and
70 chemical modifiers shall be removed.

215.07 Spreading of Chemical Modifiers

Where type A-6 or A-7 soils are used or encountered, the surface shall be scarified
to the specified depth prior to distribution of the chemical modifier. If a combination
of modifiers is used, the modifiers shall be mixed mechanically prior to being
incorporated. The chemical modifier shall be distributed uniformly by a cyclone,
screw-type, or pressure manifold type distributor. If a slurry is used, the surface shall
be scarified prior to the distribution of the slurry. The chemical modifier shall not be
applied when wind conditions create problems in adjacent areas or create a hazard to
80 traffic on any adjacent roadway. The spreading of the chemical modifier shall be
limited to an amount which can be incorporated into the soil within the same work
day. If weather causes stoppage of work or exposes the chemical modifier to washing
or blowing, additional chemical modifier may be spread when the work resumes.

215.08 Mixing
The chemical modifier, soil, and water when necessary, shall be thoroughly mixed
by rotary speed mixers or a disc harrow. The mixing shall continue until a homogenous
layer of the required thickness has been obtained. One hundred percent of the material,
exclusive of rock particles, shall pass a 1 in. (25 mm) sieve and at least 60% shall pass
90 a No. 4 (4.75 mm) sieve. The mixing depth shall be 14 in.

215.09 Compaction
Compaction of the mixture shall begin as soon as practicable after mixing and
shall be in accordance with 203 or 207.03 as applicable. Compaction after mixing shall
be as follows:

(a) For portland cement modified soils, mixing shall be completed

within 1 h of portland cement placement and grading and final
compaction shall be completed within 3 h after mixing.
100
(b) Fly ash modified soils shall be compacted within 4 h.

(c) Lime modified soils shall be compacted within 24 h.

Acceptance of chemically modified soils will be determined by measuring the

compaction with a Dynamic Cone Penetrometer, DCP, in accordance with ITM 509
or with a Light Weight Deflectometer, LWD, in accordance with 203.24(b). Testing
of the chemically modified soils will begin 24 hours after compaction.
241
 215.10

110 For measuring the compaction with a DCP, three random test locations will be
determined in accordance with ITM 802 for each 1,500 lft of chemically modified soil
for each 2-lane pavement section. The average of the blow counts obtained at the three
random locations will be the DCP blow count representing the 1,500 lft section. Blow
counts of 15 and above will be used to determine the average for the top 6 in. of a 14
in. lift. Blow counts of 14 and above will be used to determine the average for the
bottom 8 in. of a 14 in. lift. Blow counts of 18 and above will be used to determine the
average for the 8 in. lift. Locations with test results less than the specified minimum
blow counts will be retested and shall be reworked if the minimum blow count is not
obtained.
120
The chemically modified soil lift shall meet the following requirements for
compaction:

(a) The average DCP blow count shall not be less than 17 for the
top 6 in. of a 14 in. lift.

(b) The average DCP blow count shall not be less than 16 for the
bottom 8 in. of a 14 in. lift.

130 (c) The average DCP blow count shall not be less than 20 for an 8
in. lift.

Moisture tests for chemically modified soils mixture will be performed every 4 h
during chemical and soils mixing. One gradation test in accordance with 215.08 will
be performed for each 2,500 lft of chemically modified soil for each 2-lane pavement
section.

Construction traffic or equipment will not be allowed on the treated soils until the
soil meets the DCP test requirements.
140
215.10 Curing
The moisture content of the mixture shall be at the optimum moisture content or
above the optimum moisture content as determined by the mix design in accordance
with 215.03. Moisture content will be determined in accordance with ITM 506.
Moisture content shall be maintained above the optimum moisture content for the first
48 h after mixing with quicklime or hydrated lime.

215.11 Method of Measurement

The accepted quantity of chemically modified soils will be measured by the
150 square yard, complete in place. All removal and replacement required to modify the
soils below the specified depth will be measured in accordance with 203.27(b).

215.12 Basis of Payment

The accepted quantity of chemically modified soils will be paid for by the square
yard, complete in place. All removal and replacement required to modify the soils
242
 216.02

below the specified depth will be paid for in accordance with 203.28.

Adjustment of materials for chemical modification that exceeds the limits of

215.03 will be included in a change order for materials only and paid for as chemical
160 modifier adjustments. If mix design test results show that the chemical modifier as bid
by the Contractor is not appropriate and the strength of the modified soil can not be
achieved, a price adjustment will be made for the use of portland cement. The price
adjustment will be calculated at a cost equal to the difference in the invoice cost of the
chemical modifier found to be appropriate for use and the invoice or quoted delivered
cost of the chemical modifier as bid by the Contractor. This adjustment will be
included in a change order and will be paid for as chemical modifier adjustments.
Payment for chemical modifier adjustments will be made for direct delivered material
costs incurred by the Contractor and shall not include any other markups.

170 Payment will be made under:

Pay Item Pay Unit Symbol

Chemical Modification, Soils .................................................... SYS

The cost of performing the laboratory tests, providing an approved geotechnical

consultant, scarification of the subgrade, spreading and mixing of the chemical
modifier and soil, compaction of the resultant mixture, shaping the subgrade, work
required due to adjustments of modifier proportioning, additional modification
180 required due to weather conditions, correction of deficient areas, water required for
the modification process, modified subgrade trimming, and all operations needed to
meet the requirements of this specification shall be included in the cost of the pay
items of this section.

SECTION 216 – CELLULAR CONCRETE FILL, CCF

216.01 Description
This work shall consist of furnishing and placing a lightweight, low absorbability
cellular concrete fill in accordance with 105.03.

MATERIALS

216.02 Materials
10 Materials shall be in accordance with the following:

Cement .......................................................... 901.01(b)

Fly Ash .......................................................... 901.02
Water ............................................................. 913.01

An admixture in accordance with 912.03 may be used as recommended by the

CCF manufacturer.
243
 216.03

A foam liquid concentrate in accordance with ASTM C 796 shall be used to

produce the CCF properties in accordance with 216.04. The foam liquid concentrate
20 shall be chosen from those shown on the Department’s list of approved CCF
Manufacturers/Installers.

CONSTRUCTION REQUIREMENTS

216.03 Mix Design

A mix design prepared in accordance with the geotechnical report shall be
submitted to the Engineer for approval at least five work days before the CCF
operations begin. A cellular concrete manufacturer shall be chosen from those shown
on the Department’s list of approved CCF Manufacturers/Installers.
30
216.04 Properties and Tests
The CCF shall be in accordance with the manufacturer’s recommendations and
the minimum physical properties as follows:

Properties Class II Class III Class IV

Cast Density Mix 810 lb/cu yd 972 lb/cu yd 1,134 lb/cu yd
Compressive Strength, ASTM C
40 psi 80 psi 120 psi
495*, min.
Freeze-thaw Resistance, min. at
relative E = 70%, ASTM C 666, 80 cycles 300 cycles
modified
Water Absorption, max.** 20% 16% 14%
Shear Modulus, G, ASTM D 4015 25,000 psi 34,000 psi
Young Modulus, E, ASTM D 4015 67,000 psi 102,000 psi
* Specimens shall not be oven dried for the compressive strength test.
** Percentage after 120 days. Long-term total immersion as a percent of cast density in
accordance with ASTM C 796.

(a) CCF Cast Density

The density shall be monitored at the point of placement at hourly intervals during
placement. Adjustments shall be made as necessary to maintain the specified cast
density, ±10%. If two consecutive test results are failing, operations shall cease and
40 corrective action taken before placement of the CCF resumes.

(b) Foam Density

Foam density shall be tested twice during each 24 h period for each mixer. The
foam density shall be within 10% of the target provided in the approved mix design.

216.05 Storage and Handling

Protection of the material during and after placement shall be in accordance with
the manufacturer’s recommendations.

244
 216.12

50 216.06 Weather Limitations

CCF shall be placed when the ambient temperature is 32°F or above. CCF shall
not be placed on frozen subsoil. The installation procedure shall not begin if a
temperature of less than 32°F is expected within a 10 h period from the completion of
the CCF placement, unless recommended by the manufacturer.

216.07 Preparation of Subgrade

The subgrade shall be prepared in accordance with 207. All standing water shall
be removed prior to placement of CCF.

60 216.08 Installation
CCF shall be proportioned, mixed, and placed in lifts as recommended by the
manufacturer. Transit mixers will not be acceptable for mixing the CCF. The CCF
shall not be subjected to load or disturbed by construction activities until a minimum
compressive strength of 25 psi has been achieved.

The final surface finish shall be within ±0.1 ft of the plan elevation.

216.09 Lots
Lots will be defined as 300 cu yd of CCF placed. A partial lot equal to or less than
70 60 cu yd shall be included in the previous lot. A partial lot greater than 60 cu yd but
less than 300 cu yd will be considered a full lot.

216.10 Testing
Acceptance of the work will be based on successful test results for compressive
strength. The Contractor shall cast four specimens for each lot. Testing of the
specimens will be in accordance with ASTM C 495, except test specimens shall be
covered immediately after casting. The specimens shall be moist cured for 26 days and
then air cured for two days prior to the compressive strength testing. The specimens
shall not be oven dried. Test specimens will become the property of the Department
80 after curing and will be tested at 28 days.

216.11 Method of Measurement

CCF will be measured by the cubic yard for each class as computed from the neat
lines shown on the plans.

216.12 Basis of Payment

CCF will be paid for at the contract unit price per cubic yard of the class specified.

Payment will be made under:

90
Pay Item Pay Unit Symbol

Cellular Concrete Fill, _____ .................................................... CYS

class

245
 217.01

Water, curing, molds, equipment, materials, and other incidentals necessary for
finishing CCF specimens shall be included in the cost of CCF.

No payment will be made for replacement of damaged CCF.

100

SECTION 217 – SOILS DRYING WITH CHEMICAL MODIFIERS

217.01 Description
This work shall consist of drying soils by uniformly mixing fly ash or lime with
soil to aid in achieving the workability of soils having moisture over 2% above
optimum moisture content.

MATERIALS

10 217.02 Materials
Materials shall be in accordance with the following:

Fly ash ........................................................... 901.02

Lime .............................................................. 913.04(b)
Water ............................................................. 913.01

Soils containing organic content greater than 6% by dry weight or having a

maximum dry density of less than 95 pcf, or with soluble sulfate content greater than
1,000 ppm shall not be used. The maximum dry density shall be determined in
20 accordance with AASHTO T 99, the organic content shall be determined in
accordance with AASHTO T 267, and the sulfate content shall be determined in
accordance with ITM 510.

CONSTRUCTION REQUIREMENTS

217.03 Testing and Mix Design

The Contractor shall be responsible for all tests required to determine the chemical
modifier type and the relationship between the soils, chemical modifier, and moisture
content. The modifier selection, laboratory testing, and mix design shall be performed
30 by an approved geotechnical consultant in accordance with the Department’s Design
Procedures for Soil Modification or Stabilization.

Chemical modifier, mix design, test results, and the geotechnical consultant
recommendations shall be submitted to the Engineer and to the Office of Geotechnical
Services for approval at least three business days prior to use. Fly ash and lime shall
be from the Department’s list of approved sources.

The quantity of chemical modifier may be adjusted for different soil types and
moisture content.
40

246
 217.09

217.04 Storage and Handling

The chemical modifier shall be stored and handled in accordance with 215.04.

217.05 Weather Limitations

The chemical soil treatment shall be performed when the soil has a minimum
temperature of 35°F, measured 4 in. below the surface, and with the air temperature
rising. The chemical modifier shall not be mixed with frozen soils or with soil
containing frost. When the soil temperature is expected to fall below 35°F prior to the
next lift being placed, chemically treated soils shall be protected from freezing by
50 placing a minimum of 12 in. thick soil.

217.06 Preparation of Soils

The preparation of the soil shall be in accordance with 215.06. The maximum
loose lift shall be no more than 12 in.

217.07 Spreading of Chemical Modifiers

The specified quantity of chemical modifier shall be spread on the surface. The
chemical modifier shall be distributed uniformly by a cyclone, screw-type, or pressure
manifold type distributor. Where type A-7 soils are encountered, the soil shall be
60 scarified prior to spreading the chemical modifier. The chemical modifier shall not be
applied when wind conditions create problems in adjacent areas or create a hazard to
traffic on any adjacent roadway. The spreading of the chemical modifier shall be
limited to an amount which can be incorporated into the soil within the same work
day. The chemical modifier spreading rate shall be adjusted to the current soil moisture
content. If weather causes stoppage of work or exposes the chemical modifier to
washing or blowing, additional chemical modifier may be spread when the work
resumes. Any materials wasted or disturbed by the Contractor’s actions shall be
repaired or replaced at no additional cost.

70 217.08 Mixing
The chemical modifier, soil, and water when necessary, shall be thoroughly mixed
by rotary speed mixers. The mixing shall continue until a homogenous layer of the
required thickness has been obtained. One hundred percent of the material, exclusive
of rock particles, shall pass a 1 in. (25 mm) sieve and at least 60% shall pass a No. 4
(4.75 mm) sieve. The mixing depth shall not exceed 12 in.

217.09 Compaction
The moisture content of the mixture shall be at the optimum moisture content or
above the optimum moisture content as determined by the mix design in accordance
80 with 215.03. Moisture content will be determined in accordance with ITM 506.
Aeration or drying by further mixing may be done to obtain the required moisture
content. Compaction of the mixture shall begin as soon as practical. Compaction shall
be in accordance with 203 or 207.03, as applicable.

Acceptance of chemically modified soils will be performed on the finished grade

with a Dynamic Cone Penetrometer, DCP, in accordance with ITM 509. The

247
 217.10

chemically treated soil lift shall meet the following requirements for compaction:

(a) A minimum DCP blow count of 20 for 12 in. of in place

90 modification.

(b) A minimum of two passing DCP tests for each 1,000 lft or less
of chemically treated soil for each two-lane pavement section.

(c) A minimum of one gradation test shall be performed every

2,500 lft for each two-lane pavement section.

(d) A minimum of one moisture test shall be performed for every 4

h of lime soils mixing. A moisture test shall be performed if soil
100 changes.

During embankment construction, placing of the second 12 in. lift is allowed

when the first lift meets the blow counts requirements of 203.23. A third lift will not
be allowed until the first lift complies with 217.09(a).

Construction traffic or equipment will be allowed after the minimum DCP blow
count is obtained. Construction traffic or equipment shall be routed in one direction so
that the chemically modified soil does not pump or rut.

110 217.10 Method of Measurement

The accepted quantity for drying soils will be measured by the ton of chemical
modifier complete in place. Soils required to construct the fill will be measured in
accordance with 203.

217.11 Basis of Payment

The accepted quantity of chemically modified soils will be paid for by the ton of
chemical modifier used for drying. Soils required to construct the fill will be paid for
in accordance with 203.

120 Payment will be made under:

Pay Item Pay Unit Symbol

Drying Soils for Embankment ................................................... TON

The cost of performing the laboratory tests, providing an approved geotechnical

consultant, scarification of in-situ soil, spreading, pulverization, mixing of the
chemical modifier and soil, moisture compaction of the resultant mixture, shaping the
grade, work required due to adjustments of modifier proportioning, correction of
130 deficient areas, water required for the modification process, and all operations needed
to meet the requirements of this specification shall be included in the cost of the pay
item of this section.

248
 301.06

DIVISION 300 – AGGREGATE PAVEMENT AND BASES

SECTION 301 – AGGREGATE BASE

301.01 Description
This work shall consist of placing coarse aggregate on a prepared subgrade in
accordance with 105.03.

MATERIALS

301.02 Materials
10 Materials shall be in accordance with the following:

Coarse Aggregate, Class D or Higher........................................ 904

Geotextile .................................................................................. 918.02

CONSTRUCTION REQUIREMENTS

301.03 Preparation of Subgrade

Subgrade shall be compacted in accordance with 207.04. In areas of 500 ft or less
in length, or for temporary runarounds, proofrolling will not be required. Proofrolling
20 will not be required in trench sections where proofrolling equipment cannot be used.

301.04 Temperature Limitations

Aggregate shall not be placed when the air temperature is less than 35°F.
Aggregate shall not be placed on a frozen subgrade. Frozen aggregate shall not be
placed.

301.05 Spreading
The moisture content of dense graded aggregate shall be between 4% and the
optimum moisture content prior to placement when the aggregate is delivered to the
30 project. Unless otherwise directed, water shall not be added to the aggregate on the
grade. The aggregate shall be spread in uniform lifts with a spreading and leveling
device approved by the Engineer. The spreading and leveling device shall be capable
of placing aggregate to the depth, width, and slope specified. The compacted depth of
each lift shall be a minimum of 3 in. and a maximum of 6 in. The aggregate shall be
handled and transported to minimize segregation and the loss of moisture. In areas
inaccessible to mechanical equipment, approved hand spreading methods may be used.

301.06 Compacting
Dense graded aggregate shall be compacted to achieve the maximum allowable
40 deflection as determined with the Light Weight Deflectometer, LWD, testing in
accordance with ITM 508. Compaction shall not occur if the moisture content of the
aggregate is greater than 6.0%. The maximum allowable deflection will be determined
from a test section or will be specified. Test sections shall be constructed in accordance

249
 301.07

with ITM 514 for other materials not included in Table 1 to determine the maximum
allowable deflection. The optimum moisture content will be determined in accordance
with 203.24(a).

Samples for moisture content testing shall be taken on the grade from the first
truck of the day. The frequency of the moisture content test for aggregates will be one
50 test for each day of aggregate placement. The maximum allowable deflection for
aggregate over chemically modified soils shall be in accordance with the following:

Maximum Allowable
Material Type
Deflection (mm)
Aggregate over Lime Modified Soil 0.30
Aggregate over Cement Modified Soil 0.27
Table 1

Acceptance of the compaction of aggregates will be determined by averaging

three LWD tests obtained at a random station determined in accordance with ITM 802.
The location of the three tests will be at 2 ft from each edge of the construction area
and at 1/2 of the width of the construction area. The average deflection shall be equal
to or less than the maximum allowable deflection allowed in Table 1 or determined by
60 the test section. The frequency of the LWD testing will be three tests for each 800 t
for compacted aggregate.

As an alternate, aggregates shall be compacted to a minimum of 100% of the

maximum dry densities in accordance with AASHTO T 99. In situ density will be
determined in accordance with 203.24(b). The aggregate shall meet the compaction
requirements at the time subsequent courses are placed. In areas inaccessible to
compaction equipment such as private drives, mailbox approaches, and temporary
runarounds, the compaction requirements may be accepted by visual inspection.

70 All displacement or rutting of the aggregate shall be repaired prior to placing

subsequent material.

Coarse graded aggregates shall be compacted in accordance with 203.25. When

specified, geotextiles shall be installed in accordance with 616.11.

301.07 Checking and Correcting Base

The top of each aggregate course shall be checked transversely to the cross section
and all deviations in excess of 1/2 in. shall be corrected. If additional aggregate is
required, the course shall be remixed and re-compacted.
80
301.08 Priming
A prime coat, when required, shall be in accordance with 405.

301.09 Method of Measurement

Compacted aggregate base will be measured by the cubic yard based on the

250
 302.02

theoretical volume to the neat line as shown on the plans. Geotextiles will be measured
in accordance with 616.12.

301.10 Basis of Payment

90 The accepted quantities of compacted aggregate base will be paid for at the
contract unit price per cubic yard, complete in place. Geotextiles will be paid for in
accordance with 616.13.

Payment will be made under:

Pay Item Pay Unit Symbol

Compacted Aggregate, No. 2 .................................................... CYS

Compacted Aggregate, No. 5 .................................................... CYS
100 Compacted Aggregate, No. 8 .................................................... CYS
Compacted Aggregate, No. 53 .................................................. CYS

The cost of placing, compacting, water, aggregate placed outside neat lines as
shown on the plans, and necessary incidentals shall be included in the cost of the pay
item.

Payment will not be made for material placed outside of a 1:1 slope from the
planned typical section.

110 Replacement of pavement damaged by the Contractor’s operations shall be at no

additional payment.

SECTION 302 – SUBBASE

302.01 Description
This work shall consist of a foundation course of selected materials, placed and
compacted on a prepared subgrade in accordance with 105.03.

Subbase for PCCP shall consist of 3 in. of coarse aggregate No. 8 as the aggregate
drainage layer placed over a 6 in. coarse aggregate No. 53 as the separation layer.
Dense graded subbase shall consist of a 6 in. coarse aggregate No. 53.
10
MATERIALS

302.02 Materials
Materials shall be in accordance with the following:

Coarse Aggregate, Class B or Higher, Size No. 8 ..................... 904

Coarse Aggregate, Class D or Higher, Size No. 53 ................... 904

251
 302.03

Coarse aggregate No. 8 used as an aggregate drainage layer shall consist of 100%
20 crushed stone or ACBF.

CONSTRUCTION REQUIREMENTS

302.03 Preparation of Subgrade

Subgrade shall be prepared in accordance with 207.

302.04 Temperature Limitations

Aggregate shall not be placed when the air temperature is less than 35°F.
Aggregate shall not be placed on a frozen subgrade. Frozen aggregate shall not be
30 placed.

302.05 Spreading
The moisture content of the aggregate shall be between 4% and the optimum
moisture content prior to placement when the aggregate is delivered to the project.
Unless otherwise directed, water shall not be added to the aggregate on the grade. The
aggregate shall be spread in uniform lifts with a spreading and leveling device
approved by the Engineer. The spreading and leveling device shall be capable of
placing aggregate to the depth, width, and slope specified. The compacted depth of
each lift shall be a minimum of 3 in. and a maximum of 6 in. The aggregate shall be
40 handled and transported to minimize segregation and the loss of moisture. In areas
inaccessible to mechanical equipment, approved hand spreading methods may be used.

302.06 Compacting
Subbases shall be compacted as follows:

(a) Aggregate Separation Layers and Dense Graded Subbase

Compaction shall be in accordance with 301.06.

All displacement or rutting of the aggregate separation layers shall be repaired

50 prior to placing subsequent material.

(b) Aggregate Drainage Layers

Compaction shall consist of two passes with a vibratory roller before trimming,
and one pass with the same roller in static mode after trimming. A vibratory roller shall
be equipped with a variable amplitude system, a speed control device, and have a
minimum vibration frequency of 1,000 vibrations per minute. A roller in accordance
with 409.03(d)4 may be used.

Construction traffic shall not be allowed on the aggregate drainage layer, except
60 where placement of the PCCP is restricted. Exceptions shall be submitted for approval.
All displacement or rutting of the aggregate drainage layers shall be repaired prior to
placing subsequent material.

252
 303.02

In areas inaccessible to standard size compacting equipment a specialty

roller/compactor in accordance with 409.03(d)7 shall be used.

302.07 Checking and Correcting Subbase

The top of each aggregate course shall be checked transversely and all deviations
in excess of 1/2 in. shall be corrected. If additional aggregate is required, the course
70 shall be remixed and recompacted.

302.08 Method of Measurement

Subbase for PCCP or dense graded subbase will be measured by the cubic yard
based on the theoretical volume to the neat lines as shown on the plans. The quantity
shown in the Schedule of Pay Items will be adjusted if it is shown to be different by
more than 2% of the measured quantity.

302.09 Basis of Payment

The accepted quantities of subbase for PCCP or dense graded subbase will be paid
80 for at the contract unit price per cubic yard, complete in place.

Payment will be made under:

Pay Item Pay Unit Symbol

Dense Graded Subbase .............................................................. CYS

Subbase for PCCP ..................................................................... CYS

The cost of compacting, water, aggregate placed outside neat lines as shown on
90 the plans, and necessary incidentals shall be included in the cost of the subbase.

SECTION 303 – AGGREGATE PAVEMENTS OR SHOULDERS

303.01 Description
This work shall consist of placing a dense-graded compacted aggregate on
prepared subgrade in accordance with 105.03.

MATERIALS

303.02 Materials
10 Materials shall be in accordance with the following:

Coarse Aggregate, Class D or Higher, Size No. 53 ................... 904

Coarse Aggregate, Class D or Higher, Size No. 73* ................. 904
* Surface courses only, when specified.

253
 303.03

CONSTRUCTION REQUIREMENTS

303.03 Preparation of Subgrade

Subgrade shall be compacted in accordance with 207.04. In areas of 500 ft or less
20 in length, or for temporary runarounds, proofrolling will not be required. Proofrolling
will not be required in trench sections where proofrolling equipment cannot be used.

303.04 Temperature Limitations

Aggregate shall not be placed when the air temperature is less than 35°F.
Aggregate shall not be placed on a frozen subgrade. Frozen aggregate shall not be
placed.

303.05 Spreading
The moisture content of the aggregate shall be between 4% and the optimum
30 moisture content prior to placement when the aggregate is delivered to the project.
Unless otherwise directed, water shall not be added to the aggregate on the grade. The
aggregate shall be spread in uniform lifts with a spreading and leveling device
approved by the Engineer. The spreading and leveling device shall be capable of
placing aggregate to the depth, width, and slope specified. The compacted depth of
each lift shall be a minimum of 3 in. and a maximum of 6 in., except where utilized as
a shoulder. The compacted depth of a lift for a shoulder shall be a minimum of 3 in.
and a maximum of 9 in. The aggregate shall be handled and transported to minimize
segregation and the loss of moisture. In areas inaccessible to mechanical equipment,
approved hand spreading methods may be used.
40
303.06 Compacting
Compaction shall be in accordance with 301.06.

All displacement or rutting of the compacted aggregate shall be repaired prior to

placing subsequent material.

303.07 Checking and Correcting Base and Surface

The top of each aggregate course shall be checked transversely and all deviations
in excess of 1/2 in. shall be corrected. If additional aggregate is required, the course
50 shall be remixed and re-compacted.

303.08 Dust Palliative

A dust palliative, if required, shall be in accordance with 407.

303.09 Method of Measurement

Compacted aggregate will be measured by the ton in accordance with 109.01(b)
for the type specified.

303.10 Basis of Payment

60 The accepted quantities of compacted aggregate will be paid for at the contract
unit price per ton, for the type specified, complete in place.

254
 304.04

Payment will be made under:

Pay Item Pay Unit Symbol

Compacted Aggregate, No. 53 .................................................. TON

Compacted Aggregate, No. 73 .................................................. TON

70 The cost of placing, compacting, water, and necessary incidentals shall be

included in the costs of the compacted aggregate.

Payment will not be made for material placed outside of a 1:1 slope from the
planned typical section.

Replacement or repair of pavement or shoulders damaged by the Contractor’s

operations shall be at no additional payment.

SECTION 304 – ASPHALT BASES

304.01 Description
This work shall consist of constructing an HMA base on a prepared surface or
preparing an existing asphalt pavement for use as an asphalt base in accordance with
105.03.

MATERIALS

10 304.02 Materials
Materials shall be in accordance with the appropriate sections.

304.03 Sealing Cracks and Joints

Cracks and joints shall be sealed in accordance with 408.

304.04 Patching
Areas to be patched will be marked on the surface by the Engineer. The marked
pavement shall be removed to the depth shown on the typical section or as directed. A
minimum 2 in. vertical joint shall be constructed with the pavement that remains in
20 place. If it is determined that the marked pavement is to be removed full depth, the
patch depth shall be to the bottom of the existing asphalt material or as directed.

Subgrade of aggregate base under patches shall be compacted in accordance with

203.25. If the excavation for patches reveals unsuitable subgrade material, such
material shall be removed to a depth of 6 in. and backfilled to the top of subgrade with
compacted aggregate in accordance with 301. Unauthorized excavation beyond neat
lines shall be replaced with compacted aggregate in accordance with 301.

255
 304.05

The excavated patch areas shall be filled with HMA for patching of the type
30 specified in the pay item. Partial depth patches shall use HMA intermediate mixture
and full depth patches shall use HMA base mixture in accordance with 402. A MAF
in accordance with 402.05 will not apply. Mixtures will be accepted in accordance
with 402.09.

Each course shall be compacted by approved mechanical equipment in

accordance with 409.03(d).

A smooth riding surface shall be maintained on HMA patches at all times.

Deformation due to traffic or other conditions shall be corrected immediately. HMA
40 base, intermediate, or surface mixtures may be used to maintain patches. Unless
otherwise specified, patches shall be completed during daylight hours and opened to
traffic at the close of the workday. Patches that cannot be completed prior to the end
of daily operations shall be backfilled, compacted, and a temporary surface placed to
carry traffic, unless otherwise specified.

304.05 Widening
The outside face of the excavated area shall be left as nearly vertical as the nature
of the material will allow and not wider than the outside limits of the widening section.
The subgrade in the widened area shall be compacted in accordance with 207.
50
Widening mixtures shall be HMA mixtures in accordance with 402 and as shown
on the typical section or as directed.

For widening 3 ft or less and 330 lb/sq yd or less, six passes of trench rollers in
accordance with 409.03(d)6 shall be used. For widening 3 ft or less and greater than
330 lb/sq yd, 12 passes of trench rollers in accordance with 409.03(d)6 shall be used.

For widening greater than 3 ft and 330 lb/sq yd or less, six passes of rollers with
a compaction wheel bearing of no less than 300 lb/in. shall be used. For widening
60 greater than 3 ft and greater than 330 lb/sq yd, 12 passes of rollers with a compaction
wheel bearing of no less than 300 lb/in. shall be used.

Except for surface mixtures, the course flush with the top of the existing surface
shall be compacted with equipment entirely on the widening.

A MAF in accordance with 401.05 or 402.05 will not apply. HMA mixtures will
be accepted in accordance with 402.09.

304.06 Method of Measurement

70 Widening and patching will be measured by the ton of the type of HMA specified,
in accordance with 109.01(b). Compacted aggregate for base will be measured by the
ton in accordance with 109.01(b).

256
 305.02

304.07 Basis of Payment

The accepted quantities for widening and patching will be paid for at the contract
unit price per ton, of the type of HMA specified, complete in place. Compacted
aggregate for base will be paid for in accordance with 301.10.

Payment will be made under:

80
Pay Item Pay Unit Symbol

HMA Patching, * ............................................................... TON

type
Widening with HMA, * ..................................................... TON
type
* Mixture type in accordance with 402.04.

Excavation for patching will not be paid for separately but shall be included in the
90 cost of the patching material.

The cost of furnishing, storage, hauling, and placing of all materials; pavement
removal as required; temporary pavement required to carry traffic; choke aggregate
required to eliminate pickup; disposal; excavation; preparation of subgrade;
compacting; and finishing except as otherwise provided shall be included in the cost
of the patching materials.

The cost of excavation and disposal of existing materials required for the
compacted aggregate or HMA widening material shall be included in the cost of the
100 HMA widening material.

Replacement of pavement damaged by the Contractor’s operations shall be at no

additional payment.

SECTION 305 – CONCRETE BASES

305.01 Description
This work shall consist of constructing a PCC base on a prepared surface or
preparing an existing concrete surface for use as a base all in accordance with 105.03.

MATERIALS

305.02 Materials
10 Materials shall be in accordance with the following:

Asphalt for Undersealing ........................................................... 612.02

Coarse Aggregate, Class A or Higher, Size No. 8 ..................... 904
Coarse Aggregate, Class D or Higher, Size No. 53 ................... 904
Coarse Aggregate, Class D or Higher, Size No. 73 ................... 904
257
 305.03

CONSTRUCTION REQUIREMENTS

305.03 New PCC Base

20 Construction of new PCC bases shall be in accordance with 502, except for
502.14, and 502.20. The CMDS shall be in accordance with 502.03 except utilization
of the Department provided spreadsheet is not required. The surface shall be finished
with wet burlap or by wood floats. Smoothness of the base will be controlled with a
16 ft long straightedge longitudinally and a 10 ft long straightedge transversely.

Joints shall be in accordance with 503, except for the following:

(a) the second saw cut and sealing shall not be performed for
transverse joints;
30
(b) sealing shall not be performed for longitudinal joints; and

(c) sawing and sealing shall not be performed for construction

joints.

305.04 Existing PCCP

Preparation of PCCP for use as a base shall be in accordance with 507, except for:

(a) Patching
40 Patching PCC base shall be in accordance with 506 except the coarse aggregate
shall be Class A or higher.

(b) Surface Milling

Surface milling shall be in accordance with 306.

(c) Retrofit Load Transfer

Retrofit load transfer shall be in accordance with 507.08.

(d) Rubblizing Existing PCCP

50 The existing pavement shall be rubblized with a self-contained, self-propelled,
resonant frequency pavement breaking unit capable of producing low amplitude, 2,000
lbf blows at a rate of not less than 44 per second or with a self-contained, self-
propelled, multiple headed, impact hammer with the heads directly adjacent to each
other and the lift height of each head independently adjustable. The sequence of
impacts shall be on a random basis. The unit shall be equipped with a water system to
suppress dust generated by the operation.

The operating speed of the unit shall be such that the existing pavement is reduced
to particles ranging from sand sized to pieces not exceeding 6 in. in the largest
60 dimension, the majority being a nominal 1 to 2 in. in size. The concrete from the
surface to the top of the reinforcement shall be reduced to the 1 to 2 in. size to the

258
 305.04

fullest extent possible. Continuous coverage, overlapped if necessary, with the

breaking shoe or impact hammers shall be used. Additional passes of the resonator or
multiple headed impact hammer may be required if larger sizes remain above the
reinforcement.

Subsurface drains shall be installed along the edges of the pavement prior to the
rubblization.

70 Rubblizing shall begin at the edge of pavement and proceed to the center of the
pavement. The rubblization of the first lane shall extend 6 in. into the adjoining lane.

Prior to placing HMA mixtures, the complete width of the rubblized pavement
shall be compacted by means of vibratory steel wheel and pneumatic-tired rollers in
accordance with 409.03(d) in the following sequence: two initial passes with a
vibratory roller, two passes with a pneumatic-tired roller, and then four final passes
with a vibratory roller. The last two roller passes shall be immediately prior to priming
operations. When the multiple headed impact hammer is used, a Z-pattern grid
cladding bolted to the surface of the drum of the vibratory roller shall be used at least
80 for the final two passes.

The vibratory roller shall be operated in the vibration mode at a speed not to
exceed 6 ft per s. All depressions 1 in. or greater in depth from that of the immediate
surrounding area that result from the rubblizing or compaction effort shall be filled
with coarse aggregate No. 53 or 73 and struck off level with the surrounding area.
Filled depressions shall be compacted with the same roller and compactive effort
previously described.

Reinforcement in the rubblized pavement shall be left in place. Any reinforcement

90 protruding above the surface as a result of rubblizing or compaction operations shall
be cut off below the surface and removed from the site. All loose joint fillers,
expansion material, or other similar materials shall also be removed from the rubblized
surface.

Traffic will not be allowed on the rubblized pavement before the HMA base or
immediate courses are in place unless otherwise directed. Rubblized material
dislodged by traffic shall be removed from the pavement. The initial HMA course shall
be placed within 48 h of rubblizing. However, in the event of rain, this time limitation
may be waived to allow sufficient time for the rubblized pavement to dry to the
100 satisfaction of the Engineer. Crossover and ramp crossings shall be maintained in the
same compacted state as other areas until the initial HMA course is placed.

The preceding rubblizing operations shall be scheduled after widening or shoulder

work has progressed up to the elevation of the existing pavement grade. These areas
may then be utilized to support the breaking unit while the existing pavement is being
rubblized. Shoulders may then be completed in conjunction with the placement of
HMA pavement courses over the compacted rubblized pavement.

259
 305.05

A joint shall be saw cut full depth or load transfer devices shall be severed at an
110 existing joint on ramps or mainline where the rubblizing abuts concrete pavement
which is to remain in place.

305.05 Widening With PCC Base

The subgrade shall be prepared in accordance with 207. Subbase shall be in
accordance with 302.

The concrete shall be placed directly against the existing pavement edges, which
shall be free from all foreign materials. The surface of the concrete widening shall be
at the same elevation as the top of the existing concrete base.
120
Materials and construction requirements shall be in accordance with the
applicable requirements of 502, except the following:

(a) coarse aggregate shall be Class A or higher;

(b) joints shall be sawed in one pass and not sealed. Transverse
joints constructed in the widening shall be aligned with existing
transverse joints or cracks;

130 (c) tining is not required;

(d) shoulder corrugations are not required;

(e) pavement smoothness shall be controlled by a 16 ft

straightedge; and

(f) utilization of the Department provided spreadsheet is not

required.

140 When the widening is not open to traffic prior to placing an overlay, liquid
membrane compounds shall not be used and an alternative curing option shall be used.
Tack coat in accordance with 406 may be used as a curing option.

305.06 Method of Measurement

Compacted aggregate will be measured by the ton in accordance with 109.01(b)
for the type specified. Retrofit load transfer will be measured in accordance with
507.09. Surface milling will be measured in accordance with 306.10. PCC base, PCC
base patching, and widening with PCC base will be measured by the square yard of
the thickness specified. The area of PCC will be the planned width of the base,
150 patching or widening multiplied by the measured length or as directed in writing. The
planned width of the base, patching and widening will be as shown on the typical cross
section of the plans.

Rubblized PCCP will be measured by the square yard of rubblized pavement.

260
 305.07

305.07 Basis of Payment

The accepted quantities of compacted aggregate will be paid for in accordance
with 303.10, for the type specified, complete in place. Retrofit load transfer will be
paid for in accordance with 507.10. Surface milling will be paid for in accordance with
160 306.11. PCC base, PCC base patching, and widening with PCC base will be paid for
at the contract unit price by the square yard of the thickness specified.

Rubblized PCCP will be paid for at the contract unit price per square yard for
rubblized pavement.

Payment will be made under:

Pay Item Pay Unit Symbol

170 PCC Base, __________ in. ........................................................ SYS

thickness
PCC Base Patching, __________ in. ......................................... SYS
thickness
Rubblizing PCCP ...................................................................... SYS
Widening With PCC Base, __________ in. .............................. SYS
thickness

If PCC base is found to be deficient in thickness, price adjustments in accordance

with 502.23 will be determined.
180
The cost of excavation, disposal of existing materials, preparation of subgrade,
and subbase required for the PCC base widening shall be included in the cost of
widening with PCC base.

The cost of excavation, disposal of existing materials, preparation of subgrade,

and subbase required for PCC base patching shall be included in the cost of PCC base
patching.

Replacement of pavement damaged by the Contractor’s operations shall be

190 without additional payment.

The cost of furnishing all labor, materials, and equipment necessary to rubblize,
suppress dust, cut and remove exposed reinforcement, cut and remove joint fillers or
similar materials, saw cutting of the pavement, severing existing joints, compacting
and maintaining the compacted condition of the rubblized pavement shall be included
in the cost of rubblized PCCP.

The cost of furnishing, hauling, placing, leveling, and compacting the aggregate
to fill depressions in the rubblized PCCP shall be included in the cost of coarse
200 aggregate No. 53 or 73.

261
 306.01

SECTION 306 – MILLING

306.01 Description
This work shall consist of the milling of asphalt and concrete pavements and the
disposal of milled materials in accordance with 105.03.

CONSTRUCTION REQUIREMENTS

306.02 General
10 Milling operations shall be described in the QCP in accordance with ITM 803.
Where the milling operation in a partial-day closure results in a longitudinal vertical
or near vertical face exceeding 2 in. in height, the adjacent lane shall be milled during
the same day, the milled lane resurfaced during the same day, or the vertical face
tapered at a 45° angle or flatter. Where located within 3 in. of a curb, surface material
that cannot be removed by the cold-milling machine shall be removed by other
approved methods.

Transverse milled vertical faces greater than 1 in. that are exposed to traffic shall
be transitioned in an approved manner.
20
Castings located in milling areas that are not to be adjusted may remain in place
during the milling, or may be removed and replaced at the Contractor’s option.

Localized weak areas uncovered by the milling process shall be patched in

accordance with 304 or 305.

The milled material shall become the property of the Contractor, unless otherwise
specified.

30 The roadway shall be cleaned before opening to traffic.

306.03 Equipment
Equipment for milling shall be in accordance with the following.

(a) Roadway Milling Machine

A milling machine shall be a power operated cold-milling machine, equipped with
automatic control devices to establish profile grades by referencing from either the
existing pavement or from independent grade control. The equipment shall have a
positive means of controlling cross slope elevations, have an effective means for
40 removing excess material from the surface, preventing airborne dust escaping from the
operation, and producing a finished surface that provides a good bond to the new
overlay.

Sufficient cutting teeth shall be on the coarse milling or fine milling cutting drum
to produce cuttings such that 90% of the conglomerate particles pass a 2 in. sieve. A
coarse milling cutting drum shall have 5/8 in. spacing between the cutting teeth and

262
 306.04

be capable of producing a surface macrotexture ratio in accordance with ITM 812

equal to or greater than 1.8. A fine milling cutting drum shall have 5/16 in. or 3/8 in.
spacing between the cutting teeth and be capable of producing a surface macrotexture
50 ratio in accordance with ITM 812 equal to or greater than 5.0.

(b) Power Saw

Sawing equipment shall be capable of maintaining the specified alignment and
depth of cut without damaging the pavement.

(c) Rotary Power Broom

A motorized, pneumatic tired unit with rotary bristle broom head.

(d) Straightedge
60
1. Straightedge – 16 ft
A 16 ft straightedge shall be a rigid beam mounted on two solid wheels on axles
16 ft apart. The straightedge has a mounted push bar to facilitate propelling the device
along or across the pavement. Tolerance points are located at the 1/4, 1/2, and 3/4
points and may be composed of threaded bolts capable of being adjusted to the
tolerance required.

2. Straightedge – 10 ft
A 10 ft straightedge is the same as a 16 ft straightedge except that the wheels are
70 mounted 10 ft apart. A handheld rigid beam may be substituted.

306.04 Asphalt or PCCP Scarification Milling

Scarification milling shall consist of preparing a base for resurfacing by
roughening the entire existing asphalt or PCCP surface. The milled pavement profile
shall have a surface finish that does not vary longitudinally more than 1/4 in. from a
16 ft straightedge or as described in the QCP in accordance with 401.02.

A fine milling cutting drum in accordance with 306.03(a) shall be used when a
single course overlay is specified with a lay rate as shown on the plans less than 165
80 lb/sq yd and the maximum scarification mill cut depth is expected to be less than 3/4
in. for asphalt or PCCP, otherwise, a coarse milling cutting drum in accordance with
306.03(a) shall be used.

The scarified milled surface shall have a macrotexture ratio in accordance with
ITM 812 as follows:

(a) equal to or greater than 5.0 when using a fine milling cutting
drum for a single course overlay, or

90 (b) equal to or greater than 2.2 for a single course overlay, or

(c) equal to or greater than 1.8 for multiple course overlays.

263
 306.05

Frequency of macrotexture testing shall be a minimum of once per day and shall
be described in the QCP. The cross-slope shall not vary more than 1/8 in. when
measured with a 10 ft straightedge.

Milled traveled way areas left open to traffic for longer than five work days will
be assessed $1,600.00 per day per lane mile, or portion thereof, as liquidated damages,
100 not as a penalty, but as damages sustained for each work day that the milled area
remains open to traffic.

Milled non-traveled way areas such as auxiliary lanes and shoulders left open to
traffic for longer than 10 work days will be assessed $800.00 per day per lane mile, or
portion thereof, as liquidated damages, not as a penalty, but as damages sustained for
each work day that the milled area remains open to traffic.

306.05 Asphalt or PCCP Profile Milling to Correct Cross-Slope

Profile milling shall consist of preparing a base for resurfacing by removing the
110 existing asphalt or PCCP material to the specified cross-slope as shown on the plans.
The milled pavement profile shall have a surface finish that does not vary
longitudinally more than 1/4 in. from a 16 ft straightedge or as described in the QCP
in accordance with 401.02.

A fine milling cutting drum in accordance with 306.03(a) shall be used when a
single course overlay is specified with a lay rate as shown on the plans less than 165
lb/sq yd and the maximum profile mill cut depth is expected to be less than or equal
to 1 1/2 in. for asphalt or 3/4 in. for PCCP, otherwise, a coarse milling cutting drum in
accordance with 306.03(a) shall be used.
120
The profile milled surface shall have a macrotexture ratio in accordance with ITM
812 as follows:

(a) equal to or greater than 5.0 when using a fine milling cutting
drum for a single course overlay, or

(b) equal to or greater than 2.2 for a single course overlay, or

(c) equal to or greater than 1.8 for multiple course overlays.

130
Frequency of macrotexture testing shall be a minimum of once per day and shall
be described in the QCP. The cross-slope shall not vary more than 1/8 in. when
measured with a 10 ft straightedge.

Milled traveled way areas left open to traffic for longer than five work days will
be assessed $1,600.00 per day per lane mile, or portion thereof, as liquidated damages,
not as a penalty, but as damages sustained for each work day that the milled area
remains open to traffic.

264
 306.07

140 Milled non-traveled way areas such as auxiliary lanes and shoulders left open to
traffic for longer than 10 work days will be assessed $800.00 per day per lane mile, or
portion thereof, as liquidated damages, not as a penalty, but as damages sustained for
each work day that the milled area remains open to traffic.

306.06 Approach Milling

Approach milling shall consist of milling the surface and cutting a wedge at the
driveways, commercial or public road approaches. The existing approach shall be
milled a minimum depth of no less than 1/4 in. to accommodate the approach
pavement. The approach milling shall be completed to provide a smooth transition
150 from the traveled way pavement to the termini of the approach. The existing approach
pavement shall be cut to provide a vertical face of 1 1/2 in. for the termini of surface.

Mailbox approaches to be resurfaced shall be milled to maintain the traveled way

profile and cross-slope.

Automatic control devices will not be required on surface milling equipment used
for approach milling. Milling shall not damage any pavement that is to remain in place.

Approach milling shall not be performed at driveways unless it is required to meet

160 a paved surface that continues beyond the construction limit. If the driveway is other
than HMA or PCC beyond the construction limits, the approach milling is not required.

The transverse vertical cut face for commercial or public road approaches shall be
transitioned at a rate of 24:1 or as approved.

306.07 Asphalt or PCCP Milling to a Specified Average Depth

Milling shall consist of preparing a base for resurfacing by removing the existing
asphalt material or PCCP to the specified average depth as shown on the plans. The
milled pavement shall have a surface finish that does not vary longitudinally more than
170 1/4 in. from a 16 ft straightedge or as described in the QCP in accordance with 401.02.

A fine milling cutting drum in accordance with 306.03(a) shall be used when a
single course overlay is specified with a lay rate as shown on the plans less than 165
lb/sq yd and the average mill cut depth is less than or equal to 1 1/2 in. for asphalt or
3/4 in. for PCCP, otherwise, a coarse milling cutting drum in accordance with
306.03(a) shall be used.

The milled surface shall have a macrotexture ratio in accordance with ITM 812
as follows:
180
(a) equal to or greater than 5.0 when using a fine milling cutting
drum for a single course overlay, or

(b) equal to or greater than 2.2 for a single course overlay, or

265
 306.08

(c) equal to or greater than 1.8 for multiple course overlays.

Frequency of macrotexture testing shall be a minimum of once per day and shall
be described in the QCP. The cross-slope shall not vary more than 1/8 in. when
190 measured with a 10 ft straightedge.

If shoulders or turn lanes are not milled and the overlay material is not placed in
the milled areas within the same day, drainage slots shall be provided to eliminate
ponding of water.

Milled traveled way areas left open to traffic for longer than five work days will
be assessed $1,600.00 per day per lane mile, or portion thereof, as liquidated damages,
not as a penalty, but as damages sustained for each work day that the milled area
remains open to traffic.
200
Milled non-traveled way areas such as auxiliary lanes and shoulders left open to
traffic for longer than 10 work days will be assessed $800.00 per day per lane mile, or
portion thereof, as liquidated damages, not as a penalty, but as damages sustained for
each work day that the milled area remains open to traffic.

The transverse vertical cut face shall be transitioned by HMA, CMA or

prefabricated materials at a rate of 24:1 or as approved.

306.08 Asphalt Overlay Removal

210 Asphalt removal shall consist of complete removal of an asphalt overlay by
milling from a portland cement concrete or brick base and the satisfactory disposal of
the milled materials. Minor amounts of asphalt pavement material bonded to a
concrete base at joints or cracks may remain in place. If this material becomes
displaced during subsequent operations, it shall be removed. Minor amounts of asphalt
pavement material bonded to a brick base may remain in place. Removal of minor
areas of portland cement concrete or brick base during the milling operations is
acceptable.

Milled areas shall be cleaned prior to reopening to traffic or before continuing

220 construction operations.

The transverse vertical cut face shall be transitioned by HMA, CMA or

prefabricated materials at a rate of 24:1 or as approved.

306.09 Transition Milling

Transition milling shall consist of cutting a wedge at the beginning and ending of
projects, and paving exceptions. The existing pavement shall be cut to provide a nearly
vertical face of 1 1/2 in. for the termini of each overlay lift of base, intermediate, and
surface. The existing pavement shall be milled at a rate of 720:1 or as directed to
230 achieve the specified cut where the pavement transition overlay lifts differ from cut

266
 306.11

depth. The transverse vertical cut face shall be transitioned by HMA, CMA or
prefabricated materials at a rate of 24:1 or as approved.

Automatic control devices will not be required on surface milling equipment used
for transitions cut off the traveled way. Cutting shall not damage any pavement that is
to remain in place.

306.10 Method of Measurement

Approach milling, asphalt milling, asphalt removal, PCCP milling, scarification
240 milling, profile milling, and transition milling will be measured by the square yard of
the milled area.

306.11 Basis of Payment

Approach milling, asphalt milling, asphalt removal, PCCP milling, scarification
milling, profile milling, and transition milling will be paid for at the contract unit price
per square yard.

Payment will be made under:

250 Pay Item Pay Unit Symbol

Milling, Approach ..................................................................... SYS

Milling, Asphalt, ________ in................................................... SYS
thickness
Milling, Asphalt Removal ......................................................... SYS
Milling, PCCP ________ in. ..................................................... SYS
thickness
Milling, Profile .......................................................................... SYS
Milling, Scarification................................................................. SYS
260 Milling, Transition..................................................................... SYS

The cost for castings removed and replaced at the Contractor’s option in
accordance with 306.02 shall be included in the cost of the milling.

Any portion of the pavement that is damaged or removed outside the milling limits
shall be replaced with no additional payment.

The cost of tapering of vertical faces and removal of milled material from the
project site shall be included in the cost of milling.
270
The cost of cutting of the surface course shall be included in the milling.

267
 307.01

SECTION 307 – CEMENT STABILIZED FULL DEPTH RECLAMATION,

FDR

307.01 Description
This work shall consist of pulverizing and stabilizing an existing asphalt pavement
along with existing base and subgrade materials to construct a reclaimed base course,
RBC, to the approved design properties in accordance with 105.03.

307.02 Just-in-Time Training, JITT

10 The Engineer and Contractor are required to attend a JITT course regarding FDR
and both shall mutually agree on the course instructor, course content and training site.
The training class shall be conducted at a project field location convenient for all
project construction personnel responsible for FDR operations and inspection to
attend.

The JITT course shall be held during normal working hours and be completed not
more than 14 days prior to the start of FDR operations.

The Contractor shall provide a JITT instructor experienced in the construction

20 methods, materials and test methods associated with cement stabilized FDR. A copy
of the course syllabus, handouts and presentation materials shall be submitted to the
Engineer at least five business days before the course is to be taught.

307.03 Quality Control

A quality control plan, QCP, shall be submitted to the Engineer a minimum of
five calendar days prior to the JITT. The QCP shall include the proposed FDR mix
design; a start to finish process description including discussion on corrective action
measures; a list of proposed equipment; a list of proposed QC tests and testing
frequencies; the curing methods applied to the cement stabilized RBC and the
30 stabilization process applied to the RBC and subgrade after a failed proofroll. All QC
test results shall be maintained during the duration of the contract and made available
to the Engineer upon request.

QC Testing
Test Frequency1,2
Depth of Pulverization 1 per 500 ft
Pulverized Material Gradation 1 per 0.5 day of production
In-place Moisture of Pulverized Material 1 per 0.5 day of production
Cement Application Rate 1 per 500 ft
Maximum Density and Moisture Content of
1 per 0.5 day of production
Stabilized Material
Compacted In-Place Field Density 1 per 1,000 ft
1. The Contractor shall perform all QC tests within the first 500 ft after startup and after
any change in the mix design.
2. Testing frequency is based upon linear feet of FDR laydown.
3. The density probe shall be no more than 2.0 in. above the bottom of the FDR treatment.

268
 307.05

MATERIALS

307.04 Materials
RBC shall consist of a homogenous blend of reclaimed asphalt pavement, RAP,
base and subgrade materials that are combined with cement, water, and when required,
40 recycling additives such as corrective aggregate. The cement may be dry powder or
slurry with a minimum dry solids content of 60%. The actual materials used are
dependent on the FDR mix design and project requirements.

Materials for use in RBC shall be in accordance with the following:

Corrective aggregate to adjust gradation or supplement material volume:

1. Coarse or Dense Graded Aggregate,
Class C or Higher ........................................... 904.03
2. Fine Aggregate ............................................................ 904.02
50 3. RAP shall be the product resulting from the cold
milling or crushing of an existing asphalt pavement.
The RAP coarse aggregate shall be processed so that
100% passes the 1 1/2 in. (37.5 mm) sieve.
Portland Cement, Type I............................................................ 901.01(b)
Water ......................................................................................... 913.01

Acceptance of the RBC will be in accordance with the Frequency Manual on the
basis of a type D certification in accordance with ITM 804.

60 307.05 Mix Design

The FDR mix design shall be in accordance with ITM 595 and comprised of
existing RAP, existing base and subgrade materials, cement and if necessary, recycling
additives. The 7-day unconfined strength shall be based on the overlay lay rate
specified on the plans.

Test Procedure Requirement

7-Day Unconfined ASTM D 1633,
see notes 1, 2, 3
Strength Method A
Notes:
1. 300 psi minimum when an HMA overlay with a total lay rate ≥ 330 lb/sq yd.
2. 400 psi minimum when an HMA overlay with a total 165 lb/sq yd ≤ lay rate
< 330 lb/sq yd.
3. 500 psi minimum when an HMA overlay with a total lay rate < 165 lb/sq yd
or an applied seal coat surface.

The mix design and all associated testing shall be performed using samples of the
existing pavement, base and subgrade material from the project site representing the
reclaiming depth, by a design laboratory that is AASHTO Material Reference
70 Laboratory, AMRL, accredited for soil, aggregates, and concrete.

269
 307.06

The sulfate content for the subgrade material shall be less than or equal to 1,000
ppm as determined in accordance with ITM 510.

Additional mix designs shall be performed when the in-place material changes
significantly in order to establish representative mixes for the entire job. The
Contractor shall obtain all samples required to develop the mix design. One sample
per lane mile of planned RBC shall be the minimum sampling frequency for mix
design preparation.
80
The Contractor shall provide a mix design or designs for approval at least five
calendar days prior to the JITT. The mix design shall include all test results performed.
If new materials are added, a new mix design, including the revised test results, shall
be submitted at least one day prior to implementation.

CONSTRUCTION REQUIREMENTS

307.06 Roadway Preparation

Snowplowable raised pavement markers shall be removed in accordance with
90 808.11(e) prior to FDR operations.

Grass and other vegetation shall be removed from the edge of the existing
pavement to prevent contamination of the RBC during milling operation.

Grade adjustments of existing structures shall be made in accordance with 720.04

except existing structures shall be lowered prior to FDR operations, properly covered
and filled with material compatible with the FDR mix design to maintain traffic.

All areas of soft or yielding subgrade, as shown on the plans, shall be corrected
100 prior to pulverization operations.

307.07 Equipment
The equipment shall be capable of pulverizing the existing asphalt pavement, base
and subgrade materials. The equipment used for mixing the pulverized materials with
cement, water, additives and corrective aggregate, when required, shall be capable of
producing a homogenous and uniformly blended RBC. The equipment used for
placement of the RBC shall be capable of placement in accordance to 105.03.

The equipment shall consist of the following major components:

110
(a) Spreaders and Distributors
Spreaders or distributors used to apply dry powder additives shall be non-
pressurized mechanical vane-feed, cyclone or screw type capable of providing a
consistent, accurate and uniform distribution of material while minimizing dust during
construction. Corrective aggregate, when required, may be placed by a mechanical
spreader, a conventional paver or by tailgating with end dump trucks and spread to a
uniform thickness with a motor grader.

270
 307.07

(b) Additive Slurry Storage and Supply Equipment

120 Slurry shall be produced using a batch or continuous-flow type stationary mixer
equipped with calibrated metering and feeding devices that introduce the cement,
water and additives into the mixer in the specified quantities. Additive slurry storage
and supply equipment shall have agitators or similar equipment to keep the slurry in
suspension when held in the slurry batch or storage tanks. Slurry shall be kept in
suspension during transport using agitator equipment.

(c) Mixing and Reclaiming Equipment

Only self-propelled, high powered, minimum 500 hp rotary mixers or reclaimers
capable of mixing in-place to the depth specified shall be used. The minimum cutting
130 drum width shall be 7 ft and fitted with cutting teeth capable of trimming earth,
aggregate and HMA and be so designed that they may be accurately adjusted vertically
and held in-place. The machine shall not weigh less than 25,000 lbs and shall have the
strength and rigidity so that it shall not develop a center deflection of more than 1/8
in.

The mixer or reclaimer shall be fitted with an integrated water injection system
capable of introducing the water into the cutting drum during the mixing process. The
metering device shall be capable of automatically adjusting the flow of material to
compensate for any variation in the amount of reclaimed material introduced into the
140 mixing chamber. The water shall be calculated on a volumetric basis tied to a speed
gauge, ft/min, using a calibrated meter that is capable of accurately measuring the
amount of material to within 0.5% of the rate required. Automatic digital readings
shall be displayed for both the flow rate and total amount of reclaimed material in
appropriate units of weight and time.

(d) Motor Grader

A motor grader for pre-shaping, aerating, spreading and final shaping of the
material shall be utilized. The motor grader shall have a cross slope indicator.

150 (e) Compaction Equipment

The RBC shall be compacted using self-propelled rollers. The number, weight
and types of rollers shall be as necessary to obtain the required compaction throughout
the entire RBC thickness. The rollers may be used in any combination and may include
a pneumatic tire roller, an 84 in. wide drum vibratory pad-foot roller equipped with a
knockdown blade or a 10 t minimum single or double drum vibratory steel roller.

(f) Water Trucks

A water truck shall be used for supplying water to the reclaimer or roadway for
the addition of moisture during the reclaiming operation. The water truck shall be
160 capable of providing a controlled and consistent spray without eroding or otherwise
damaging the compacted RBC.

271
 307.08

307.08 Weather Limitations

FDR operations shall be performed when the ambient temperature is 40°F or
above. The FDR shall not be performed when the soil, aggregate, or subgrade is frozen
or when freezing temperatures are anticipated within seven days of the end of RBC
placement. The Engineer may restrict work when the heat index is greater than 100°F.
The FDR shall not be performed before May 1 or after October 1.

170 307.09 Pulverization

The existing pavement shall be pulverized and stabilized in separate operations.
Corrective aggregate, when required, shall be spread onto the existing surface in
accordance with 307.07(a). The pre-determined full depth of asphalt pavement, base
and subgrade materials shall be pulverized, along with the corrective aggregate, to a
homogenous mixture. The mixture may be brought to the desired moisture content
during this process by means of surface application or through the mixing or
reclaiming equipment’s integrated fluid injection system for dust control. The base
course shall not contain roots, sod, topsoil, weeds, wood or any material deleterious to
its reaction with the cement stabilizer.
180
For cement stabilized RBC, the pulverization shall produce a gradation that has
100% passing the 2 in. (50 mm) sieve and ≥ 55% passing the No. 4 (4.75 mm) sieve.

When a paving fabric is encountered during the pulverization operation, the

Contractor shall make the necessary changes in equipment or operations so that
incorporation of shredded fabric into the RBC does not affect the performance
parameters or inhibit placement or compaction of the RBC. The Contractor shall be
required to remove and properly dispose of oversized pieces of paving fabric. The
Contractor shall make the necessary adjustments in equipment or operations so that
190 the shredded fabric in the recycled material is no more than 5 sq in. No fabric piece
shall have a dimension exceeding a length of 4 in.

Rubberized crack filler, durable pavement markings, loop wires, and other non-
pavement materials shall be removed as observed from the roadway during the
pulverization process. Residual materials that cannot be completely removed may be
incorporated into the mixture if the Contractor can demonstrate that those added
materials will not adversely affect performance.

Any such materials retained in the mixture shall be appropriately sized and
200 blended so as to not adversely affect the strength of the RBC.

307.10 Stabilization
The cement used to stabilize the RBC may be dry powder or slurry and the
Contractor shall address the application methods and fugitive dust control procedures
in the QCP when dry powder materials are used. The pulverized surface shall be
scarified or knifed prior to applying materials in slurry form to prevent runoff or
ponding. Any dry additives used shall be spread onto the pulverized surface using a

272
 307.11

mechanical spreader. The pulverized material shall be mixed with the stabilizer and
additives as required by the mix design to create a homogeneous RBC.
210
The in-place moisture content of the material shall be within -1% to +2% of the
design moisture content as determined by the mix design.

Cement stabilizing materials shall have an application tolerance determined by

adding ±0.5% to the percent total cement content.

The cement shall be incorporated into the pulverized material at the initial rate
determined by the mix design and approved by the Engineer. Sampling and mix design
may determine different levels of cement at various portions of the project.
220
The Contractor can request the cement percentage to exceed the upper tolerance
provided the mix design requirements are satisfied at the requested percentage. The
request will be subject to approval by the Engineer.

307.11 Control Strip and Compaction

A minimum 500 ft long control strip shall be conducted on the first day of
production to verify the construction process meets the requirements as specified. The
control strip shall allow the Contractor to:

230 (a) demonstrate the equipment, materials and processes proposed

can produce a RBC layer in accordance with specification
requirements;

(b) determine the optimal rates for the cement, water and any
additives recommended for the reclaimed material;

(c) determine the sequence and manner of rolling necessary to

obtain strength requirements in one uniformly compacted layer.

240 The RBC density shall be achieved with the same equipment, materials,
construction methods and density requirements used on the accepted control strip. A
new control strip shall be constructed if changes are made outside the tolerances of the
original mix design, equipment or construction methods.

The processed material shall be uniformly compacted in one layer to a minimum

of 95% of the maximum density. Maximum density shall be determined in accordance
with AASHTO T 180 at the required QC frequency from a representative sample
collected after the cement has been added and mixed into the pulverized material but
prior to compaction.
250
Compaction shall be monitored in accordance with AASHTO T 310 in the direct
transmission mode and continue to reach a minimum of 95% of the established
maximum density during the control strip and for the remainder of the compaction
operation.
273
 307.12

Compaction equipment shall be in accordance with 307.07(e). Initial compaction

shall be within 500 ft of the reclaiming unit using either a vibratory pad-foot roller, a
pneumatic tire roller or a combination of the two. The pass counts shall continue to
increase until the cleat indentations from the pad-foot roller are no more than 3/16 in.
260 in depth and light can be seen between the pad-foot and RBC interface or there are no
wheel impressions from the pneumatic tire roller remaining in the RBC.

The cement stabilized material shall be bladed and shaped by a motor grader in
accordance with 307.07(d) to remove any remaining roller marks or indentations then
leveled in accordance with 301.07. The profile grade and cross section of the RBC
shall be finished within a tolerance of ±1/2 in. from the plan RBC elevation prior to
profile milling.

Intermediate and final compaction shall be applied to the bladed and shaped RBC
270 using either a pneumatic tire roller, a single or double drum vibratory steel roller or a
combination of the two. Finish rolling shall not be performed in vibratory mode. The
compaction operation shall be performed while the RBC remains in a workable
condition and continued until roller marks no longer appear.

Any type of rolling effort that causes cracking, displacement or other type of
pavement distress shall be discontinued until such time as the problem can be resolved
and approved by the Engineer.

The QC technician shall be on site, observing all compaction efforts and

280 approving areas as they reach minimum relative compaction. Care shall be taken to
not over compact the mat.

All tests shall be conducted at the stated QC testing frequencies throughout FDR
operations.

307.12 Opening to Traffic

Opening to traffic shall occur after sufficient cure time has been applied to the
RBC so traffic will not initiate raveling or permanent deformation. All loose particles
that may develop on the pavement surface shall be removed by a rotary power broom
290 in accordance with 409.

After opening to traffic, the surface of the RBC shall be maintained in a condition
suitable for the safe movement of traffic.

307.13 Maintenance
The Contractor shall maintain the RBC until the surface course has been
constructed.

Any damage to the completed recycled material shall be repaired by the

300 Contractor prior to the placement of new HMA or final surface sealing. Patching shall

274
 307.18

be in accordance with 304. The excavated patch areas shall be filled and compacted
with HMA or RBC material as directed by the Engineer. No direct payment will be
made for damage or repair unless approved by the Engineer.

307.14 Curing
The planned method and duration of curing for cement stabilized RBC shall be in
accordance with the QCP. The specified surface course shall be placed within two
weeks of the RBC final cure, but no later than November 1.

310 Before placing the final surfacing, the cement stabilized RBC shall remain in-
place for a minimum of three days.

Cement stabilized RBC shall be cured to minimize moisture loss from the surface
for a time period that achieves the minimum required 7-day unconfined strength.

307.15 Proofrolling
The cement stabilized RBC shall be proofrolled in accordance with 203.26 using
a tandem or tri-axle dump truck loaded to the legal limit and operated between 2 to 4
mph over the RBC. The Engineer will determine the limits for any area that has
320 deflection or rutting greater than 1/2 in.

The Contractor shall rework the areas failed in proofrolling by re-pulverizing and
re-stabilizing the RBC in-place at no additional cost or by removing the RBC and
stabilizing the subgrade with subgrade treatment Type IC in accordance with 207.

In locations of failing subgrade the RBC shall be removed and subgrade treatment
Type IC shall be placed in accordance with 207. HMA patching, type B shall be placed
in accordance with 304.

330 307.16 Milling

The entire surface of the cement stabilized RBC shall be scarified in accordance
with 306 to the specified cross-slope in preparation for the overlay. Construction
engineering in accordance with 105.08(b) shall be provided.

307.17 Underdrain Installation

Underdrain installation in accordance with 718, when required, shall begin after
having completed the proofrolling.

307.18 RBC Overlay

340 The overlay atop the RBC shall be as shown on the plans. The overlay shall be
placed after having completed the proofrolling.

The RBC shall be swept of all loose material and standing water with a rotary
power broom in accordance with 409 immediately prior to placing the surface. The
RBC shall be swept lightly to avoid damage to the RBC.

275
 307.19

A tack coat shall be required only for the HMA overlay and shall be applied to
the RBC in accordance with 406 immediately following sweeping operations.

350 Monuments shall be reestablished in accordance with 615.10.

307.19 Method of Measurement

The RBC will be measured by the square yard complete in place. Cement, used
as stabilizing material, will be measured by the ton. Subgrade treatment will be
measured in accordance with 207.05. Corrective aggregate to adjust the RBC
gradation will be measured by the ton of material used. HMA patching, type B will be
measured in accordance with 304.06. Milling will be measured in accordance with
306.10. Re-established monuments will be measured in accordance with 615.13.
Removal of snowplowable raised pavement markers will be measured in accordance
360 with 808.12.

307.20 Basis of Payment

The RBC will be paid for as full depth reclamation at the contract unit price per
square yard, complete in place. Cement, used as stabilizing material, will be paid for
at the contract unit price per ton, complete in place. Subgrade treatment will be paid
for in accordance with 207.06. Corrective aggregate used to adjust the RBC gradation
will be paid for at the contract unit price per ton, complete in place. HMA patching,
type B will be paid for in accordance with 304.07, of the thickness specified on the
plans. Milling will be paid for in accordance with 306.11. Re-established monuments
370 will be paid for in accordance with 615.14. Removal of snowplowable raised pavement
markers will be paid for in accordance with 808.13.

Payment will be made under:

Pay Item Pay Unit Symbol

Corrective Aggregate, FDR ....................................................... TON

Full Depth Reclamation ............................................................. SYS
Stabilizing Material, Portland Cement ...................................... TON
380
The costs of the FDR mix design and QC testing shall be included in the cost of
the full depth reclamation.

The costs associated with removal of grass and vegetation, rubberized crack filler,
durable pavement markings, loop wires and other non-pavement materials shall be
included in the cost of the full depth reclamation.

The costs associated with pulverizing, stabilizing, compacting curing and

maintenance of the RBC shall be included in the cost of the full depth reclamation.
390
The cost associated with mixing water shall be included in the cost of the full
depth reclamation.

276
 308.03

The cost associated with aggregate when used to supplement material volume
shall be included in the cost of the corrective aggregate pay item.

The cost associated with aggregate when used to adjust the RBC gradation shall
be included in the cost of the corrective aggregate pay item.

400 In the locations of failing subgrade, removal of the RBC shall be included in the
cost of subgrade treatment.

SECTION 308 – ASPHALT EMULSION STABILIZED FULL DEPTH

RECLAMATION, FDR

308.01 Description
This work shall consist of pulverizing and stabilizing an existing asphalt pavement
and base material, excluding subgrade, to construct a reclaimed base course, RBC, to
the approved design properties in accordance with 105.03.

308.02 Just in Time Training, JITT

10 The Engineer and Contractor are required to attend a JITT course regarding FDR
and both shall mutually agree on the course instructor, course content and training site.
The training class shall be conducted at a project field location convenient for all
project construction personnel responsible for FDR operations and inspection to
attend.

The JITT course shall be held during normal working hours and be completed not
more than 14 days prior to the start of FDR operations.

The Contractor shall provide a JITT instructor experienced in the construction

20 methods, materials and test methods associated with asphalt emulsion stabilized FDR.
A copy of the course syllabus, handouts and presentation materials shall be submitted
to the Engineer at least five business days before the course is to be taught.

308.03 Quality Control

A quality control plan, QCP, shall be submitted to the Engineer a minimum of
five calendar days prior to the JITT. The QCP shall include the proposed FDR mix
design; a start to finish process description including discussion on corrective action
measures; a list of proposed equipment; a list of proposed QC tests and testing
frequencies; the curing methods applied to the asphalt emulsion stabilized RBC and
30 the stabilization process applied to the RBC and subgrade after a failed proofroll. All
QC test results shall be maintained during the duration of the contract and made
available to the Engineer upon request.

277
 308.04

QC Testing
Test Frequency1,2
Depth of Pulverization 1 per 500 ft
Pulverized Material Gradation 1 per 0.5 day of production
In-place Moisture of Pulverized Material 1 per 0.5 day of production
Asphalt Emulsion Content 1 per 500 ft
Maximum Density and Moisture
1 per 0.5 day of production
Content of Injected Material
Compacted In-Place Field Density 1 per 1,000 ft
Field Moisture Content for Curing 1 per each day of production
Notes:
1. The Contractor shall perform all QC tests within the first 500 ft after startup and after
any change in the mix design.
2. Testing frequency is based upon linear feet of FDR laydown.
3. The density probe shall be no more than 2.0 in. above the bottom of the FDR treatment.

MATERIALS

308.04 Materials
RBC shall consist of a homogenous blend of reclaimed asphalt pavement, RAP,
and base materials that are combined with asphalt emulsion, water, and when required,
40 recycling additives such as corrective aggregate or cement. Cement recycling additives
used in asphalt emulsion stabilized RBC may be dry powder or slurry with a minimum
dry solids content of 60%. The actual materials used are dependent on the FDR mix
design and project requirements.

Materials for use in RBC shall be in accordance with the following:

Asphalt Emulsion ...................................................................... 902.1(b)3

Corrective aggregate to adjust gradation or supplement material volume:
1. Coarse or Dense Graded Aggregate,
50 Class C or Higher ................................................. 904.03
2. Fine Aggregate ............................................................ 904.02
3. RAP, shall be the product resulting from the cold
milling or crushing of an existing asphalt pavement.
The RAP coarse aggregate shall be processed so that
100% passes the 1 1/2 in. (37.5 mm) sieve.
Portland Cement, Type I............................................................ 901.01(b)
Water ......................................................................................... 913.01

Acceptance of the RBC will be in accordance with the Frequency manual on the
60 basis of a type D certification in accordance with ITM 804.

308.05 Mix Design

The FDR mix design shall be in accordance with ITM 594 and comprised of
existing RAP, existing base material, asphalt emulsion and if necessary, recycling

278
 308.07

additives. The mix design and all associated testing shall be performed using samples
of the existing pavement and base material from the project site representing the
reclaiming depth, by a design laboratory that is AASHTO Material Reference
Laboratory, AMRL, accredited for soil, aggregates, HMA and asphalt emulsion.

70 Additional mix designs shall be performed when the in-place material changes
significantly in order to establish representative mixes for the entire job. The
Contractor shall obtain all samples required to develop the mix design. One sample
per lane mile of planned RBC shall be the minimum sampling frequency for mix
design preparation.

The Contractor shall provide a mix design or designs for approval at least five
calendar days prior to the JITT. The mix design shall include all test results performed.
If new materials are added, a new mix design, including the revised test results, shall
be submitted at least one day prior to implementation.
80
CONSTRUCTION REQUIREMENTS

308.06 Roadway Preparation

Snowplowable raised pavement markers shall be removed in accordance with
808.11(e) prior to FDR operations.

Grass and other vegetation shall be removed from the edge of the existing
pavement to prevent contamination of the RBC during milling operation.

90 Grade adjustments of existing structures shall be made in accordance with 720.04

except existing structures shall be lowered prior to FDR operations, properly covered
and filled with material compatible with the FDR mix design to maintain traffic.

All areas of soft or yielding subgrade, as shown on the plans, shall be corrected
prior to pulverization operations.

308.07 Equipment
The equipment shall be capable of pulverizing the existing asphalt pavement and
base materials. The equipment used for mixing the pulverized materials with asphalt
100 emulsion, water, additives and corrective aggregate, when required, shall be capable
of producing a homogenous and uniformly blended RBC. The equipment used for
placement of the RBC shall be capable of placement in accordance to 105.03.

The equipment shall consist of the following major components:

(a) Spreaders and Distributors

Spreaders or distributors used to apply dry powder additives shall be non-
pressurized mechanical vane-feed, cyclone or screw type capable of providing a
consistent, accurate and uniform distribution of material while minimizing dust during
110 construction. Corrective aggregate, when required, may be placed by a mechanical

279
 308.07

spreader, a conventional paver or by tailgating with end dump trucks and spread to a
uniform thickness with a motor grader.

(b) Additive Slurry Storage and Supply Equipment

Slurry shall be produced using a batch or continuous-flow type stationary mixer
equipped with calibrated metering and feeding devices that introduce the cement,
water and additives into the mixer in the specified quantities. Additive slurry storage
and supply equipment shall have agitators or similar equipment to keep the slurry in
suspension when held in the slurry batch or storage tanks. Slurry shall be kept in
120 suspension during transport using agitator equipment.

(c) Mixing and Reclaiming Equipment

Only self-propelled, high powered, minimum 500 hp rotary mixers or reclaimers
capable of mixing in-place to the depth specified shall be used. The minimum cutting
drum width shall be 7 ft and fitted with cutting teeth capable of trimming earth,
aggregate and HMA and be so designed that they may be accurately adjusted vertically
and held in-place. The machine shall not weigh less than 25,000 lbs and shall have the
strength and rigidity so that it shall not develop a center deflection of more than 1/8
in.
130
The mixer or reclaimer shall be fitted with an integrated water and asphalt
emulsion injection system capable of introducing both materials into the cutting drum
during the mixing process. The metering device shall be capable of automatically
adjusting the flow of material to compensate for any variation in the amount of
reclaimed material introduced into the mixing chamber. The water or asphalt emulsion
shall be calculated on a volumetric basis tied to a speed gauge, ft/min, using a
calibrated meter that is capable of accurately measuring the amount of material to
within 0.5% of the rate required. Automatic digital readings shall be displayed for both
the flow rate and total amount of reclaimed material in appropriate units of weight and
140 time.

(d) Motor Grader

A motor grader for pre-shaping, aerating, spreading and final shaping of the
material shall be utilized. The motor grader shall have a cross slope indicator.

(e) Compaction Equipment

The RBC shall be compacted using self-propelled rollers. The number, weight
and types of rollers shall be as necessary to obtain the required compaction throughout
the entire RBC thickness. The rollers may be used in any combination and may include
150 a pneumatic tire roller, an 84 in. wide drum vibratory pad-foot roller equipped with a
knockdown blade or a 10 t minimum single or double drum vibratory steel roller.

(f) Water Trucks

A water truck shall be used for supplying water to the reclaimer or roadway for
the addition of moisture during the reclaiming operation. The water truck shall be

280
 308.10

capable of providing a controlled and consistent spray without eroding or otherwise

damaging the compacted RBC.

308.08 Weather Limitations

160 FDR operations shall be performed when the ambient temperature is 50°F or
above. The FDR shall not be performed when the soil, aggregate, or subgrade is frozen
or when freezing temperatures are anticipated within seven days of the end of RBC
placement. The Engineer may restrict work when the heat index is greater than 100°F.
The FDR shall not be performed before May 1 or after October 1.

308.09 Pulverization
The existing pavement shall be pulverized and stabilized in separate operations.
Corrective aggregate, when required, shall be spread onto the existing surface in
accordance with 308.07(a). The pre-determined full depth of asphalt pavement and
170 base materials shall be pulverized, along with the corrective aggregate, to a
homogenous mixture. The mixture may be brought to the desired moisture content
during this process by means of surface application or through the mixing or
reclaiming equipment’s integrated fluid injection system for dust control. The base
course shall not contain subgrade, roots, sod, topsoil, weeds, wood or any material
deleterious to its reaction with the asphalt emulsion.

For asphalt emulsion stabilized RBC, the pulverization shall produce a gradation
that has 100% passing the 2 in. (50 mm) sieve and ≥ 35% passing the No.4 (4.75 mm)
sieve.
180
When a paving fabric is encountered during the pulverization operation, the
Contractor shall make the necessary changes in equipment or operations so that
incorporation of shredded fabric into the RBC does not affect the performance
parameters or inhibit placement or compaction of the RBC. The Contractor shall be
required to remove and properly dispose of oversized pieces of paving fabric. The
Contractor shall make the necessary adjustments in equipment or operations so that
the shredded fabric in the recycled material is no more than 5 sq in. No fabric piece
shall have a dimension exceeding a length of 4 in.

190 Rubberized crack filler, durable pavement markings, loop wires, and other non-
pavement materials shall be removed as observed from the roadway during the
pulverization process. Residual materials that cannot be completely removed may be
incorporated into the mixture if the Contractor can demonstrate that those added
materials will not adversely affect performance.

Any such materials retained in the mixture shall be appropriately sized and
blended so as to not adversely affect the strength of the RBC.

308.10 Injection
200 An additive used in asphalt emulsion stabilized RBC may be dry powder or slurry
and the Contractor shall address the application methods and fugitive dust control

281
 308.11

procedures in the QCP when dry powder materials are used. The pulverized surface
shall be scarified or knifed prior to applying materials in slurry form to prevent runoff
or ponding. Any dry additives used shall be spread onto the pulverized surface using
a mechanical spreader. The pulverized material shall be mixed with the stabilizer and
additives as required by the mix design to create a homogeneous RBC.

The in-place moisture content of the material shall be within -1% to +2% of the
design moisture content as determined by the mix design.
210
Asphalt stabilizing materials shall have an application tolerance determined by
adding ±0.25% to the percent total asphalt emulsion content.

The asphalt emulsion shall be incorporated into the pulverized material at the
initial rate determined by the mix design and approved by the Engineer. Sampling and
mix design may determine different levels of asphalt emulsion at various portions of
the project.

The Contractor can request the asphalt emulsion percentage to exceed the upper
220 tolerance provided the mix design requirements are satisfied at the requested
percentage. The request will be subject to approval by the Engineer.

308.11 Control Strip and Compaction

A minimum 500 ft long control strip shall be conducted on the first day of
production to verify the construction process meets the requirements as specified. The
control strip shall allow the Contractor to:

(a) demonstrate the equipment, materials and processes proposed

can produce a RBC layer in accordance with specification
230 requirements;

(b) determine the optimal rates for the asphalt emulsion, water and
any additives recommended for the reclaimed material;

(c) determine the sequence and manner of rolling necessary to

obtain specified density requirements in one uniformly
compacted layer.

The RBC density shall be achieved with the same equipment, materials,
240 construction methods and density requirements used on the accepted control strip. A
new control strip shall be constructed if changes are made outside the tolerances of the
original mix design, equipment or construction methods.

The processed material shall be uniformly compacted in one layer to a minimum

of 95% of the maximum density. Maximum density shall be determined in accordance
with AASHTO T 180 at the required QC frequency from a representative sample
collected after injection but prior to compaction.

282
 308.12

Compaction shall be monitored in accordance with AASHTO T 310 in the direct

250 transmission mode and continue to reach a minimum of 95% of the established
maximum density during the control strip and for the remainder of the compaction
operation.

Compaction equipment shall be in accordance with 308.07(e). Initial compaction

shall be within 500 ft of the reclaiming unit using either a vibratory pad-foot roller, a
pneumatic tire roller or a combination of the two. The pass counts shall continue to
increase until the cleat indentations from the pad-foot roller are no more than 3/16 in.
in depth and light can be seen between the pad-foot and RBC interface or there are no
wheel impressions from the pneumatic tire roller remaining in the RBC.
260
The asphalt emulsion stabilized material shall be bladed and shaped by a motor
grader in accordance with 308.07(d) to remove any remaining roller marks or
indentations then leveled in accordance with 301.07. The profile grade and cross
section of the RBC shall be finished within a tolerance of ±1/2 in. from the plan RBC
elevation prior to profile milling.

Intermediate and final compaction shall be applied to the bladed and shaped RBC
using either a pneumatic tire roller, a single or double drum vibratory steel roller or a
combination of the two. Finish rolling shall not be performed in vibratory mode. The
270 compaction operation shall be performed while the RBC remains in a workable
condition and continued until roller marks no longer appear.

Any type of rolling effort that causes cracking, displacement or other type of
pavement distress shall be discontinued until such time as the problem can be resolved
and approved by the Engineer.

The QC technician shall be on site, observing all compaction efforts and

approving areas as they reach minimum relative compaction. Care shall be taken to
not over compact the mat.
280
All tests shall be conducted at the stated QC testing frequencies throughout FDR
operations.

308.12 Opening to Traffic

Opening to traffic shall occur after sufficient cure time has been applied to the
RBC so traffic will not initiate raveling or permanent deformation. All loose particles
that may develop on the pavement surface shall be removed by a rotary power broom
in accordance with 409.

290 After opening to traffic, the surface of the RBC shall be maintained in a condition
suitable for the safe movement of traffic.

283
 308.13

308.13 Maintenance
The Contractor shall maintain the RBC in a satisfactory manner until the surface
course has been constructed.

Any damage to the completed recycled material shall be repaired by the

Contractor prior to the placement of new asphalt concrete or final surface sealing.
Patching shall be in accordance with 304. The excavated patch areas shall be filled and
300 compacted with HMA or RBC material as directed by the Engineer. No direct payment
will be made for damage or repair unless approved by the Engineer.

308.14 Curing
Before placing the final surfacing, the asphalt emulsion stabilized RBC shall
remain in-place for a minimum of three days and meet one of the following conditions:

(a) there is less than 3.0% moisture remaining in the mixture, or

(b) the in-place moisture contents have remained constant at 50%

310 or less of the design optimum moisture content for a continuous
time period of five days.

The planned method and duration of curing for asphalt emulsion stabilized RBC
shall be in accordance with the QCP. The specified surface course shall be placed
within two weeks of the RBC final cure, but no later than November 1.

308.15 Proofrolling
The asphalt emulsion stabilized RBC shall be proofrolled in accordance with
203.26 using a tandem or tri-axle dump truck loaded to the legal limit and operated
320 between 2 to 4 mph over the RBC. The Engineer will determine the limits for any area
that has deflection or rutting greater than 1/2 in.

The Contractor shall rework the areas failed in proofrolling by re-pulverizing and
re-stabilizing the RBC in-place at no additional cost or by removing the RBC and
stabilizing the subgrade with subgrade treatment Type IC in accordance with 207.

The reworked areas shall be proofrolled for final acceptance.

In locations of failing subgrade the RBC shall be removed and subgrade treatment
330 Type IC shall be placed in accordance with 207. HMA patching, type B shall be placed
in accordance with 304.

308.16 Milling
The entire surface of the asphalt emulsion stabilized RBC shall be scarified in
accordance with 306 to the specified cross-slope in preparation for the overlay.
Construction engineering in accordance with 105.08(b) shall be provided.

284
 308.20

308.17 Underdrain Installation

Underdrain installation in accordance with 718, when required, shall begin after
340 having completed the proofrolling.

308.18 RBC Overlay

The overlay atop the RBC shall be as shown on the plans. The overlay shall be
placed after having completed the proofrolling.

The RBC shall be swept of all loose material and standing water with a rotary
power broom in accordance with 409 immediately prior to placing the surface. The
RBC shall be swept lightly to avoid damage to the RBC.

350 A tack coat shall be required only for the HMA overlay and shall be applied to
the RBC in accordance with 406 immediately following sweeping operations.

Monuments shall be reestablished in accordance with 615.10.

308.19 Method of Measurement

The RBC will be measured by the square yard complete in place. Asphalt
emulsion will be measured by the ton. Subgrade treatment will be measured in
accordance with 207.05. Corrective aggregate to adjust the RBC gradation will be
measured by the ton of material used. HMA patching, type B will be measured in
360 accordance with 304.06. Milling will be measured in accordance with 306.10. Re-
established monuments will be measured in accordance with 615.13. Removal of
snowplowable raised pavement markers will be measured in accordance with 808.12.
Portland cement will be measured by the ton.

308.20 Basis of Payment

The RBC will be paid for as full depth reclamation at the contract unit price per
square yard, complete in place. Asphalt emulsion will be paid for at the contract unit
price per ton, complete in place. Subgrade treatment will be paid for in accordance
with 207.06. Corrective aggregate used to adjust the RBC gradation will be paid for at
370 the contract unit price per ton, complete in place. HMA patching, type B will be paid
for in accordance with 304.07, of the thickness specified on the plans. Milling will be
paid for in accordance with 306.11. Re-established monuments will be paid for in
accordance with 615.14. Removal of snowplowable raised pavement markers will be
paid for in accordance with 808.13.

Portland cement will be paid for in accordance with 104.03. The change order will
include direct material costs, delivery costs, and shall not include any other markups.

Payment will be made under:

380
Pay Item Pay Unit Symbol

Corrective Aggregate, FDR ....................................................... TON

Full Depth Reclamation ............................................................. SYS
285
 308.20

Stabilizing Material, Asphalt Emulsion..................................... TON

Stabilizing Material, Portland Cement ...................................... TON

The costs of the RBC mix design and QC testing shall be included in the cost of
the full depth reclamation.
390
The costs associated with removal of grass and vegetation, rubberized crack filler,
durable pavement markings, loop wires and other non-pavement materials shall be
included in the cost of the full depth reclamation.

The costs associated with pulverizing, stabilizing, compacting, curing and

maintenance of the RBC shall be included in the cost of the full depth reclamation.

The cost associated with mixing water shall be included in the cost of the full
depth reclamation.
400
The cost associated with aggregate when used to supplement material volume
shall be included in the cost of the corrective aggregate pay item.

When portland cement is a required stabilizing material, costs associated with

mixing, installation, compaction, curing, and maintenance shall be included in the cost
of the full depth reclamation.

The cost associated with aggregate when used to adjust the RBC gradation shall
be included in the cost of the corrective aggregate pay item.
410
In the locations of failing subgrade, removal of the RBC shall be included in the
cost of subgrade treatment.

286
 401.04

DIVISION 400 – ASPHALT PAVEMENTS

SECTION 401 – QC/QA HMA PAVEMENT

401.01 Description
This work shall consist of one or more courses of QC/QA HMA base,
intermediate, or surface mixtures constructed on prepared foundations in accordance
with 105.03.

401.02 Quality Control

The HMA shall be supplied from a certified HMA plant in accordance with
10 ITM 583; Certified Hot Mix Asphalt Producer Program. The HMA shall be
transported and placed according to a Quality Control Plan, QCP, prepared and
submitted by the Contractor in accordance with ITM 803; Contractor Quality Control
Plans for Hot Mix Asphalt Pavements. The QCP shall be submitted to the Engineer at
least 15 days prior to commencing HMA paving operations.

When a safety edge is required for a project, the QCP shall identify the device or
devices in accordance with 409.03(c) to be used for constructing the safety edge.

MATERIALS
20
401.03 Materials
Materials shall be in accordance with the following:

Asphalt Materials
PG Binder ............................................................. 902.01(a)
Coarse Aggregates ....................................................... 904
Base Mixtures – Class D or Higher
Intermediate Mixtures – Class C or Higher
Surface Mixtures* – Class B or Higher
30 Fibers ........................................................................... AASHTO M 325
Fine Aggregates ........................................................... 904
* Surface aggregate requirements are listed in 904.03(d).

401.04 Design Mix Formula

A design mix formula, DMF, shall be prepared in accordance with 401.05 and
submitted in a format acceptable to the Engineer one week prior to use. The DMF shall
be based on the ESAL category identified in the pay item and shall state the mixture
designation and maximum particle size in the mixture. No mixture will be accepted
for use until the DMF has been assigned a mixture number by the Engineer.
40
The DMF shall state the binder content, the ΔPb determined in accordance with
ITM 591 and a Mixture Adjustment Factor, MAF. The DMF shall state the source,
type, and dosage rate of any stabilizing additives.

287
 401.05

The ESAL category identified in the pay item correlates to the following ESAL
ranges.

ESAL Category ESAL

2* < 3,000,000
3 3,000,000 to < 10,000,000
4* > 10,000,000
* A category 2 mixture shall replace a category 1 mixture and
a category 4 mixture shall replace a category 5 mixture.

The plant discharge temperature for any mixture shall not be more than 315°F
50 whenever PG 64-22 or PG 70-22 binders are used or not more than 325°F whenever
PG 76-22 binder is used. QC/QA HMA may be produced using a water-injection
foaming device. The DMF shall list the minimum and maximum plant discharge
temperatures as applicable to the mixture.

401.05 Volumetric Mix Design

The DMF shall be determined for each mixture from a volumetric mix design by
a design laboratory selected from the Department’s list of approved Mix Design
Laboratories. A volumetric mixture shall be designed in accordance with AASHTO R
35 and the respective AASHTO reference as listed below. All loose mixtures shall be
60 conditioned for 4 h in accordance with AASHTO R 30 prior to testing. Steel furnace
slag coarse aggregate, when used in an intermediate or base mixture application, shall
have a deleterious content less than 4.0% as determined in accordance with ITM 219.

Bulk Specific Gravity and Density of

Compacted Asphalt Mixtures using
Automatic Vacuum Sealing ......................................... AASHTO T 331

The single percentage of aggregate passing each required sieve shall be within the
limits of the following gradation tables:
70

288
 401.05

Dense Graded, Mixture Designation – Control Point

Sieve Size (Percent Passing)
25.0 mm 19.0 mm 12.5 mm 9.5 mm 4.75 mm**
50.0 mm
37.5 mm 100.0
25.0 mm 90.0 - 100.0 100.0
19.0 mm < 90.0 90.0 - 100.0 100.0
12.5 mm < 90.0 90.0 - 100.0 100.0 100.0
9.5 mm < 90.0 90.0 - 100.0 95.0 - 100.0
4.75 mm < 90.0 90.0 - 100.0
2.36 mm 19.0 - 45.0 23.0 - 49.0 28.0 - 58.0 32.0 - 67.0*
1.18 mm 30.0 - 55.0
600 µm
300 µm
75 µm 1.0 - 7.0 2.0 - 8.0 2.0 - 10.0 2.0 - 10.0 3.0 - 8.0
* The mix design gradation shall be less than or equal to the PCS control point for all 9.5 mm
surface mixtures. The mix design gradation can be greater than the PCS control point when
used on non-Department maintained facilities.
** The total blended aggregate gradation for the 4.75 mm mixture shall have a fineness
modulus greater than or equal to 3.30 as determined in accordance with AASHTO T 27.

PCS Control Point for Mixture Designation (Percent Passing)

Mixture Designation 25.0 mm 19.0 mm 12.5 mm 9.5 mm 4.75 mm
Primary Control Sieve 4.75 mm 4.75 mm 2.36 mm 2.36 mm n/a
PCS Control Point 40 47 39 47 n/a

Open Graded, Mixture Designation – Control Point

Sieve Size (Percent Passing)
OG9.5 mm OG19.0 mm OG25.0 mm
37.5 mm 100.0
25.0 mm 100.0 70.0 – 98.0
19.0 mm 70.0 – 98.0 50.0 – 85.0
12.5 mm 100.0 40.0 – 68.0 28.0 – 62.0
9.5 mm 75.0 – 100.0 20.0 – 52.0 15.0 – 50.0
4.75 mm 10.0 – 35.0 10.0 – 30.0 6.0 – 30.0
2.36 mm 0.0 – 15.0 7.0 – 23.0 7.0 – 23.0
1.18 mm 2.0 – 18.0 2.0 – 18.0
600 µm 1.0 – 13.0 1.0 – 13.0
300 µm 0.0 – 10.0 0.0 – 10.0
150 µm 0.0 – 9.0 0.0 – 9.0
75 µm 0 – 6.0 0.0 – 8.0 0.0 – 8.0
% of Binder > 3.0 > 3.0 > 3.0

289
 401.05

Dust/Calculated Effective Binder Ratio shall be 0.6 to 1.4. The Dust/Calculated

Effective Binder Ratio for 4.75 mm mixtures shall be 1.0 to 2.0.

The optimum binder content shall produce a ΔPb ≤ 0.20 as determined in

80 accordance with ITM 591 and the following air voids at Ndes:

Air Voids at Optimum Binder Content

Dense Graded Open Graded
Mixture 25.0 19.0 12.5 9.5 4.75 25.0 19.0 9.5
Designation mm mm mm mm mm mm mm mm
Air Voids 5.0% 5.0% 5.0% 5.0% 5.0% 15.0% - 20.0% 10.0% - 15.0%

The design for dense graded mixtures shall have at least four points, including a
minimum of two points above and one point below the optimum. A one point design
may be used for open graded mixtures. The maximum specific gravity shall be mass
determined in water in accordance with AASHTO T 209. The bulk specific gravity of
the gyratory specimens shall be determined in accordance with AASHTO T 166,
Method A or AASHTO T 331, if required, for dense graded and open graded mixtures.

90 The percent draindown of open graded mixtures shall not exceed 0.30% in
accordance with AASHTO T 305. Open graded mixtures may incorporate recycled
materials and fibers. The recycled materials shall be in accordance with 401.06, and
the fiber type and minimum dosage rate shall be in accordance with AASHTO M 325.
The binder for open graded mixtures may have the upper temperature classification
reduced by 6°C from the specified binder grade if fibers are incorporated into the
mixture or if 3.0% reclaimed asphalt shingles by weight of the total mixture is used.

The percent draindown of dense graded mixtures shall not exceed 0.30% in
accordance with AASHTO T 305. Dense graded mixture shall be tested for moisture
100 susceptibility in accordance with AASHTO T 283 except that the loose mixture curing
shall be replaced by mixture conditioning for 4 h in accordance with AASHTO R 30.
The minimum tensile strength ratio, TSR, shall be 80%. The 6 in. mixture specimens
shall be compacted in accordance with AASHTO T 312. If anti-stripping additives are
added to the mixture to be in accordance with the minimum TSR requirements, the
dosage rate shall be submitted with the DMF.

A PG binder grade or source change will not require a new mix design. If the
upper temperature classification of the PG binder is lower than the original PG grade,
a new TSR value is required.
110
The MAF equals the Gmm from the mixture design divided by the following:
2.465 for 9.5 mm mixtures and 2.500 for 12.5 mm, 19.0 mm, and 25.0 mm mixtures.
If the MAF calculation results in a value where 0.980 ≤ MAF ≤ 1.020, then the MAF
shall be considered to be 1.000. If the MAF is greater than 1.020, the calculated MAF
value shall have 0.020 subtracted from the value. If the MAF is less than 0.980, the
calculated MAF value shall have 0.020 added to the value. The MAF does not apply
to OG mixtures.
290
 401.05

Changes in the source or types of aggregates shall require a new DMF.

120
The mixture design compaction temperature for the specimens shall be 300 ±9°F
for dense graded mixtures and 260°F for open graded mixtures.

Design criteria for each mixture shall be based on the ESAL shown in the contract
documents and shall be as follows:

Gyratory Compaction Effort

Max. Max.
ESAL Nini* Ndes* Nmax* %Gmm %Gmm
@ Nini @ Nmax
Dense Graded 4.75 mm
< 3,000,000 7 75 115 90.5 98.0
3,000,000 to <
8 100 160 89.0 98.0
10,000,000
> 10,000,000 8 100 160 89.0 98.0
Dense Graded 9.5 mm, 12.5 mm, 19.0 mm, and 25.0 mm
< 3,000,000 5 30 40 91.5 97.0
3,000,000 to <
6 50 75 91.5 97.0
10,000,000
> 10,000,000 6 50 75 91.5 97.0
Open Graded
All ESAL n/a 20 n/a n/a n/a
* Nini, Ndes, Nmax - definitions are included in AASHTO R 35.

VOIDS IN MINERAL AGGREGATE, VMA, CRITERIA @ Ndes

Mixture Designation Minimum VMA, %
4.75 mm 17.0
9.5 mm 16.0
12.5 mm 15.0
19.0 mm 14.0
25.0 mm 13.0
OG n/a

130
VOLUME OF EFFECTIVE BINDER, Vbe, CRITERIA @ Ndes
Mixture Designation Minimum Vbe, %
4.75 mm 12.0
9.5 mm 11.0
12.5 mm 10.0
19.0 mm 9.0
25.0 mm 8.0
OG n/a
291
 401.06

VOIDS FILLED WITH ASPHALT, VFA, CRITERIA @ Ndes

ESAL VFA, %
< 3,000,000 60 – 73
3,000,000 to < 10,000,000 60 – 70
≥ 10,000,000 60 – 70
Notes:
1. For 4.75 mm mixtures, the specified VFA range shall be 67% to 79%.
2. For 9.5 mm mixtures, the specified VFA range shall be 68% to 71% for
design traffic levels ≥ 3,000,000 ESALs.
3. For 25.0 mm mixtures, the specified lower limit of the VFA shall be 62%
for design traffic levels < 300,000 ESALs.
4. For OG mixtures, VFA is not applicable.

401.06 Recycled Materials

Recycled materials may consist of reclaimed asphalt pavement, RAP, or
reclaimed asphalt shingles, RAS, or a blend of both. RAP shall be the product resulting
from the cold milling or crushing of an existing HMA pavement. Before entering the
plant, RAP shall be processed so that 100% will pass the 2 in. (50 mm) sieve and RAS
shall be processed so that 100% will pass the 3/8 in. (9.5 mm) sieve. The RAP coarse
140 aggregate shall pass the maximum size sieve for the mixture being produced.

RAP for the ESAL category 3 and 4 surface mixtures shall be a fine RAP with
100% passing the 3/8 in. (9.5 mm) sieve and 95 to 100% passing the No. 4 (4.75 mm)
sieve. The Contractor may request the use of coarse RAP in a category 4 surface
mixture up to a maximum 20.0% by volume of material retained on the No. 4 (4.75
mm) sieve. The election to use coarse RAP in a category 4 surface mixture will void
the allowed use of crushed stone and gravel coarse aggregate materials in accordance
with 904.03(d). SMA RAP as defined in 410.06 shall not be used in any HMA mixture.

150 Recycled materials may be used as a substitute for a portion of the new materials
required to produce HMA mixtures. The amount of total binder replaced by binder in
the recycled material shall be computed as follows:

A x B  C x D x 100%
Binder Replacement, % =
E
where:

A = RAP, % Binder Content by Mass of RAP

B = RAP, % by Total Mass of Mixture
C = RAS, % Binder Content by Mass of RAS
160 D = RAS, % by Total Mass of Mixture
E = Total, % Binder Content by Total Mass of Mixture

RAS may be obtained from either pre-consumer or post-consumer asphalt

shingles but the two RAS types shall not be blended together for use in HMA mixtures.
292
 401.08

Post-consumer asphalt shingles shall be in accordance with the following:

(a) post-consumer asphalt shingles shall be essentially nail-free

170 (b) extraneous metallic materials retained on or above the No. 4

(4.75 mm) sieve shall not exceed 0.5% by mass

(c) extraneous non-metallic materials such as glass, rubber, soil,

brick, paper, wood and plastic retained on or above the No. 4
(4.75 mm) sieve shall not exceed 1.5% by mass

(d) post-consumer shingles shall be prepared by a processing

company with an IDEM Legitimate Use Approval letter. The
approval letter shall be submitted with the DMF to the Engineer.
180
The recycled material percentages shall be as specified on the DMF. HMA
mixtures utilizing recycled materials shall be limited to the binder replacement
percentages in the following table:

HMA mixtures utilizing RAP or RAS or a blend of RAP and RAS

Maximum Binder Replacement, %
Base and Intermediate Surface
Mixture Dense Graded Open Graded Dense Graded
Category 25.0 19.0 12.5 9.5 25.0 19.0 9.5 12.5 9.5 4.75
mm mm mm mm mm mm mm mm mm mm
2 25.0* 25.0* 25.0*
3 25.0* 25.0* 25.0*
4 25.0* 25.0* 25.0*
* The contribution of RAS to any HMA mixture shall be ≤ 3.0% by total mass of mixture
and ≤ 15.0% binder replacement.

The combined aggregate properties shall be in accordance with 904. The

combined aggregate bulk specific gravity shall be determined in accordance with ITM
584 and the combined aggregate gradation shall be in accordance with 401.05 for the
190 HMA mixture specified.

401.07 Lots and Sublots

Lots will be defined as 5,000 t of base or intermediate mixtures or 3,000 t of
surface mixture. Lots will be further sub-divided into sublots not to exceed 1,000 t of
base or intermediate mixtures or 600 t of surface mixture. Partial sublots of 100 t or
less will be added to the previous sublot. Partial sublots greater than 100 t constitute a
full sublot. Partial lots of four sublots or less will be added to the previous lot to create
an extended lot.

200 401.08 Blank

293
 401.09

401.09 Acceptance of Mixtures

Acceptance of mixtures for Vbe at Ndes, and air voids at Ndes for each lot will be
based on tests performed by the Engineer for dense graded 9.5 mm, 12.5 mm, 19.0
mm and 25.0 mm mixtures with original contract pay item quantities greater than or
equal to 300 t.

Acceptance of mixtures for binder content and air voids at Ndes will be based on a
type D certification in accordance with 402.09 for dense graded mixtures with original
210 contract pay item quantities less than 300 t. Acceptance of mixtures for binder content
and air voids at Ndes for each lot will be based on a type D certification in accordance
with 402.09 for dense graded 4.75 mm mixtures.

Acceptance of mixtures for binder content and air voids at Ndes for each lot will
be based on tests performed by the Engineer for open graded mixtures with original
contract pay item quantities greater than or equal to 300 t. Acceptance of mixtures for
binder content and air voids at Ndes will be based on a type D certification in
accordance with 402.09 for open graded mixtures with original pay item quantities
less than 300 t, except the air voids tolerance shall be ±3.5% from the DMF.
220
The Engineer will randomly select the location within each sublot for sampling in
accordance with ITM 802. The first 300 t of the first sublot of the first lot for each
mixture pay item will not be sampled. An acceptance sample will consist of plate
samples obtained in accordance with ITM 802 and ITM 580. The Engineer will take
immediate possession of the samples.

Acceptance samples will be reduced to the appropriate size for testing in

accordance with ITM 587. The binder content and gradation will be determined in
accordance with ITM 571. The maximum specific gravity will be mass determined in
230 water in accordance with AASHTO T 209.

The effective specific gravity, Gse, of the mixture will be determined in each
sublot and reported from the acceptance sample testing.

The total aggregate bulk specific gravity, Gsb, value will be determined in
accordance with ITM 597.

The air voids will be determined in accordance with AASHTO R 35 based on the
average bulk specific gravity from two gyratory specimens and the MSG for the sublot.
240 The VMA will be determined in accordance with AASHTO R 35 based on the average
bulk specific gravity from two gyratory specimens, the percent aggregate in the
mixture from the sublot and the BSG of the aggregate blend from the DMF as
applicable. The gyratory pills will be prepared in accordance with AASHTO T 312.

The dust/calculated effective binder ratio and the volume of effective binder in
the mixture will be determined and reported from the acceptance sample testing
conducted in each sublot. The volume of effective binder will be the difference
between VMA and air voids. The Contractor shall take action in accordance with ITM
294
 401.09

583 to address a dust/calculated effective binder ratio not in accordance with 401.05,
250 a volume of effective binder in the mixture below design minimums, or a volume of
effective binder in the mixture greater than 2.0% above design minimums.

The bulk specific gravity of gyratory specimens for dense graded mixtures will
be determined in accordance with AASHTO T 166, Method A or AASHTO T 331, if
required, except samples are not required to be dried overnight. The bulk specific
gravity of gyratory specimens for open graded mixtures will be determined in
accordance with AASHTO T 331.

A binder draindown test in accordance with AASHTO T 305 for open graded
260 mixtures shall be completed once per lot in accordance with 401.07 and shall not
exceed 0.50%.

The Contractor shall make available the sublot quality control results within seven
calendar days from the date the acceptance sample was taken.

The Engineer will make available the sublot acceptance test results after receiving
the sublot quality control results from the Contractor.

Air voids, binder content and Vbe values will be reported to the nearest 0.01%.
270 Draindown test results will be rounded to the nearest 0.01%. Rounding will be in
accordance with 109.01(a).

Pay factors for dense graded mixtures with original contract pay item quantities
greater than or equal to one lot will be determined in accordance with 401.19(a). Partial
lots of four sublots or less will have pay factors determined in accordance with
401.19(b) if the previous lot is not available.

Pay factors for dense graded mixtures with original contract pay item quantities
greater than or equal to 300 t and less than one lot and open graded mixtures will be
280 determined in accordance with 401.19(b).

The Contractor may request an appeal of the Engineer’s test results in accordance
with 401.20.

Fibers incorporated into the mixture will be accepted on the basis of a type A
certification for the specified material properties for each shipment of fibers. Fibers
from different manufacturers and different types of fibers shall not be intermixed.

In the event that an acceptance sample is not available to represent a sublot, all
290 test results of the previous sublot will be used for acceptance. If the previous sublot is
not available, the subsequent sublot will be used for acceptance.

Samples shall not be obtained from areas placed with paving equipment in
accordance with 409.03(c)2 or 409.03(c)3. If a random location falls within this area,
the Engineer will randomly select another location within the sublot for sampling. If
295
 401.10

an entire sublot falls within this area, test results from the previous sublot will be used
for acceptance. If the previous sublot is not available, the subsequent sublot will be
used for acceptance. If previous or subsequent sublot results for a mixture accepted by
401.19(a) will be replicated for an entire lot, each sublot in that lot will be accepted by
300 401.19(b).

CONSTRUCTION REQUIREMENTS

401.10 General
Equipment for HMA operations shall be in accordance with 409. The Contractor
shall submit to the Engineer written documentation that includes the manufacturer’s
make, model, serial number, manufactured year, and the manufacturer’s literature with
pictures. The documentation shall be submitted prior to use and shall certify that the
paving equipment proposed for the project is new and includes the modifications or
310 have been modified in accordance with the following.

The paver shall be equipped with means of preventing the segregation of the
coarse aggregate particles when moving the mixture from the paver hopper to the
paver augers. The means and methods used shall be in accordance with the paver
manufacturer’s instructions and may consist of chain curtains, deflector plates, or other
such devices, or any combination of these.

The following specific requirements shall also apply to identified HMA pavers:

320 1. Blaw-Knox HMA pavers shall be equipped with the

Blaw-Knox Materials Management Kit, MMK.

2. Cedarapids HMA pavers shall be those that were

manufactured in 1989 or later.

3. Barber-Green/Caterpillar HMA pavers shall be

equipped with deflector plates as identified in the
December, 2000 Service Magazine entitled “New
Asphalt Deflector Kit {6630-DFL, 6631-DFL, or
330 6640-DFL}”.

The Contractor is also required to demonstrate to the Engineer prior to use, that
the modifications to the paving equipment have been implemented on all pavers to be
used on the project.

Fuel oil, kerosene, or solvents shall not be transported in open containers on

equipment. Cleaning of equipment and small tools shall not be accomplished on the
pavement or shoulder areas.

340 Segregation or flushing or bleeding of HMA mixtures will not be allowed.

Corrective action shall be taken to prevent continuation of these conditions.

296
 401.14

Segregated or flushed or bleeding HMA mixtures shall be removed if directed. All

areas showing an excess or deficiency of binder shall be removed and replaced.

All mixtures that become loose and broken, mixed with dirt, or is in any way
defective shall be removed and replaced.

401.11 Preparation of Surfaces to be Overlaid

The subgrade shall be shaped to the required grade and sections, free from all ruts,
350 corrugations, or other irregularities, and uniformly compacted and approved in
accordance with 207. Milling of an existing pavement surface shall be in accordance
with 306. Surfaces on which a mixture is placed shall be free from objectionable or
foreign materials at the time of placement.

Prior to placing an open graded mixture, the underlying HMA course shall have
a full width base seal applied in accordance with 415. The base seal materials shall be
applied within three calendar days after all density cores in accordance with 401.16
have been obtained.

360 Rubblized concrete pavements shall be primed in accordance with 405. PCCP,
milled asphalt surfaces, and asphalt surfaces shall be tacked in accordance with 406.
Contact surfaces of curbing, gutters, manholes, and other structures shall be tacked in
accordance with 406.

All partially completed sections of roadway that are 8 in. or less in thickness shall
be proofrolled prior to the placement of additional materials unless otherwise directed
by the Engineer. Proofrolling shall be accomplished in accordance with 203.26. The
contact pressure shall be 70 to 80 psi. Soft yielding areas shall be removed and
replaced.
370
401.12 Process Control
The Engineer and Contractor will jointly review the operations to ensure
compliance with the QCP. Continuous violations of compliance with the QCP will
result in suspension of paving operations.

401.13 Weather Limitations

HMA courses of less than 138 lb/sq yd shall be placed when the ambient
temperature and the temperature of the surface on which it is to be placed is 45°F or
above. No mixture shall be placed on a frozen subgrade.
380
401.14 Spreading and Finishing
The mixture shall be placed upon an approved surface by means of laydown
equipment in accordance with 409.03(c). Prior to paving, both the planned quantity
and lay rate shall be adjusted by multiplying by the MAF. When mixture is produced
from more than one DMF for a given pay item, the MAF will be applied to the
applicable portion of the mixture for each. The temperature of each mixture at the time
of spreading shall be less than 315°F whenever PG 64-22 or PG 70-22 binders are used
or not more than 325°F whenever PG 76-22 binder is used.
297
 401.15

390 Planned HMA courses greater than 220 lb/sq yd placed under traffic, shall be
brought up even with each adjacent lane at the end of each work day. Planned HMA
courses less than or equal to 220 lb/sq yd shall be brought forward concurrently, within
practical limits, limiting the work in one lane to not more than one work day of
production before moving back to bring forward the adjacent lane. Traffic shall not be
allowed on open graded mixtures.

Hydraulic extensions on the paver will not be allowed for continuous paving
operations. Fixed extensions or extendable screeds shall be used on courses greater
than the nominal width of the paver except in areas where the paving width varies.
400 Hydraulic extensions may be used in tapers and added lanes less than 250 ft in length.

Automatic slope and grade controls shall be used as outlined in the QCP.

HMA mainline and HMA shoulders which are 8 ft or more in width shall be
placed with paving equipment in accordance with 409.03(c)1.

When laying mixtures with density not controlled by cores, the speed of the paver
shall not exceed 50 ft per minute. Rollers shall be operated to avoid shoving of the
HMA and at speeds not to exceed 3 mph. However, vibratory rollers will be limited to
410 2.5 mph.

The finished thickness of any course shall be at least two times but not more than
four times the maximum particle size as shown on the DMF, except 4.75 mm mixtures
shall be at least 1.5 times but not more than 3 times the maximum particle size shown
on the DMF.

A safety edge shall be constructed at locations where a dense graded intermediate

mixture or a surface mixture is constructed adjacent to an aggregate or earth shoulder.

420 Vibratory rollers in accordance with 409.03(d)4 shall not be operated in the
vibratory mode at locations indicated on the plans. Oscillatory rollers in accordance
with 409.03(d)5 will be allowed for use but the vertical impact force capability shall
not be used. Density acceptance shall be in accordance with 401.16.

401.15 Joints
Longitudinal joints in the surface shall be at the lane lines of the pavement.
Longitudinal joints below the surface shall be offset from previously constructed joints
by approximately 6 in., and be located within 12 in. of the lane line.

430 Hot poured joint adhesive in accordance with 906 shall be applied to longitudinal
joints constructed between two adjacent HMA courses in the top course of dense
graded intermediate mixtures and all 4.75 mm, 9.5 mm and 12.5 mm surface mixture
courses. This includes joints within the traveled way as well as between any of the
following: traveled way and an auxiliary lane; traveled way and a paved shoulder; and
auxiliary lane and a paved shoulder.
298
 401.16

The material shall be heated in a jacketed, double boiler melting kettle. The kettle
shall have an attached pressure feed wand system with applicator shoe.

440 The joint adhesive shall be applied to the face of the previously constructed edge
at the joint using a wand applicator. Prior to application of the joint adhesive, the joint
face shall be dry and free of loose material and foreign objects. The adhesive shall be
applied on the joint face 1/8 in. thick at the temperature recommended by the
manufacturer. Excess joint adhesive shall not be allowed to pool on the top of the
previously constructed pavement course or the pavement to be overlaid. The
application of the adhesive shall be made within the same day, but at least 30 minutes
prior to construction of the longitudinal joint.

All 9.5 mm and 12.5 mm surface mixture longitudinal joints that have the joint
450 adhesive applied shall be sealed using SS-1h or AE-NT asphalt emulsion in
accordance with 902.01(b). The sealing operation shall not begin until all density cores
in accordance with 401.16 and 401.20 have been obtained and the installation of
pavement corrugations, when specified in accordance with 606, has been completed.

The liquid asphalt sealant shall be a minimum width of 24 in., centered on the
joint line, and shall be extended, when necessary, to provide coverage beyond the edge
of the pavement corrugation. The sealant shall be applied at an application rate of 0.03
±0.01 gal./sq yd onto a dry surface, free of any foreign or loose material, using a
distributor in accordance with 409.03(a). Areas receiving greater than 0.04 gal./sq yd
460 shall be lightly broomed to reduce the effects of excess sealant on the pavement
surface. The sealant temperature at the time of application shall be at least 135°F and
shall not exceed 180°F. The ambient air and pavement temperatures at the time of
application shall be greater than 32°F.

Temporary pavement markings in accordance with 801.12 shall be offset a

sufficient distance from the longitudinal joint so as not to obstruct the installation of
the pavement corrugations or the application of the liquid asphalt sealant. The sealant
shall be cured a minimum of five days prior to applying the permanent pavement
traffic markings in accordance with 808.
470
Transverse joints shall be constructed by exposing a near vertical full depth face
of the previous course. For areas inaccessible to rollers, other mechanical devices shall
be used to achieve the required density.

If constructed under traffic, temporary transverse joints shall be feathered to

provide a smooth transition to the driving surface.

401.16 Density
Acceptance will be based on lots and sublots in accordance with 401.07.
480
Density of the compacted dense graded mixture will be determined from cores
except where:
299
 401.16

(a) the total planned lay rate to be placed over a shoulder existing
prior to the contract award is less than 385 lb/sq yd; or

(b) the first lift of material placed at less than 385 lb/sq yd over a
shoulder existing prior to the contract award.

490 Density of any random core location in these areas will be assigned a value of
94.0% MSG and compaction shall be in accordance with 402.15.

Open graded mixtures shall be compacted with six passes of a static tandem roller
and will be assigned a value of 84.0% MSG. Vibratory rollers shall not be used on
open graded mixtures.

Compaction of 4.75 mm mixtures shall be in accordance with 402.15, except

vibratory rollers shall be operated in static mode and the vertical impact force
capability of oscillatory rollers shall not be used.
500
Compaction of mixtures with original contract pay item quantities less than 300 t
shall be in accordance with 402.15.

Density acceptance by cores will be based on samples obtained from two random
locations selected by the Engineer within each sublot in accordance with ITM 802.
One core shall be cut at each random location in accordance with ITM 580. The
transverse core location will be located so that the edge of the core will be no closer
than 3 in. from a confined edge or 6 in. from a non-confined edge of the course being
placed. The maximum specific gravity will be determined from the samples obtained
510 in 401.09.

The Contractor shall obtain cores in the presence of the Engineer with a device
that shall produce a uniform 6.00 ±0.25 in. diameter pavement sample. Coring shall
be completed prior to the random location being covered by the next course.

All core locations will be marked and shall be cored within two work days of
placement. A damaged core shall be discarded and replaced with a core from a location
selected by adding 1 ft to the longitudinal location of the damaged core using the same
transverse offset.
520
The Contractor and the Engineer shall mark the core to define the course to be
tested. If the core indicates a course thickness of less than two times the maximum
particle size, the core will be discarded and a core from a new random location will be
selected for testing.

Cores shall not be obtained from areas placed with paving equipment in
accordance with 409.03(c)2 or 409.03(c)3. If a random location falls within this area,
the Engineer will randomly select another location within the sublot for coring. If an
entire sublot falls within this area, test results from the previous sublot will be used for
300
 401.18

530 acceptance. If the previous sublot is not available, the subsequent sublot will be used
for acceptance.

The Engineer will take immediate possession of the cores. If the Engineer’s cores
are subsequently damaged, additional coring will be the responsibility of the
Department. Subsequent core locations will be determined by subtracting 1 ft from the
random location using the same transverse offset.

The density for the mixture will be expressed as the percentage of maximum
specific gravity, %MSG, obtained by dividing the average bulk specific gravity by the
540 maximum specific gravity for the sublot, times 100. Samples for the bulk specific
gravity and maximum specific gravity will be dried in accordance with ITM 572. The
Engineer will determine the bulk specific gravity of the cores in accordance with
AASHTO T 166, Method A or AASHTO T 331, if required. The maximum specific
gravity will be mass determined in water in accordance with AASHTO T 209.

Within one work day of coring operations the Contractor shall clean, dry, and
refill the core holes with HMA of similar or smaller size particles.

The Engineer’s acceptance test results for each sublot will be available when the
550 sublot testing is complete. Acceptance of the pavement for density, %MSG, will be
reported to the nearest 0.01%. Rounding will be in accordance with 109.01(a).

401.17 Pavement Corrugations

Pavement corrugations shall be in accordance with 606.

401.18 Pavement Smoothness

Pavement smoothness will be accepted by means of a profilograph, a 16 ft long
straightedge, or a 10 ft long straightedge as described below.

560 (a) Profilograph

When a pay item for Profilograph, HMA is included in the contract, the Contractor
shall furnish, calibrate, and operate an approved profilograph in accordance with ITM
912 on the mainline traveled way and ramps, including adjacent acceleration or
deceleration lane, where all of the following conditions are met:

1. The design speed is greater than 45 mph.

2. The traveled way or ramp lane width is constant and is

0.1 mi in length or longer.
570
3. The HMA is placed on a milled surface or the total
combined planned lay rate of surface, intermediate,
and base courses is 385 lb/sq yd or greater.

The profilogram produced shall become the property of the Department. The
profilograph shall remain the property of the Contractor.
301
 401.18

The project area, less paving exceptions and areas exempt from profilograph
operation in accordance with ITM 912, will be divided into individual smoothness
580 sections measuring 0.1 mi in length for each lane. Partial length smoothness sections
adjacent to project limits, paving exceptions, or areas exempt from profilograph
operation will be considered in accordance with ITM 912.

If the original contract pay item quantity for a surface mixture is less than or equal
to one sublot, the item will be exempt from profilograph operation and the smoothness
will be accepted in accordance with 401.18(b).

If the posted speed limit for an entire smoothness section is less than or equal to
45 mph, the section will be exempt from profilograph operation and the smoothness
590 within the section will be accepted in accordance with 401.18(b).

If the posted speed limit is greater than 45 mph for a portion of a smoothness
section and is less than or equal to 45 mph for the remainder, the section smoothness
acceptance will be as follows:

1. By profilograph for the portion of the section with a

posted speed limit greater than 45 mph.

2. In accordance with 401.18(b) for the portion of the

600 section with a posted speed limit less than or equal to
45 mph.

At locations where the profilograph is required, it shall be used on the surface

course and on any dense graded intermediate course immediately below the surface
course.

(b) 16 ft Straightedge and 10 ft Straightedge

The Department will furnish and operate 16 ft and 10 ft straightedges as described
below. The 16 ft straightedge is used to accept smoothness along the direction of
610 mainline traffic and the 10 ft straightedge is used to accept smoothness transverse to
the direction of mainline traffic. This includes longitudinal smoothness on public road
approaches and median crossovers.

For contracts which include the Profilograph, HMA pay item, the 16 ft long
straightedge will be used to accept longitudinal smoothness on surface courses at the
following locations:

1. All mainline traveled way lanes shorter than 0.1 mi.

620 2. All mainline traveled way lanes within smoothness

sections with posted speed limits less than or equal to
45 mph throughout the entire section length.

302
 401.18

3. All mainline traveled way lanes at locations exempted

from profilograph operation in accordance with ITM
912.

4. All tapers.

630 5. All turn lanes, including bi-directional left turn lanes.

6. All ramps with design speeds of 45 mph or less.

7. All acceleration and deceleration lanes associated with

ramps with design speeds of 45 mph or less.

8. All shoulders.

For contracts where the profilograph is not used for smoothness acceptance, the
640 16 ft straightedge will be used to accept longitudinal smoothness on all dense graded
courses at the above locations as well as all mainline travel way lanes and ramps with
design speeds of greater than 45 mph. Smoothness acceptance on ramp acceleration or
deceleration lanes will also be based on operation of the 16 ft straightedge.

The 10 ft long straightedge shall be used to check transverse slopes, across travel
lanes and shoulders, approaches, and crossovers.

(c) Smoothness Correction

At locations where the profilograph is being used on an intermediate course, all
650 areas having a high or low point deviation in excess of 0.30 in. shall be corrected. After
corrective action is taken on an intermediate course, a 16 ft straightedge may be used
to verify the adequacy of the corrective action.

At locations where the profilograph is being used on a surface course, all areas
having a high or low point deviation in excess of 0.30 in. shall be corrected. All
smoothness sections with a deficient profile index in accordance with 401.19(c) shall
be corrected. Underlying courses that are exposed by corrective action shall be milled
to a depth of 1 1/2 in. and replaced with surface course. After the corrective action is
taken on a surface course, the profilograph shall be operated throughout the entire
660 affected smoothness section to verify the adequacy of the corrective action.

At locations where the 16 ft straightedge is used, the pavement variations shall be

corrected to 1/4 in. or less. When the 10 ft straightedge is used, the pavement variations
shall be corrected to 1/8 in. or less.

If grinding of an intermediate course is used for pavement smoothness

corrections, the grinding shall not precede the surface placement by more than 30
calendar days if open to traffic.

303
 401.19

670 401.19 Pay Factors

(a) Dense Graded Mixture ≥ One Lot

Pay factors, PF, are calculated for the air voids at Ndes, Vbe at Ndes and in-place
density, %Gmm. The Percent Within Limits, PWL, for each lot will be determined in
accordance with ITM 588. The appropriate pay factor for each property is calculated
as follows:

Estimated PWL greater than 90:

680 PF = ((0.50 x PWL) + 55.00)/100

Estimated PWL greater than 70 and equal to or less than 90:

PF = ((0.40 x PWL) + 64.00)/100

Estimated PWL greater than or equal to 50 and equal to or less than 70:

PF = ((0.85 x PWL) + 32.5)/100

690 If the Lot PWL for any one of the properties is less than 50, a sublot has an air
void content less than 1.0% or greater than 7.0%, or a sublot has a volume of effective
binder greater than 3.0% above design minimums, the lot will be referred to the Office
of Materials Management for adjudication as a failed material in accordance with
normal Department practice as listed in 105.03.

Air voids, Vbe, and in-place density, %Gmm, PF values will be reported to the
nearest 0.01. Rounding will be in accordance with 109.01(a).

A composite pay factor for each lot based on test results for mixture properties
700 and density is determined by a weighted formula as follows:

Lot PF = 0.30(PFVOIDS) + 0.35(PFVbe) + 0.35(PFDENSITY)

where:

Lot PF = Lot Composite Pay Factor for Mixture and Density

PFVOIDS = Lot Pay Factor for Air Voids at Ndes
PFVbe = Lot Pay Factor for Vbe at Ndes
PFDENSITY = Lot Pay Factor for In-Place Density, % Gmm

The lot quality assurance adjustment for mixture properties and density is
calculated as follows:

710 q = L x U x (Lot PF – 1.00)/MAF

where:
304
 401.19

q = quality assurance adjustment for mixture

properties and density of the lot
L = Lot quantity
U = Unit price for the material, $/ton
Lot PF = Lot Pay Factor

Lot test results for the air voids at Ndes, Vbe at Ndes, and density will be used to
determine the Lot Pay Factors.

The specification limits for the air voids at Ndes, Vbe at Ndes, and density will be
as follows:

Specification Limits
Mixture
LSL* USL**
Air Voids at Ndes, % 3.60 6.40
Volume of Effective Binder at Ndes, % Spec Spec +2.50
Density
LSL* USL**
Roadway Core Density (%Gmm), % 93.00 n/a
* LSL, Lower Specification Limit
** USL, Upper Specification Limit
720
(b) Dense Graded Mixture < One Lot and Open Graded Mixture
A composite pay factor for each sublot based on test results for mixture properties
and density is determined in a weighted formula as follows:

Dense Graded Mixture:

SCPF = 0.30(PFVOIDS) + 0.35(PFVbe) + 0.35(PFDENSITY)

Open Graded Mixture:

730
SCPF = 0.20(PFBINDER) + 0.35(PFVOIDS) + 0.45

where:

SCPF = Sublot Composite Pay Factor for Mixture and Density

PFBINDER = Sublot Pay Factor for Binder Content
PFVOIDS = Sublot Pay Factor for Air Voids at Ndes
PFVbe = Sublot Pay Factor for Vbe at Ndes
PFDENSITY = Sublot Pay Factor for Density

If the SCPF for a sublot is less than 0.85 or the volume of effective binder is
greater than 3.0% above design minimums, the sublot will be referred to the Office of
Materials Management for adjudication as a failed material in accordance with 105.03.

305
 401.19

740 The sublot quality assurance adjustment for mixture properties and density is
calculated as follows:
q = L x U x (SCPF – 1.00)/MAF
where:
q = quality assurance adjustment for the sublot
L = sublot quantity
U = unit price for the material $/ton
SCPF = sublot composite pay factor

Sublot test results for mixture properties will be assigned pay factors in
accordance with the following:

Binder Content
Open Graded
Pay Factor
Deviation from DMF (±%)
≤ 0.2 1.05
0.3 1.04
0.4 1.02
0.5 1.00
0.6 0.90
0.7 0.80
0.8 0.60
0.9 0.30
1.0 0.00
Submitted to the Office of
>1.0
Materials Management*
* Test results will be considered and adjudicated as a failed material in
accordance with normal Department practice as listed in 105.03.

Volume of Effective Binder, Vbe

Dense Graded
Deviation from Pay Factors
Spec Minimum
Submitted to the Office of Materials
> +3.0
Management*
≥ +2.5 and ≤ +3.0 1.00 - 0.05 for each 0.1% above +2.5%
> +2.0 and < +2.5 1.05 - 0.01 for each 0.1% above +2.0%
> +0.5 and < +2.0 1.05
≥ 0.0 and ≤ +0.5 1.05 - 0.01 for each 0.1% below +0.5%
≥ -0.5 and < 0.0 1.00 - 0.02 for each 0.1% below 0.0%
≥ -2.0 and < -0.5 0.90 - 0.06 for each 0.1% below - 0.5%
Submitted to the Office of Materials
< -2.0
Management*
* Test results will be considered and adjudicated as a failed material in
accordance with normal Department practice as listed in 105.03.

306
 401.19

Air Voids
Dense Graded Open Graded
Pay Factor
Deviation from Spec (±%) Deviation** (±%)
≤ 0.5 ≤ 3.0 1.05
> 0.5 and ≤ 1.7 > 3.0 and ≤ 4.0 1.00
4.1 0.98
1.8 4.2 0.96
4.3 0.94
4.4 0.92
1.9 4.5 0.90
2.0 4.6 0.84
4.7 0.78
4.8 0.72
4.9 0.66
5.0 0.60
Submitted to the Office
> 2.0 > 5.0
of Materials Management*
* Test results will be considered and adjudicated as a failed material in accordance
with normal Department practice as listed in 105.03.
** Deviation shall be from 17.5% for OG25.0 mm and OG19.0 mm mixtures and
shall be from 12.5% for OG9.5 mm mixtures.
750
For mixtures produced during a plant’s adjustment period, pay factors based on
the DMF with the above tolerances will be used to compute quality assurance
adjustments.

Sublot test results for density will be assigned pay factors in accordance with the
following:

Density
Percentages are
based on %MSG Pay Factors, %
Dense Graded
≥ 98.0 Submitted to the Office of Materials Management*
97.0 - 97.9 1.00
96.6 - 96.9 1.05 - 0.01 for each 0.1% above 96.5
95.0 - 96.5 1.05
94.1 - 94.9 1.00 + 0.005 for each 0.1% above 94.0
93.0 - 94.0 1.00
92.0 - 92.9 1.00 - 0.005 for each 0.1% below 93.0
91.0 - 91.9 0.95 - 0.010 for each 0.1% below 92.0
90.0 - 90.9 0.85 - 0.030 for each 0.1% below 91.0
≤ 89.9 Submitted to the Office of Materials Management*
* Test results will be considered and adjudicated as a failed material in
accordance with normal Department practice as listed in 105.03.

307
 401.19

The pay factors will be rounded to the nearest 0.01.

760
(c) Smoothness
Smoothness pay adjustments will only be applied when the smoothness is
measured by a profilograph. The pay adjustment will be based on the profile index
generated on the surface course only.

At locations where a profilograph is used to accept smoothness, a quality

assurance adjustment will be determined for each 0.1 mile section of each lane. This
adjustment will be applied to all QC/QA HMA pay items within the pavement section.
The adjustment for each section will be calculated using the following formula:
770
n
 S 

q s  (PFs - 1.00)  A x x U
i 1 
T 

where:

qs = quality assurance adjustment for smoothness for one section

PFs = pay factor for smoothness
n= number of layers
A= area of the section, sq yd
S= planned spread rate for material, lb/sq yd
T= conversion factor: 2,000 lb/ton
U= unit price for the material, $/ton.

For smoothness sections that are less than 0.1 mile in length or require
profilograph operation along both lane edges, the profile index used to obtain the
smoothness pay factor used in the above formula will be determined in accordance
with ITM 912.
780
The quality assurance adjustment for smoothness, Qs, for the contract will be the
total of the quality assurance adjustments for smoothness, qs, on each section by the
following formula:

Qs = ∑qs

When smoothness is measured by a profilograph, payment adjustments will be

made based on a zero blanking band on the final profile index in accordance with the
following table. Regardless of the tabulated value, the maximum pay factor for a
790 smoothness section where corrective action has been performed will be 1.00.

308
 401.20

PAY FACTORS FOR SMOOTHNESS

(PI0.0) ZERO BLANKING BAND
Design Speed greater than 45 mph
Profile Index in./0.1 mi. Pay Factor, PFs
Over 0.00 to 1.20 1.06
Over 1.20 to 1.40 1.05
Over 1.40 to 1.60 1.04
Over 1.60 to 1.80 1.03
Over 1.80 to 2.00 1.02
Over 2.00 to 2.40 1.01
Over 2.40 to 3.20 1.00
Over 3.20 to 3.40 0.96
All pavement with a profile index (PI0.0) greater than 3.40 in. shall
be corrected to a profile index less than or equal to 3.40 in.

The total quality assurance adjustment is calculated as follows:

Q = Qs + (∑ q)
where:

Q = total quality assurance adjustment

Qs = quality assurance adjustment for smoothness
q = lot or sublot quality assurance adjustment

401.20 Appeals
800 If the QC test results do not agree with the acceptance test results in a sublot, a
request, along with a comparison of the QC and acceptance test results, may be made
in writing for additional testing of that sublot. The appeal sample will be analyzed in
a lab different than the lab that analyzed the original sample at the discretion of the
Engineer.

The Contractor may appeal an individual sublot for the binder content, the MSG,
the BSG of the gyratory specimens or the BSG of the density cores when the QC
results are greater than one standard deviation from the acceptance test results as
follows: 0.25 for binder content, 0.010 for the MSG and 0.010 for the BSG of the
810 gyratory specimens and 0.020 for the BSG of the density cores. Upon request from the
Contractor, the BSG of the density core may be exempted from the individual sublot
appeal if both the QC and QA results show a %MSG for the density greater than or
equal to 93.0%.

A $500.00 credit adjustment will be included in a quality adjustment pay item in

accordance with 109.05.1(d) for each appealed sublot that did not result in an
improvement to the SCPF or Lot PF.

309
 401.21

A written request for an appeal shall be submitted within seven calendar days of
820 receipt of the Department’s written results for the lot accepted under 401.19(a) or the
sublot accepted under 401.19(b). The conditions for an extended lot appeal are as
follows:

1. One appeal will be allowed for the entire extended lot

if the Contractor informs the Department of the
anticipated extended lot condition within seven
calendar days of receipt of the lot results, or;

2. One appeal will be allowed only for the extended

830 sublots if the Contractor did not inform the
Department of the anticipated extended lot condition
within seven calendar days of receipt of the lot results.

The backup sample will be tested in accordance with the applicable test method
for the sublot requested for all tests exceeding the sublot standard deviation criteria.

(a) MSG
The backup MSG will be dried in accordance with ITM 572 and mass determined
in water in accordance with AASHTO T 209.
840
(b) BSG of the Gyratory Specimen
New gyratory specimens will be prepared and tested in accordance with AASHTO
T 312 from the backup sample.

(c) Binder Content

The backup binder content sample will be prepared and tested in accordance with
ITM 571.

(d) BSG of the Density Core

850 Additional cores shall be taken within seven calendar days unless otherwise
directed. Additional core locations will be determined by adding 1 ft longitudinally of
the cores tested using the same transverse offset. The appeal density cores will be dried
in accordance with ITM 572 and tested in accordance with AASHTO T 166, Method
A or AASHTO T 331, if required.

The appeal results will replace all previous test result for acceptance of mixture
in accordance with 401.09 and density in accordance with 401.16. The results will be
furnished to the Contractor.

860 401.21 Method of Measurement

HMA mixtures will be measured by the ton of the type specified, in accordance
with 109.01(b). The measured quantity will be divided by the MAF to determine the
pay quantity.

Milled shoulder corrugations will be measured in accordance with 606.02.

310
 401.22

Joint adhesive will be measured by the linear foot in accordance with 109.01(a).
Liquid asphalt sealant will be measured by the linear foot.

870 401.22 Basis of Payment

The accepted quantities for this work will be paid for at the contract unit price per
ton for QC/QA-HMA, of the type specified, complete in place.

Payment for furnishing, calibrating, and operating the profilograph, and

furnishing profile information will be made at the contract lump sum price for
profilograph, HMA.

Adjustments to the contract payment with respect to mixture, density, and

smoothness for mixture produced will be included in a quality adjustment pay item in
880 accordance with 109.05.1.

Milled shoulder corrugations will be paid for in accordance with 606.03.

Joint adhesive will be paid for at the contract unit price per linear foot, complete
in place. Liquid asphalt sealant will be paid for at the contract unit price per linear foot.

Payment will be made under:

Pay Item Pay Unit Symbol

890
Joint Adhesive, __________ ..................................................... LFT
course type
Liquid Asphalt Sealant .............................................................. LFT
Profilograph, HMA ................................................................... LS
QC/QA-HMA, ______, ______, ______, ______mm .............. TON
(ESAL(1)) (PG(2)) (Course(3)) (Mix(4))
(1)
ESAL Category as defined in 401.04
(2) Number represents the high temperature binder grade. Low
900 temperature grades are - 22
(3)
Surface, Intermediate, or Base
(4) Mixture Designation

Preparation of surfaces to be overlaid shall be included in the cost of other pay

items.

Coring and refilling of the core holes shall be included in the cost of other pay
items within this section.

910 No payment will be made for additional anti-stripping additives, appeal coring or
traffic control expenditures related to coring operations.

311
 402.01

The cost of removing and replacing soft and yielding areas shall be included in
the cost of other pay items in this section.

Corrections for pavement smoothness shall be included in the cost of other pay
items within this section.

The price for Profilograph, HMA will be full compensation regardless of how
920 often the profilograph is used or how many profilograms are produced.

If QC/QA-HMA 19.0 mm over QC/QA-HMA 25.0 mm mixtures are specified,

QC/QA-HMA 19.0 mm mixture may be considered as a substitute for the QC/QA-
HMA 19.0 mm and QC/QA-HMA 25.0 mm mixtures upon a written request by the
Contractor. The request for the substitution shall be prepared in advance of the work.
A computation will be made in order to obtain a unit price for the QC/QA-HMA 19.0
mm mixture. The quantity and amount for QC/QA-HMA 19.0 mm mixture shall equal
the sum of the contract quantities and amounts shown for QC/QA-HMA 19.0 mm and
QC/QA-HMA 25.0 mm mixtures. The unit price for QC/QA-HMA 19.0 mm mixture
930 shall be equal to the sum of contract amounts divided by the sum of contract quantities.
Payment for the QC/QA-HMA 19.0 mm mixture will be made at the unit price per ton
for QC/QA-HMA 19.0 mm mixture. No payment will be made for additional work or
costs which may result due to this change.

SECTION 402 – HMA PAVEMENT

402.01 Description
This work shall consist of one or more courses of miscellaneous mixtures
constructed in accordance with 105.03.

402.02 Quality Control

The HMA shall be supplied from a certified HMA plant in accordance with
ITM 583; Certified Hot Mix Asphalt Producer Program. The HMA shall be
10 transported and placed according to a Quality Control Plan, QCP, prepared and
submitted by the Contractor in accordance with ITM 803; Contractor Quality Control
Plans for Hot Mix Asphalt Pavements. The QCP shall be submitted to the Engineer at
least 15 days prior to commencing HMA paving operations.

When a safety edge is required for a project, the QCP shall identify the device or
devices in accordance with 409.03(c) to be used for constructing the safety edge.

MATERIALS

20 402.03 Materials
Materials shall be in accordance with the following:

Asphalt Materials
PG Binder ............................................................. 902.01(a)
312
 402.05

Coarse Aggregates ....................................................... 904

Base Mixtures – Class D or Higher
Intermediate Mixtures – Class C or Higher
Surface Mixtures* – Class B or Higher
Fine Aggregates ........................................................... 904
30 * Surface aggregate requirements are listed in 904.03(d).

402.04 Design Mix Formula

A DMF shall be prepared in accordance with 401.04 and submitted in a format
acceptable to the Engineer one week prior to use.

The DMF will be based on the ESAL and mixture designation as follows:

Mixture Type Type B* Type C Type D

Design ESAL < 3,000,000 3,000,000 to < 10,000,000 ≥ 10,000,000
4.75 mm 4.75 mm 4.75 mm
Surface 9.5 mm 9.5 mm 9.5 mm
12.5 mm 12.5 mm 12.5 mm
Surface – PG Binder 64-22 70-22 70-22
9.5 mm 9.5 mm 9.5 mm
12.5 mm 12.5 mm 12.5 mm
Intermediate
19.0 mm 19.0 mm 19.0 mm
25.0 mm 25.0 mm 25.0 mm
Intermediate – PG Binder 64-22 64-22 70-22
19.0 mm 19.0 mm 19.0 mm
Base
25.0 mm 25.0 mm 25.0 mm
Base – PG Binder 64-22 64-22 64-22
*A type B mixture shall replace a type A mixture.

Surface 4.75 mm mixtures shall not be used when the required lay rate shown on
40 the plans is greater than 100 lb/sq yd. Surface 12.5 mm mixtures shall not be used
when the required lay rate shown on the plans is less than 195 lb/sq yd.

The plant discharge temperature for any mixture shall not be more than 315°F
whenever PG 64-22 or PG 70-22 binders are used. HMA may be produced using a
water-injection foaming device. The DMF shall list the minimum and maximum plant
discharge temperatures as applicable to the mixture.

No mixture will be accepted for use until the DMF has been assigned a mixture
number by the Engineer.
50
402.05 Volumetric Mix Design
The DMF shall be determined for each mixture from a volumetric mix design in
accordance with 401.05.

313
 402.06

A DMF developed for a QC/QA HMA mixture may be used and the source or
grade of the binder may be changed; however, the high temperature grade shall meet
the minimum requirements of 402.04.

The MAF equals the Gmm from the mixture design divided by the following: 2.465
60 for 9.5 mm mixtures and 2.500 for 12.5 mm, 19.0 mm, and 25.0 mm mixtures. If the
MAF calculation results in a value where 0.980 ≤ MAF ≤ 1.020, then the MAF shall
be considered to be 1.000. If the MAF is greater than 1.020, the calculated MAF value
shall have 0.020 subtracted from the value. If the MAF is less than 0.980, the
calculated MAF value shall have 0.020 added to the value.

402.06 Blank

402.07 Mix Criteria

70 (a) Composition Limits for HMA Transverse Rumble Strip Mixtures

Transverse rumble strip mixtures shall be type B surface in accordance with
402.04. A MAF in accordance with 402.05 will not apply. Aggregate requirements of
904.03(d) do not apply.

(b) Composition Limits for HMA Wedge and Leveling Mixtures

The mixture shall consist of surface or intermediate mixtures in accordance with
402.04. Aggregate requirements of 904.03(d) do not apply when the wedge and
leveling mixture is covered by a surface or intermediate mixture.

80 (c) Composition Limits for Temporary HMA Mixtures

Temporary HMA mixtures shall be the type specified in accordance with 402.04.
A MAF in accordance with 402.05 will not apply.

(d) Composition Limits for HMA Curbing Mixes

The mixture shall be HMA surface type B in accordance with 402 except 402.05
shall not apply and RAP shall not be used. The binder content shall be 7.0% and the
gradations shall meet the following.

HMA Curbing Gradations

Sieve Size Percent Passing
1/2 in. (12.5 mm) 100.0
3/8 in. (9.5 mm) 80.0 - 100.0
No. 4 (4.75 mm) 73.0 ±5.0
No. 30 (600 µm) 20.0 - 50.0
No. 200 (75 µm) 6.0 - 12.0

90 A DMF shall be prepared in accordance with the above table and submitted in a
format acceptable to the Engineer one week prior to use. The DMF shall state the
binder content.

314
 402.11

402.08 Recycled Materials

Recycled materials shall be in accordance with 401.06 except type B mixtures
shall correspond to category 2 mixtures, type C mixtures shall correspond to category
3 mixtures and type D mixtures shall correspond to category 4 mixtures.

402.09 Acceptance of Mixtures

100 Acceptance of mixtures will be in accordance with the Frequency Manual on the
basis of a type D certification in accordance with 916. The test results shown on the
certification shall be the quality control tests representing the material supplied and
include air voids and binder content. Air voids tolerance shall be ±1.5% and binder
content tolerance shall be ±0.7% from DMF.

Single test values and averages will be reported to the nearest 0.1%. Rounding
will be in accordance with 109.01(a).

Test results exceeding the tolerance limits will be considered as a failed material
110 and adjudicated in accordance with 105.03.

CONSTRUCTION REQUIREMENTS

402.10 General
Equipment for HMA operations shall be in accordance with 409. The Contractor
shall submit to the Engineer prior to use a written Certificate of Compliance that the
proposed paving equipment has been modified in accordance with 401.10 or is new
and includes the modifications.

120 Fuel oil, kerosene, or solvents shall not be transported in open containers on any
equipment at any time. Cleaning of equipment and tools shall not be accomplished on
the pavement or shoulder areas.

Segregation, flushing or bleeding of HMA mixtures will not be allowed.

Corrective action shall be taken to prevent continuation of these conditions. Areas of
segregation, flushing or bleeding shall be corrected, if directed. All areas showing an
excess or deficiency of asphalt materials shall be removed and replaced.

All mixtures that become loose and broken, mixed with dirt, or is in any way
130 defective shall be removed and replaced.

Mixture shall not be dispatched from the plant that cannot be spread and
compacted before sundown of that day, unless otherwise specified.

402.11 Preparation of Surfaces to be Overlaid

The subgrade shall be shaped to the required grade and sections, free from all ruts,
corrugations, or other irregularities, and uniformly compacted and approved in
accordance with 207. Milling of an existing surface shall be in accordance with 306.
Surfaces on which a mixture is placed shall be free from objectionable or foreign
140 materials at the time of placement.
315
 402.12

Prior to placing an open graded mixture, the underlying HMA course shall have
a full width base seal applied in accordance with 415. The base seal materials shall be
applied within three calendar days upon completion of paving the underlying HMA
course.

Rubblized concrete pavements shall be primed in accordance with 405. PCCP,

milled asphalt surfaces, and asphalt surfaces shall be tacked in accordance with 406.
Contact surfaces of curbing, gutters, manholes, and other structures shall be tacked in
150 accordance with 406.

402.12 Weather Limitations

HMA courses less than 110 lb/sq yd are to be placed when the ambient and surface
temperatures are 60°F or above. HMA courses equal to or greater than 110 lb/sq yd
but less than 220 lb/sq yd are to be placed when the ambient and surface temperatures
are 45°F or above. HMA courses equal to or greater than 220 lb/sq yd and HMA
curbing are to be placed when the ambient and surface temperatures are 32°F or above.
Mixture shall not be placed on a frozen subgrade. However, HMA courses may be
placed at lower temperatures, provided the density of the HMA course is in accordance
160 with 402.16.

All partially completed sections of roadway that are 8 in. or less in thickness shall
be proofrolled prior to the placement of additional materials unless otherwise directed
by the Engineer. Proofrolling shall be accomplished in accordance with 203.26. The
contact pressure shall be 70 to 80 psi. Soft yielding areas shall be removed and
replaced.

402.13 Spreading and Finishing

The mixture shall be placed upon an approved surface by means of laydown
170 equipment in accordance with 409.03(c). Prior to paving, both the planned quantity
and lay rate shall be adjusted by multiplying by the MAF. When a mixture is produced
from more than one DMF for a given pay item, the MAF will be applied to the
applicable portion of the mixture for each. Mixtures in areas inaccessible to laydown
equipment or mechanical devices may be placed by other methods.

The temperature of each mixture at the time of spreading shall be less than 315°F
whenever PG 64-22 or PG 70-22 binders are used.

Planned HMA courses greater than 220 lb/sq yd placed under traffic shall be
180 brought up even with each adjacent lane at the end of each work day. Planned HMA
courses less than or equal to 220 lb/sq yd shall be brought forward concurrently, within
practical limits, limiting the work in one lane to not more than one work day of
production before moving back to bring forward the adjacent lane. Traffic shall not be
allowed on open graded mixtures.

Hydraulic extensions on the paver will not be allowed for continuous paving
operations. Fixed extensions or extendable screeds shall be used on courses greater
316
 402.14

than the nominal width of the paver except in areas where the paving widths vary.
Hydraulic extensions may be used on approaches, tapers, and added lanes less than
190 250 ft in length.

HMA shoulders which are 8 ft or more in width shall be placed with automatic
paving equipment.

HMA mixtures in hauling equipment shall be protected by tarps from adverse

weather conditions or foreign materials. Adverse weather conditions include, but will
not be limited to, precipitation or temperatures below 45°F.

The speed of the paver shall not exceed 50 ft per minute when spreading mixtures.
200
Automatic slope and grade controls shall be required except when placing
mixtures on roadway approaches which are less than 200 ft in length or on
miscellaneous work. The use of automatic controls on other courses where use is
impractical due to project conditions may be waived by the Engineer.

The finished thickness of each course shall be at least two times but not more than
four times the maximum particle size as shown on the DMF. The finished thickness of
wedge and level mixtures shall be at least 1 1/2 times but not more than six times the
maximum particle size as shown on the DMF. Feathering may be less than the
210 minimum thickness requirements.

Transverse rumble strips shall be placed to ensure uniformity of height, width,

texture, and the required spacing between strips. A tack coat in accordance with 406
shall be applied on the pavement surface prior to placing the mixture. The tack coat
may be applied with a paint brush or other approved methods.

A safety edge shall be constructed at locations where an intermediate mixture or

a surface mixture is constructed adjacent to an aggregate or earth shoulder.

220 Vibratory rollers in accordance with 409.03(d)4 shall not be operated in vibratory
mode at locations indicated on the plans. Oscillatory rollers in accordance with
409.03(d)5 will be allowed for use but the vertical impact force capability shall not be
used. Density acceptance shall be in accordance with 402.15.

402.14 Joints
Longitudinal joints in the surface shall be at the lane lines of the pavement.
Longitudinal joints below the surface shall be offset from previously constructed joints
by approximately 6 in., and be located within 12 in. of the lane line.

230 Transverse joints shall be constructed by exposing a near vertical full depth face
of the previous course.

If constructed under traffic, temporary transverse joints shall be feathered to

provide a smooth transition to the driving surface.
317
 402.15

402.15 Compaction
The HMA mixture shall be compacted with equipment in accordance with
409.03(d) immediately after the mixture has been spread and finished. Rollers shall
not cause undue displacement, cracking, or shoving.
240
A roller application is defined as one pass of the roller over the entire mat.
Compaction operations shall be completed in accordance with one of the following
options.

Number of Roller Applications

Courses
≤ 440 lb/sq yd > 440 lb/sq yd
Rollers
Option Option Option Option Option Option Option
1 2 3 4 5 1 2
Three Wheel 2 4 4
Pneumatic Tire 2 4 4
Tandem 2 2 2 4
Vibratory 6 8
Oscillatory 6 - -

A reduced number of applications on a course may be approved if detrimental

results are being observed.

Compaction equipment shall be operated with the drive roll or wheels nearest the
250 paver and at speeds not to exceed 3 mph. However, vibratory rollers will be limited to
2.5 mph. Rolling shall be continued until applications are completed and all roller
marks are eliminated.

Compaction operations shall begin at the low side and proceed to the high side of
the mat. The heaviest roller wheel shall overlap its previous pass by a minimum of 6
in.

Longitudinal joints shall be compacted in accordance with the following:

260 (a) For confined edges, the first pass adjacent to the confined edge,
the compaction equipment shall be entirely on the hot mat 6 in.
from the confined edge.

(b) For unconfined edges, the compaction equipment shall extend

6 in. beyond the edge of the hot mat.

All displacement of the HMA mixture shall be corrected at once by the use of
lutes or the addition of fresh mixture as required. The line and grade of the edges of
the HMA mixture shall not be displaced during rolling.
270

318
 402.16

The wheels shall be kept properly moistened with water or water with detergent
to prevent adhesion of the materials to the wheels.

Areas inaccessible to rollers shall be compacted thoroughly with hand tampers or

other mechanical devices in accordance with 409.03(d)7 to achieve the required
compaction. A trench roller, in accordance with 409.03(d)6, may be used to obtain
compaction in depressed areas.

The final two roller applications shall be completed at the highest temperature
280 where the mixture does not exhibit any tenderness.

Vehicular traffic will not be allowed on a course until the mixture has cooled
sufficiently to prevent distortions.

Transverse rumble strips shall be compacted with vibratory compacting

equipment in accordance with 409.03(d)7 unless otherwise stated.

402.16 Low Temperature Compaction Requirements

Compaction for mixtures placed below the temperatures listed in 402.12 shall be
290 controlled by density determined from MSG of the plate samples and cores cut from
the compacted pavement placed during a low temperature period. Samples shall be
obtained in accordance with ITM 580. Acceptance will be based on a plate sample and
two cores. The Engineer will randomly select the locations in accordance with ITM
802. The transverse core location will be located so that the edge of the core will be
no closer than 3 in. from a confined edge or 6 in. from a non-confined edge of the
course being placed.

For compaction of HMA during low temperature periods with quantities less than
100 t per day, acceptance may be visual.
300
The Contractor shall obtain cores in the presence of the Engineer with a device
that shall produce a uniform 6.00 ±0.25 in. diameter pavement sample. Coring shall
be completed prior to the random location being covered. The final HMA course shall
be cored within one work day of placement. Damaged cores shall be discarded and
replaced with a core from a location selected by adding 1 ft to the longitudinal location
of the damaged core using the same transverse offset.

The Contractor and the Engineer shall mark the core to define the course to be
tested. If the core indicates a course thickness of less than two times the maximum
310 particle size, the core will be discarded and a core from a new random location will be
selected for testing.

The Engineer will take immediate possession of the cores. If the Engineer’s cores
are subsequently damaged, additional coring within a specific section will be the
responsibility of the Department. Subsequent core locations will be determined by
subtracting 1 ft from the random location using the same transverse offset.

319
 402.17

The density for the mixture shall be expressed as:

320 Density = 100 x BSG/MSG

where:

BSG = average bulk specific gravity

MSG = maximum specific gravity

The Engineer will determine the bulk specific gravity of the cores in accordance
with AASHTO T 166 Method A or AASHTO T 331, if required. The maximum
specific gravity will be mass determined in water in accordance with AASHTO T 209.
Density shall not be less than 93.0%.

330 Within one work day of coring operations, the Contractor shall clean, dry, refill,
and compact the core holes with suitable HMA of similar or smaller size particles.

402.17 Pavement Corrugations

Pavement corrugations shall be in accordance with 606.

402.18 Pavement Smoothness

Pavement smoothness will be in accordance with 401.18 except profilograph
requirements will not apply.

340 402.19 Method of Measurement

HMA mixtures will be measured by the ton of the type specified, in accordance
with 109.01(b). The measured quantity will be divided by the MAF to determine the
pay quantity.

HMA rumble strips will be measured by the linear foot of each transverse strip,
complete in place.

Milled pavement corrugations will be measured in accordance with 606.02.

350 402.20 Basis of Payment

The accepted quantities for this work will be paid for at the contract unit price per
ton for HMA, of the type specified complete in place.

HMA rumble strips will be paid for at the contract unit price per linear foot, of
each transverse strip complete in place.

Milled pavement corrugations will be paid for in accordance with 606.03.

Payment will be made under:

360

320
 403.02

Pay Item Pay Unit Symbol

HMA Transverse Rumble Strips ............................................... LFT

HMA for Temporary Pavement, Type * ............................ TON
HMA Wedge and Level, Type * ........................................ TON
* Mixture type

Preparation of surfaces to be overlaid shall be included in the cost of other pay

items in this section.
370
No payment will be made for additional anti-stripping additives.

The cost of removing and replacing soft yielding areas shall be included in the
cost of other pay items in this section.

No payment will be made for coring operations and related traffic control
expenditures required in 402.16.

Corrections for pavement smoothness including removal and replacement of

380 pavement, shall be included in the cost of other pay items in this section.

The cost of removal of HMA for temporary pavement including the subgrade and
subbase materials shall be included in the cost of HMA for temporary pavement.

SECTION 403 – CMA PAVEMENT

403.01 Description
This work shall consist of the construction of one or more courses of CMA base,
intermediate, or surface for immediate use or stockpiled in accordance with 105.03.

MATERIALS

403.02 Materials
10 Materials shall be in accordance with the following:

Asphalt Materials
For Immediate Use,
Asphalt Emulsion AE-150, AE-90 ................ 902.01(b)
For Stockpiling,
Asphalt Emulsion AE-150 ............................ 902.01(b)
Course Aggregates ...................................................... 904
Base, Class D or Higher
Intermediate, Class C or Higher
20 Surface, Class B or Higher
Fine Aggregates ........................................................... 904

321
 403.03

Acceptance of the mixture will be in accordance with the Frequency Manual on

the basis of a type D certification in accordance with 916.

CONSTRUCTION REQUIREMENTS

403.03 Weather Limitations

CMA pavements shall not be placed on a wet surface, when the ambient
30 temperature is below 40°F, or when other unsuitable conditions exist, unless approved
by the Engineer.

403.04 Equipment
Mixing plant, hauling trucks, pavers, and rollers shall be in accordance with 409.

403.05 Preparation of Mixtures

The size of the aggregate and the grade of asphalt materials shall be as specified.
The gradations and percent of asphalt shall be as follows.

Composition Limits for CMA Mixtures

Total % of Aggregates Passing Sieves Based on Total
Sieve Size Weight of Aggregates
Size 2 Size 5 Size 8 Size 9 Size 11 Size 5D
2.5 in. (63 mm) 100
2 in. (50 mm) 95 - 100
1.5 in. (37.5 mm) 100 100
1 in. (25 mm) 0 - 25 85 - 100 100 80 - 99
3/4 in. (19.0 mm) 0 - 10 60 - 90 75 - 100 100 68 - 90
1/2 in. (12.5 mm) 0-7 30 - 65 40 - 75 65 - 90 100 54 - 76
3/8 in. (9.5 mm) 15 - 50 20 - 55 30 - 65 75 - 100 45 - 67
No. 4 (4.75 mm) 0 - 20 0 - 20 0 - 20 10 - 35 30 - 50
No. 8 (2.36 mm) 0 - 15 0 - 15 0 - 15 0 - 15 20 - 45
No. 30 (600 µm) 7 - 28
No. 200 (75 µm) 0-5 0-5 0-5 0-6 0-6 0-6
Minimum % Crushed 95 95 95 95 95 95
% of Asphalt* 2.0 - 3.5 2.5 - 4.0 3.0 - 4.5 3.5 - 5.0 4.0 - 6.0 3.5 - 5.0
* Percent of asphalt shall be calculated on the basis of the total weight of the mixture,
exclusive of water or solvent. When slag is used, the asphalt content will be adjusted to
compensate for the specific gravity and surface area.
40
The moisture condition of the aggregate shall be such that the aggregate is
uniformly coated and satisfactorily retains the required amount of asphalt during the
stockpiling, hauling, and spreading operations. Mixtures shall not be produced at
temperatures exceeding 180°F.

403.06 Preparation of Subgrade or Base

Mixtures for CMA base may be placed on an earth subgrade, on an existing
pavement surface to be used as a base, or on a previously prepared base or subbase as

322
 403.12

specified. If such material is to be laid on a newly prepared subgrade, then all

50 applicable requirements of 207 shall apply.

403.07 Spreading Mixture

The CMA mixture shall be spread in accordance with 402.13.

A safety edge shall be constructed at locations where an intermediate mixture or

a surface mixture is constructed adjacent to an aggregate or earth shoulder.

403.08 Curing
All CMA mixtures shall be allowed to cure sufficiently to prevent undue
60 distortions under the roller wheels.

When a CMA mixture is allowed to cure under traffic, the surface shall be
maintained and all damaged areas shall be satisfactorily repaired.

403.09 Compaction
Compaction shall be in accordance with 402.15. Satisfactory means to confine the
mixture within the required limits shall be in place during the compaction operation.

403.10 Surface Tolerances

70 The smoothness requirements for CMA pavements shall be in accordance with
402.18.

403.11 Method of Measurement

CMA pavement will be measured by the ton, of the type and size specified, in
accordance with 109.01(b).

403.12 Basis of Payment

The accepted quantities of CMA pavement will be paid for at the contract unit
price per ton, of the type and size specified, for the mixture.
80
Payment will be made under:

Pay Item Pay Unit Symbol

CMA Base ______ .................................................................... TON

size
CMA Intermediate ______ ........................................................ TON
size
CMA Surface ______ ................................................................ TON
90 size

The cost of repairing damaged areas of mixture allowed to cure under traffic shall
be included in the cost of the pay items in this section.

323
 404.01

SECTION 404 – SEAL COAT

404.01 Description
This work shall consist of one or more applications of asphalt material, each
followed by an application of cover aggregate in accordance with 105.03.

404.02 Quality Control

Seal coat shall be constructed according to a quality control plan, QCP, prepared
and submitted by the Contractor in accordance with ITM 803; Contractor Quality
10 Control Plan for Seal Coat. The QCP shall be submitted to the Engineer at least 15
days prior to commencing seal coat operations.

MATERIALS

404.03 Asphalt Material

The type and grade of asphalt material shall be in accordance with the following:

Asphalt Emulsion, RS-2, AE-90,

AE-90S, or HFRS-2.................................................... 902.01(b)
20
404.04 Cover Aggregate
Aggregate shall be in accordance with the following requirements. When slag is
used as an alternate to natural aggregate, adjustments will be made in accordance with
904.01, to compensate for differences in specific gravity.

Coarse Aggregates*, Class B or Higher

Size No. 8, 9, 11, 12, SC 11, SC 12, or SC 16 ...... 904
Fine Aggregate, Size No. 23 or 24 .............................. 904
* Coarse aggregate type required shall be in accordance
30 with 904.03(d)1 for ESAL categories 2 or 3.

The types of seal coats shall be as follows:

324
 404.07

Rates of Application
per sq yd
Type Cover Aggregate
Application Asphalt
(see Note 1) Size No. and Course Aggregate,
Material,
lb
Gal. at 60°F
1 or 1P
Single 23, 24 12 - 15 0.12 - 0.16
(see Note 2)
2 or 2P Single 12, SC 12 14 - 17 0.29 - 0.33
3 or 3P Single 11, SC 11, SC 16 16 - 20 0.36 - 0.40
4 or 4P Single 9 28 - 32 0.63 - 0.68
Top: 12, SC 12 16 - 19 0.41 - 0.46
5 or 5P Double
Bottom: 11, SC 11, SC 16 16 - 20 0.28 - 0.31
Top: 11, SC 11, SC 16 18 - 22 0.62 - 0.68
6 or 6P Double
Bottom: 9 28 - 32 0.42 - 0.46
Top: 11, SC 11, SC 16 18 - 22 0.62 - 0.68
7 or 7P Double
Bottom: 8 28 - 32 0.42 - 0.46
Note 1 – AE-90S and SC aggregates shall be used for type P seal coats, except SC aggregate
requirement will not apply to seal coat used on shoulders.
Note 2 – HFRS-2 shall not be used with type 1 seal coat.

Seal coat, SC, aggregates shall be 85% one face and 80% two face crushed. The
Flakiness Index in accordance with ITM 224 shall be a maximum of 25%. Non SC
aggregates shall have a minimum crushed particle percentage of 70%. Determination
of crushed particles shall be made from the mass weight of material retained on the
No. 4 (4.75 mm) sieve in accordance with ASTM D 5821.
40
CONSTRUCTION REQUIREMENTS

404.05 Weather Limitations

Asphalt material shall not be applied on a wet surface, or when other weather
conditions would adversely affect the seal coat. Seal coat shall not be placed when the
ambient or pavement temperature is below 60°F. Seal coat shall not be applied to travel
lanes or auxiliary lanes before May 1 or after October 1, but may be applied to
shoulders within the above temperature range.

50 404.06 Equipment
A distributor, rotary power broom, pneumatic tire roller, and aggregate spreader
in accordance with 409.03 shall be used.

404.07 Preparation of Surface

Surfaces to be sealed shall be patched as shown on the plans or as directed,
brought to proper section and grade, and compacted.

The surface shall be cleaned of all loose material prior to seal coat application.
Sealing operations may not commence until the surface is approved.
60

325
 404.08

All castings, detector housings, and snowplowable raised pavement markers shall
be covered prior to applying the asphalt material to prevent coating with seal coat.
These coverings shall be removed prior to opening to unrestricted traffic.

404.08 Applying Asphalt Material

Asphalt material shall be applied in a uniform continuous spread over the section
to be treated. The quantity of asphalt material to be applied per square yard shall be in
accordance with the QCP. During application, minor adjustments to the application
rate shall be made in accordance with the QCP.
70
The asphalt material shall not be spread over a greater area than that which can be
covered with the cover aggregate that is in trucks at the site.

The spread of the asphalt material shall be no wider than the width covered by the
cover aggregate from the spreading device. Operations shall not proceed such that
asphalt material is allowed to chill, set up, dry, or otherwise impair retention of the
cover coat.

404.09 Application of Cover Aggregate

80 Within 1 minute of the application of the asphalt material, cover aggregate shall
be spread in quantities as required. Spreading shall be accomplished such that the tires
of the trucks or aggregate spreader do not contact the uncovered and newly applied
asphalt material.

404.10 Rolling Operation

The aggregate shall be seated with at least three roller applications. A roller
application is defined as one pass of the roller over the width sealed. The first roller
application shall be completed within 2 minutes of aggregate application, with the final
application completed within 30 minutes after the cover aggregate is applied. The
90 rollers shall not be operated at speeds that will displace the cover aggregate from the
asphalt material.

404.11 Sweeping Operation

Excess cover aggregate shall be removed from the pavement surface by brooming
no later than the morning after placement of the seal coat. The brooming shall not
displace the imbedded aggregate. A second brooming operation shall be performed
prior to opening to unrestricted traffic in accordance with 101.33.

404.12 Protection of Surface

100 Traffic shall not be allowed on the freshly sealed surfaces until final rolling
application is complete. The seal coat shall be protected by keeping traffic off of the
freshly sealed surface or by controlling traffic speed in accordance with the QCP.
Traffic shall not displace the imbedded aggregate.

Any areas with minor bleeding will be covered with fine aggregate or other
approved blotting material.

326
 405.03

404.13 Method of Measurement

Seal coat will be measured by the square yard of the seal coated surface.
110
Patching will be measured in accordance with 304.06.

404.14 Basis of Payment

Seal coat will be paid for at the contract unit price per square yard complete in
place.

Patching will be paid for in accordance with 304.07.

Payment will be made under:

120
Pay Item Pay Unit Symbol

Seal Coat, ______...................................................................... SYS

type
Seal Coat, ______ P .................................................................. SYS
type

The cost of determination of asphalt material and cover aggregate application

rates, sweeping and rolling operations, blotting material, and other incidentals shall be
130 included in the cost of the pay items.

The Contractor shall adjust application rates as required by the Engineer within
the limits set out herein. No additional payment will be made for additional materials
necessary to meet the required application rates within the specified limits.

SECTION 405 – PRIME COAT

405.01 Description
This work shall consist of preparing and treating a rubblized PCCP with asphalt
material in accordance with 105.03.

MATERIALS

405.02 Asphalt Materials

10 The type and grade of asphalt material shall be in accordance with the following:

Asphalt Emulsion, AE-PL ........................................... 902.01(b)

405.03 Cover Aggregate

Aggregate shall be in accordance with the following:

Coarse Aggregate, Class B or Higher, Size No. 12 ..... 904

Fine Aggregate, Size No. 23 or 24 .............................. 904
327
 405.04

CONSTRUCTION REQUIREMENTS
20
405.04 Weather Limitations
Asphalt material shall not be applied on a wet surface, when the ambient
temperature is below 50°F, or when other unsuitable conditions exist, unless approved
by the Engineer.

405.05 Equipment
A distributor and aggregate spreader in accordance with 409.03 shall be used.

405.06 Preparation of Surface

30 The existing surface to be treated shall be shaped to the required grade and section,
free from all ruts, corrugations, or other irregularities; uniformly compacted; and
approved.

405.07 Application of Asphalt Material

AE-PL shall be uniformly applied at the rate of 0.50 to 0.75 gal./sq yd placed in a
single application. When placing material on a rubblized base, a carpet drag shall be
utilized behind the distributor.

When traffic is to be maintained within the limits of the section, approximately

40 one half of the width of the section shall be treated in one application. Complete
coverage of the section shall be ensured. Treated areas shall not be opened to traffic
until the asphalt material has been absorbed.

405.08 Cover Aggregate

If the asphalt material fails to penetrate and the primed surface must be used by
traffic, cover aggregate shall be spread to provide a dry surface.

405.09 Method of Measurement

Asphalt for prime coat will be measured by the ton, or by the square yard. Cover
50 aggregate will be measured by the ton.

405.10 Basis of Payment

The accepted quantities of prime coat will be paid for at the contract unit price per
ton, or per square yard for asphalt for prime coat. The accepted quantities of cover
aggregate will be paid for at the contract unit price per ton, complete in place.

Payment will be made under:

Pay Item Pay Unit Symbol

60
Asphalt for Prime Coat .............................................................. TON
SYS
Cover Aggregate, Prime Coat .................................................... TON

328
 406.06

SECTION 406 – TACK COAT

406.01 Description
This work shall consist of preparing and treating an existing pavement or concrete
surface with asphalt material in accordance with 105.03.

MATERIALS

406.02 Materials
10 The type and grade of asphalt material shall be in accordance with the following:

Asphalt Emulsion, SS-1h, AE-NT ............................... 902.01(b)

PG Asphalt Binder, PG 64-22 ..................................... 902.01(a)

CONSTRUCTION REQUIREMENTS

406.03 Equipment
A distributor in accordance with 409.03(a) shall be used.

20 406.04 Preparation of Surface

The existing surface to be treated shall be free of foreign materials deemed
detrimental by the Engineer. The surface to which the asphalt material is applied shall
not have standing water and shall be cleaned of dust, debris and any substances that
will prevent adherence.

406.05 Application of Asphalt Material

The asphalt material shall be uniformly applied across the entire width of
pavement to be overlaid and shall cover a minimum of 95% of the surface. The asphalt
material shall be given sufficient time to break and set to minimize tracking from
30 hauling and laydown equipment. Areas of inadequate coverage that create streaking
or areas of excessive coverage that create ponding shall be corrected to obtain an even
distribution.

The asphalt material application rate shall be based on the existing surface type
and shall be as follows:

Surface Type Application Rate*(gal./sg yd)

New Asphalt 0.05 to 0.08
Existing Asphalt 0.06 to 0.11
Milled Asphalt 0.06 to 0.12
PCCP 0.05 to 0.08
* The asphalt material shall not be diluted.

406.06 Method of Measurement

Asphalt for tack coat will be measured by the ton or by the square yard.
40

329
 406.07

406.07 Basis of Payment

The accepted quantities of tack coat will be paid for at the contract unit price per
ton, or per square yard for asphalt for tack coat, complete in place.

Payment will be made under:

Pay Item Pay Unit Symbol

Asphalt for Tack Coat ............................................................... TON

50 SYS

SECTION 407 – DUST PALLIATIVE

407.01 Description
This work shall consist of preparing and treating an existing aggregate surface
with asphalt material in accordance with 105.03.

MATERIALS

407.02 Asphalt Material

10 The type and grade of asphalt material shall be in accordance with the following:

Asphalt Emulsion, AE-PL ........................................... 902.01(b)

CONSTRUCTION REQUIREMENTS

407.03 Weather Limitations

Asphalt material shall not be applied on a wet surface, when the ambient
temperature is below 50°F, or when other unsuitable conditions exist, unless approved
by the Engineer.
20
407.04 Equipment
A distributor in accordance with 409.03(a) shall be used.

407.05 Preparation of Surface

The surface to be treated shall be shaped to the required section and be free from
all ruts, corrugations, or other irregularities.

407.06 Application of Asphalt Material

The asphalt material shall be uniformly applied at the rate of 0.25 to 1 gal./sq yd
30 in a uniform continuous spread over the section to be treated or as directed.

When traffic is to be maintained within the limits of the section, approximately

one half of the width of the section shall be treated in one application. Complete
coverage of the section shall be ensured. Treated areas shall not be opened to traffic
until the asphalt material has been absorbed.
330
 408.03

407.07 Method of Measurement

Asphalt for dust palliative will be measured by the ton.

40 407.08 Basis of Payment

The accepted quantities of this work will be paid for at the contract unit price per
ton for asphalt for dust palliative, complete in place.

Payment will be under:

Pay Item Pay Unit Symbol

Asphalt for Dust Palliative ........................................................ TON

SECTION 408 – SEALING OR FILLING CRACKS AND JOINTS

408.01 Description
This work shall consist of sealing or filling longitudinal and transverse cracks and
joints in existing asphalt pavement in accordance with 105.03.

Full lane width transverse cracks and longitudinal joints shall be routed and
sealed. All other cracks shall be filled.

10 MATERIALS

408.02 Materials
Materials shall be in accordance with the following:

Asphalt Binder, PG 64-22* ......................................... 902.01(a)

Asphalt Emulsion for Crack Filling, AE-90S .............. 902.01(b)
Fine Aggregates, No. 23 or 24 ..................................... 904
Joint Sealing Materials ................................................ 906.02(a)2
* A PG 64-22 asphalt binder shall be used to fill cracks on a surface
20 that is milled in accordance with 306, and polypropylene fibers shall
be used only in conjunction with warranted micro-surfacing.

CONSTRUCTION REQUIREMENTS

408.03 Equipment
A distributor in accordance with 409.03 shall be used when crack filling with
asphalt emulsion or an indirect-heat double boiler kettle with mechanical agitator shall
be used when filling with hot poured material. An indirect-heat double boiler kettle
with mechanical agitator shall be used when routing and sealing. Air compressors shall
30 be capable of producing a minimum air pressure of 100 psi.

331
 408.04

408.04 Weather Limitations

Sealing or filling operations shall not be conducted on a wet surface, when the
ambient temperature is below 40°F, or when other unsuitable conditions exist, unless
approved by the Engineer.

408.05 Routing and Sealing Cracks and Joints

Cracks and joints, 1/2 in. or less in width, shall be routed with a routing machine
capable of cutting a uniform shape to form a reservoir not exceeding 3/4 in. wide with
40 a minimum depth of 3/4 in. Cracks and joints shall be cleaned by blowing with
compressed air or by other suitable means. The operation shall be coordinated such
that routed materials do not encroach on pavement lanes carrying traffic and all routed
materials are disposed of in accordance with 104.07. Cracks and joints shall be sealed
with hot poured joint sealant to within 1/4 in. below the surface in accordance with the
manufacturer’s recommendations.

408.06 Filling Cracks

Cracks shall be cleaned by blowing with compressed air or by other suitable
means. Asphalt material shall be placed utilizing a “V” shaped wand tip, to allow the
50 penetration of the materials into the cracks. The cracks shall be completely filled or
overbanded not to exceed 5 in., or as required. All excess asphalt material shall be
removed from the pavement. The filled cracks shall be covered with sufficient fine
aggregate or other suitable material to prevent tracking of the asphalt materials. All
excess cover material shall be removed from the pavement within 24 h, when directed.

Application of asphalt materials shall be completed without covering existing

pavement markings. When traffic is to be maintained within the limits of the section,
temporary traffic control measures in accordance with 801 shall be used. Treated areas
shall not be opened to traffic until the asphalt material has been absorbed.
60
408.07 Method of Measurement
Sealing and filling of cracks and joints in asphalt pavements will be measured by
the ton of material used. Routing of cracks and joints will not be measured.

Temporary traffic control measures will be measured in accordance with 801.17.

408.08 Basis of Payment

Sealing and filling of cracks and joints in asphalt pavements will be paid for by
the ton of material used for the type specified.
70
Temporary traffic control measures will be paid for in accordance with 801.18.

Payment will be made under:

Pay Item Pay Unit Symbol

Cracks in Asphalt Pavement, Fill .............................................. TON

Cracks and Joints in Asphalt Pavement, Rout and Seal............. TON
332
 409.03

80 The cost of all materials, cover aggregate, cleaning, and all necessary incidentals
shall be included in the cost of the pay items in this section.

SECTION 409 – EQUIPMENT

409.01 Production, Transportation, and Laydown of Asphalt Mixtures

For production of asphalt mixtures, the Contractor shall provide all equipment
necessary for the production, transportation, and laydown operations.

409.02 Mixing Plant

The mixing plant shall be capable of producing a uniform mixture.

10 (a) Certified HMA Plant

A certified HMA plant shall be in accordance with ITM 583.

(b) CMA Mixing Plant

The mixing plant shall be of sufficient capacity and coordination to adequately
handle the proposed CMA construction. The mixing unit shall be a twin shaft pugmill
or other approved mixer, including the drum type capable of producing a consistent
uniform mixture. The outlet of the mixer shall be such that it prevents segregation of
the material when discharged.

20 A certified HMA plant in accordance with 409.02(a) may be utilized as a CMA

mixing plant.

409.03 HMA Laydown Operations

(a) Distributor
The distributor shall be equipped, maintained, and operated to provide uniform
heating and application rates as specified. The distributor shall have a volume
measuring device and a thermometer to monitor the asphalt material.

30 Distributors shall also be equipped with a power unit for the pump and with a full
circulation spray bar with vertical controls.

(b) Hauling Equipment

The mixtures shall be transported to the laydown operation in trucks that have
tight, clean, and smooth beds.

Truck beds may be treated with approved anti-adhesive agents. The truck beds
shall be raised after application of non-foaming anti-adhesive agents to drain liquids
from the bed prior to HMA being loaded into the truck. The Department will maintain
40 a list of approved Anti-Adhesive Materials.

333
 409.03

Hauling equipment shall be equipped with a watertight cover to protect the

mixture.

(c) Laydown Equipment

1. Paver
The paver shall be self-propelled, and equipped with a material receiving system,
and equipped with heated and vibrating screeds. The paver may also include automatic
50 slope and grade controls, extendable screeds and extendable augers.

Automatic control devices shall be separated from the paver screeds, paver tracks
or wheels and be capable of adjusting both sides of the screeds automatically to
maintain a constant angle of attack in relation to the grade leveler device or grade line.

A grade leveling system may be used to activate the control devices on each HMA
course, including matching lays. The leveling system shall be attached to the paver
and operated parallel to the paver’s line of travel.

60 Extendable screeds shall be rigid, heated, and vibrating, and be capable of

maintaining the cross slope, and line and grade of the pavement, to produce uniform
placement of the materials.

Auger extensions shall be used when required to distribute the HMA uniformly
in front of the screed.

When a dense graded intermediate or a surface mixture is placed adjacent to an

aggregate or earth shoulder, the side of the paver adjacent to the aggregate or earth
shoulder shall be equipped with a device capable of constructing a safety edge. The
70 following devices are approved for this application:

(a) Advant-Edge™, Advant-Edge Paving Equipment LLC

(b) Safety Edge End Gate, Carlson Paving Products, Inc.
(c) TransTech Shoulder Wedge Maker™, TransTech Systems, Inc.
(d) SafeTSlope Edge Smoother™, Troxler Electronic Laboratories, Inc.

2. Widener
A device capable of receiving, transferring, spreading, and striking off materials
to the proper grade and slope.
80
3. Other Mechanical Devices
Inaccessible or short sections of HMA may be placed with specialty equipment
approved by the Engineer.

(d) Compaction Equipment

Compaction equipment shall be self-propelled, steel wheel or pneumatic tire
types, in good condition, and capable of reversing direction without backlashing. All
roller wheels shall be equipped with scrapers to keep the wheels clean, have water
334
 409.03

spraying devices on the wheels, and steering devices capable of accurately guiding the
90 roller.

1. Tandem Roller
A roller having two axles and a minimum weight of 10 t.

2. Three Wheel Roller

A roller having three wheels with a minimum bearing of 300 lb/in. on the rear
wheels. The crown of the wheels shall not exceed 2.5 in. in 18 ft.

A tandem roller which has a drive wheel bearing of no less than 300 lb/in. may be
100 used in lieu of the three wheel roller.

3. Pneumatic Tire Roller

A pneumatic tire roller shall have a minimum rolling width of 5.5 ft. The roller
shall be equipped with compaction tires, minimum size 7:50 by 15, exerting a uniform,
average contact pressure from 50 to 90 psi uniformly over the pavement by adjusting
ballast and tire inflation pressures. The wheels on at least one axle shall be fully
oscillating vertically, and mounted as to prevent scuffing of the pavements during
rolling or turning operations. Charts or tabulations showing the contact areas and
pressures for the full range of tire inflation pressures and for the full range of tire
110 loadings for each compactor shall be furnished to the Engineer.

4. Vibratory Roller
A vibratory roller is a roller that has both drums equipped for vertical impact
forces, a variable amplitude system, a speed control device, and have a minimum
vibration frequency of 2,000 vibrations per minute. A reed tachometer shall be
provided for verifying the frequency of vibrations.

5. Oscillatory Roller
An oscillatory roller is a roller that has both drums equipped for horizontal and
120 vertical shear forces or one drum equipped for horizontal and vertical shear force and
the other drum equipped for a vertical impact force.

6. Trench Roller
A trench roller shall have a compaction wheel bearing of no less than 300 lb/in.

7. Specialty Roller/Compactor
Inaccessible or short sections of HMA may be compacted with specialty
equipment approved by the Engineer.

130 (e) Miscellaneous Equipment

1. Aggregate Spreader
A spreader shall be a self-propelled, pneumatic tired, motorized unit with a front
loading hopper and a transportation system for distributing the aggregates uniformly
across the pavement.
335
 410.01

2. Rotary Power Broom

A motorized, pneumatic tired unit with rotary bristle broom head.

140 (f) Smoothness Equipment

1. Profilograph
The profilograph shall be in accordance with ITM 912.

2. Straightedge – 16 ft
A 16 ft straightedge shall be a rigid beam mounted on two solid wheels on axles
16 ft apart. The straightedge has a mounted push bar to facilitate propelling the device
along or across the pavement. Tolerance points are located at the 1/4, 1/2, and 3/4
points and may be composed of threaded bolts capable of being adjusted to the
150 tolerance required.

3. Straightedge – 10 ft
A 10 ft straightedge is the same as a 16 ft straightedge except that the wheels are
mounted 10 ft apart. A handheld rigid beam may be substituted.

SECTION 410 – QC/QA HMA – SMA PAVEMENT

410.01 Description
This work shall consist of one course of QC/QA HMA – SMA mixture
constructed on prepared foundations in accordance with 105.03.

410.02 Quality Control

The SMA mixture shall be supplied from a certified HMA plant in accordance
with ITM 583; Certified Hot Mix Asphalt Producer Program. The QCP shall be
10 modified to include the requirements for the SMA mixtures. The SMA shall be
transported and placed according to a Quality Control Plan, QCP, prepared and
submitted by the Contractor in accordance with ITM 803; Contractor Quality Control
Plans for Hot Mix Asphalt Pavements. The QCP shall be submitted to the Engineer at
least 15 days prior to commencing SMA paving operations.

When a safety edge is required for a project, the QCP shall identify the device or
devices in accordance with 409.03(c) to be used for constructing the safety edge.

MATERIAL
20
410.03 Materials
Materials shall be in accordance with the following:

Asphalt Materials
PG Binder, PG 76-22, PG 70-22 .......................... 902.01(a)
Coarse Aggregates, Class AS ...................................... 904
336
 410.05

Fibers ........................................................................... AASHTO M 325

Fine Aggregates (sand, mineral filler) ......................... 904

30 410.04 Design Mix Formula

A design mix formula, DMF, shall be prepared in accordance with 410.05 and
submitted in a format acceptable to the Engineer one week prior to use. The DMF shall
state the maximum particle size in the mixture. The DMF shall state the calibration
factor, test temperature and absorption factors to be used for the determination of
binder content using the ignition oven in accordance with ITM 586, the binder content
by extraction in accordance with ITM 571, ΔPb, determined in accordance with ITM
591, the aggregate degradation loss value in accordance with ITM 220 and a Mixture
Adjustment Factor, MAF. The DMF shall state the source, type dosage rate of any
stabilizing additives. The DMF will be based on the ESAL and mixture designation.
40 No mixture will be accepted for use until the DMF has been assigned a mixture number
by the Engineer.

The ESAL category identified in the pay item correlates to the following ESAL
ranges:

ESAL Category ESAL

2* < 3,000,000
3 3,000,000 to < 10,000,000
4* > 10,000,000
* A category 2 mixture shall replace a category 1 mixture and
a category 4 mixture shall replace a category 5 mixture.

The plant discharge temperature for any mixture shall not be more than 315°F
whenever PG 70-22 binder is used or not more than 325°F whenever PG 76-22 binder
is used. SMA may be produced using a water-injection foaming device. The DMF
50 shall list the minimum and maximum plant discharge temperatures as applicable to the
mixture.

410.05 SMA Mix Design

The DMF shall be determined for each mixture from a SMA mix design by a
design laboratory selected from the Department’s list of approved Mix Design
Laboratories. A SMA mixture shall be designed in accordance with ITM 220,
AASHTO M 325 and R 46 except the design gyrations shall be 75 for all ESAL
categories. All loose mixture shall be conditioned for 4 h in accordance with AASHTO
R 30 prior to testing. Steel furnace slag coarse aggregate, when used in an intermediate
60 mixture application, shall have a deleterious content less than 4.0% as determined in
accordance with ITM 219.

The single percentage of aggregate passing each required sieve shall be within the
limits of the following gradation table.

337
 410.05

SMA Gradation Control Limits

Mixture Designation
9.5 mm 12.5 mm 19.0 mm
Sieve Size Lower Upper Lower Upper Lower Upper
1 1/2 in. (37.5 mm) 100.0 100.0
1 in. (25.0 mm) 100.0 100.0 100.0* 100.0
3/4 in. (19.0 mm) 100.0 100.0 100.0* 100.0 90.0 99.0
1/2 in. (12.5 mm) 100.0* 100.0 90.0 99.0 50.0 88.0
3/8 in. (9.5 mm) 70.0 95.0 50.0 80.0 25.0 60.0
No. 4 (4.75 mm) 30.0 50.0 20.0 35.0 20.0 28.0
No. 8 (2.36 mm) 20.0 30.0 16.0 24.0 16.0 24.0
No. 16 (1.18 mm) --- 21.0 --- --- --- ---
No. 30 (600 µm) --- 18.0 --- --- --- ---
No. 50 (300 µm) --- 15.0 --- --- --- ---
No. 200 (75 µm) 8.0 12.0 8.0 11.0 8.0 11.0
* The lower % passing gradation may be 98.0% when SMA RAP material in accordance
with 410.06 is used in the SMA mixture.

The optimum binder and aggregate gradation content shall produce a ΔPb ≤ 0.20
as determined in accordance with ITM 591 and 4.0% air voids. The maximum specific
gravity shall be mass determined in water in accordance with AASHTO T 209. The
70 percent draindown for SMA mixture shall not exceed 0.30% in accordance with
AASHTO T 305.

The MAF equals the Gmm from the mixture design divided by the following:
2.465 for 9.5 mm mixtures and 2.500 for 12.5 mm mixtures. If the MAF calculation
results in a value where 0.980 ≤ MAF ≤ 1.020, then the MAF shall be considered to
be 1.000. If the MAF is greater than 1.020, the calculated MAF value shall have 0.020
subtracted from the value. If the MAF is less than 0.980, the calculated MAF value
shall have 0.020 added to the value. The MAF does not apply to OG mixtures.

80 The mixture shall be tested for moisture susceptibility in accordance with

AASHTO T 283 except that the loose mixture curing shall be replaced by mixture
conditioning for 4 h in accordance with AASHTO R 30. The minimum tensile strength
ratio, TSR, shall be 70%. The 6 in. mixture specimens shall be compacted to 6.0 ±1.0%
air voids in accordance with AASHTO T 312. Specimens shall be prepared using
freeze-thaw preconditioning. If anti-stripping additives are added to the mixture to be
in accordance with the minimum TSR requirements, the dosage rate shall be submitted
with the DMF.

The fine aggregate portion of the aggregate blend shall be non-plastic as

90 determined in accordance with AASHTO T 90.

A change in the source or types of aggregates, a change in source or type of

stabilizing additives, or a change in the source of the specified binder shall require a
new DMF.

338
 410.07

The specific gravity of SF and the Gsb of the aggregate blend containing SF may
be adjusted once per contract upon notification by the SF source and approval by the
District Testing Engineer. A new DMF is not required for this adjustment.

100 The mixture design compaction temperature for the specimens shall be 300 ±9°F.

Voids in Mineral Aggregate, VMA, Criteria

Mixture Designation Minimum VMA, %
19.0 mm 15.0
12.5 mm 16.0
9.5 mm 17.0

410.06 Recycled Materials

Recycled materials shall be in accordance with 401.06 for dense graded mixtures
except non-SMA RAP material for use in the SMA mixture shall be 100% passing the
3/8 in. (9.5 mm) sieve and 95 to 100% passing the No. 4 (4.75 mm) sieve.

SMA RAP material shall be the product derived by exclusively milling an existing
SMA mixture. The SMA RAP material shall pass the maximum size sieve for the
110 mixture being produced as follows:

SMA RAP Gradation, %

Mixture Designation
Sieve Size 9.5 mm 12.5 mm 19.0 mm
Lower Upper Lower Upper Lower Upper
1 1/2 in. (37.5 mm) 100.0 100.0
1 in. (25.0 mm) 100.0 100.0 95.0 100.0
3/4 in. (19.0 mm) 100.0 100.0 95.0 100.0 --- ---
1/2 in. (12.5 mm) 95.0 100.0 --- --- --- ---

The Contractor may request the use of SMA RAP material in the SMA mixture
provided the material is stockpiled separately at the plant and the material properties
were determined in accordance with ITM 584 during stockpile construction. The
request shall include all QC test results describing the stockpile composition. The
Engineer will obtain a representative sample of the SMA RAP material in accordance
with ITM 207 for testing in accordance with ITM 590 to verify the proposed design
value.
120
410.07 Lots and Sublots
Lots will be defined as 4,000 t of SMA intermediate mixture or 2,400 t of SMA
surface mixture. Lots will be further sub-divided into sublots not to exceed 1,000 t of
SMA intermediate mixture or 600 t of SMA surface mixture. Partial sublots of 100 t
or less will be added to the previous sublot. Partial sublots greater than 100 t constitute
a full sublot.

339
 410.08

410.08 Job Mix Formula

A job mix formula, JMF, shall be developed by a certified HMA producer in
130 accordance with ITM 583. A JMF used for SMA mixture in the current calendar year
will be allowed.

The aggregate and recycled materials blend percentage and the amount passing
all sieves on the DMF may be adjusted provided the gradation limits do not exceed the
requirements of 410.05. Adjustments to the aggregate and recycled materials blend
percentage, gradation and the new combined aggregate bulk specific gravity shall be
included on the JMF.

The total binder content on the JMF may be determined by adjusting the DMF a
140 maximum of 0.3%. The recycled materials binder content may be adjusted as part of
the total binder content provided the binder replacement percentage is in accordance
with 410.06.

The mixture compaction temperature shall be 300 ±9°F. The JMF shall list the
minimum and maximum plant discharge temperatures as applicable to the mixture.
The JMF for each mixture shall be submitted to the Engineer.

410.09 Acceptance of Mixtures

Acceptance of mixtures for binder content and gradation for each lot will be based
150 on tests performed by the Engineer. The Engineer will randomly select the location
within each sublot for sampling in accordance with ITM 802. An acceptance sample
will consist of one plate sample at the random location. A backup sample will consist
of one plate sample located 2 ft towards the center of the mat from the acceptance
sample.

Samples from each location shall be obtained from each sublot from the pavement
in accordance with ITM 580. The Engineer will take immediate possession of the
samples.

160 A maximum specific gravity sample and a binder content and gradation sample
will be obtained from the plate sample in accordance with ITM 587. The binder content
will be determined in accordance with ITM 586 or ITM 571 as directed by the
Engineer and the gradation will be determined in accordance with AASHTO T 30. The
maximum specific gravity will be mass determined in water in accordance with
AASHTO T 209. The test results of the sublots will be averaged and shall meet the
requirements for tolerances from the JMF for each sieve and binder content.

The Engineer will make available the sublot acceptance test results after receiving
the sublot quality control results from the Contractor.
170

340
 410.09

Acceptance Tolerance for Mixtures (Percent Mass)

Mixture Sieve Size
Number
*25.0 *19.0 *12.5 *9.5 *4.75 2.36 600 75
of Tests
mm mm mm mm mm mm µm µm
1 --- --- --- --- --- 8.0 4.0 2.5
Surface
2 --- --- --- --- --- 5.7 2.8 2.1
3 --- --- --- --- --- 4.6 2.3 1.8
4 --- --- --- --- --- 4.0 2.0 1.5
1 --- --- --- --- --- 10.0 6.0 2.0
2 --- --- --- --- --- 7.0 4.2 1.4
Intermediate
3 --- --- --- --- --- 5.8 3.5 1.2
4 --- --- --- --- --- 5.0 3.0 1.0
* The acceptance tolerance for this sieve shall be the applicable composition
limits specified in 410.05.

Acceptance Tolerance for Binder

Number of Tests
Binder Content
1 2 3 4
%Binder 0.7 0.5 0.4 0.3

Acceptance of mixtures for range will be determined using the results of sublot
tests performed by the Engineer from each lot. If the range is not in accordance with
the requirements, adjustment points will be assessed in accordance with 410.19(a).

Acceptance Tolerance for Range (±Percent Mass)

Sieve Size and Percentage Points
Binder Content Surface Intermediate
No. 8 (2.36 mm) 12.0 15.0
No. 30 (600 µm) 6.0 9.0
No. 200 (75 µm) 2.0 3.0
%Binder 1.0 1.0

Acceptance tolerances for binder content and gradation will be as set out above
for the number of tests performed. The acceptance tolerance for range will be as set
180 out above for lots of more than one sublot. The range of binder shall be the difference
between the highest sublot binder content and the lowest sublot binder content in one
lot. The range of gradation shall be the difference between the highest sublot percent
passing and the lowest sublot percent passing each required sieve in one lot.

Single test values and averages will be reported to the nearest 0.1%. Rounding
will be in accordance with 109.01(a).

Lot adjustment points will be assessed in accordance with 410.19(a) when the
average or range for binder content or gradation are not met.
190

341
 410.10

The Contractor may request an appeal of the Engineer’s test results in accordance
with 410.20.

A binder draindown test in accordance with AASHTO T 305 shall be completed

once per lot in accordance with 410.07 and shall not exceed 0.30%.

Stabilizing additives incorporated into the mixture will be accepted on the basis
of a type A certification for the specified material properties for each shipment of
fibers. Stabilizing additives from different manufacturers and different types of
200 additives shall not be intermixed.

In the event than an acceptance sample is not available to represent sublot, all test
results of the previous sublot will be used for acceptance. If the previous sublot is not
available, the subsequent sublot will be used for acceptance.

Samples shall not be obtained from areas placed with paving equipment in
accordance with 409.03(c)2 or 409.03(c)3. If a random location falls within this area,
the Engineer will randomly select another location within the sublot for sampling. If
an entire sublot falls within this area, test results from the previous sublot will be used
210 for acceptance. If the previous sublot is not available, the subsequent sublot will be
used for acceptance.

CONSTRUCTION REQUIREMENTS

410.10 General
Equipment for SMA operations shall be in accordance with 409. The Contractor
shall submit to the Engineer prior to use a written Certificate of Compliance that the
proposed paving equipment has been modified in accordance with 401.10 or is new
and includes the modifications.
220
Fuel oil, kerosene, or solvents shall not be transported in open containers on
equipment. Cleaning of equipment and small tools shall not be accomplished on the
pavement or shoulder areas.

Segregation, flushing or bleeding of SMA mixtures will not be allowed.

Corrective action shall be taken to prevent continuation of these conditions.
Segregated, flushed or bleeding of SMA mixtures shall be removed if directed. All
areas showing an excess or deficiency of binder shall be removed and replaced.

230 All mixtures that become loose and broken, mixed with dirt, or is in any way
defective shall be removed and replaced.

410.11 Preparation of Surfaces to be Overlaid

Milling of an existing pavement surface shall be in accordance with 306. Surfaces
on which a mixture is placed shall be free from objectionable or foreign materials at
the time of placement.

342
 410.14

Milled asphalt surfaces and asphalt surfaces shall be tacked in accordance with
406. Contact surfaces of curbing, gutters, manholes, and other structures shall be
240 tacked in accordance with 406.

410.12 Process Control

The Engineer and Contractor will jointly review the operations to ensure
compliance with the QCP. Continuous violations of compliance with the QCP will
result in suspension of paving operations.

410.13 Weather Limitations

SMA courses shall be placed when the ambient temperature and the temperature
of the surface on which it is to be placed is 45°F or above.
250
410.14 Spreading and Finishing
The mixture shall be placed upon an approved surface by means of a paver or
other mechanical devices in accordance with 409.03. Mixtures in areas inaccessible to
mechanical devices may be placed by other methods. The temperature of mixture at
the time of spreading shall be no more than 315°F whenever PG 70-22 binder is used
or no more than 325°F whenever PG 76-22 binder is used.

Prior to paving, both the planned quantity and lay rate shall be adjusted by
multiplying by the MAF. When mixture is produced from more than one DMF or JMF
260 for a given pay item, the MAF will be applied to the applicable portion of the mixture
for each.

Planned SMA courses greater than 220 lb/sq yd placed under traffic, shall be
brought up even with each adjacent lane at the end of each work day. Planned SMA
courses less than or equal to 220 lb/sq yd shall be brought forward concurrently, within
practical limits, limiting the work in one lane to not more than one work day of
production before moving back to bring forward the adjacent lane.

Hydraulic extensions on the paver will not be allowed for continuous paving
270 operations. Fixed extensions or extendable screeds shall be used on courses greater
than the nominal width of the paver except in areas where the paving widths vary.
Hydraulic extensions may be used in tapers and added lanes less than 250 ft in length.

Automatic slope and grade controls will be required and shall be outlined in the
QCP.

SMA mainline and SMA shoulders which are 8 ft or more in width shall be placed
with automatic paving equipment.

280 The rollers shall be operated to avoid shoving of the SMA and at speeds not to
exceed 3 mph. Rollers shall be in accordance with 409.03(d)1, 2, or 7. Vibratory rollers
meeting the requirements of 409.03(d)4 may be used but shall not be operated in
vibratory mode. Oscillatory rollers in accordance with 409.03(d)5 will be allowed for
use but the vertical impact force capability shall not be used.
343
 410.15

The finished thickness of any course shall be at least two times but not more than
four times the maximum particle size as shown on the DMF.

A safety edge shall be constructed at locations where the surface mixture is

290 constructed adjacent to an aggregate or earth shoulder.

410.15 Joints
Longitudinal joints in the surface shall be at the lane lines of the pavement.

Hot poured joint adhesive in accordance with 906 shall be applied to longitudinal
joints constructed between two adjacent HMA courses in the top course of dense
graded intermediate mixtures and all 9.5 mm and 12.5 mm SMA mixture courses. This
includes joints within the traveled way as well as between any of the following:
traveled way and an auxiliary lane; traveled way and a paved shoulder; and auxiliary
300 lane and a paved shoulder.

The material shall be heated in a jacketed, double boiler melting kettle. The kettle
shall have an attached pressure feed wand system with applicator shoe.

The joint adhesive shall be applied to the face of the previously constructed edge
at the joint using a wand applicator. Prior to application of the joint adhesive, the joint
face shall be dry and free of loose material and foreign objects. The adhesive shall be
applied on the joint face 1/8 in. thick at the temperature recommended by the
manufacturer. Excess joint adhesive shall not be allowed to pool on the top of the
310 previously constructed pavement course or the pavement to be overlaid. The
application of the adhesive shall be made within the same day, but at least 30 minutes
prior to construction of the longitudinal joint.

Transverse joints shall be constructed by exposing a near vertical full depth face
of the previous course. For areas inaccessible to rollers, other mechanical devices shall
be used to achieve the required density.

If constructed under traffic, temporary transverse joints shall be feathered to

provide a smooth transition to the driving surface.
320
410.16 Density
Acceptance will be based on lots and sublots in accordance with 410.07.

The Engineer’s acceptance test results for each sublot will be available after the
sublot and testing are complete.

Sublot and lot density values will be reported to the nearest 0.1%. Rounding will
be in accordance with 109.01(a).

330 Density acceptance for all SMA mixtures shall be based on cores cut from the
compacted pavement and analysis of pavement samples obtained in accordance with
344
 410.17

ITM 580. Acceptance will be based on lots and sublots in accordance with 410.07.
The Engineer will randomly select two locations in accordance with ITM 802, within
each sublot for coring. The transverse core location will be located so that the edge of
the core will be no closer than 3 in. from a confined edge or 6 in. from a non-confined
edge of the course being placed. The maximum specific gravity will be determined
from the sample obtained in 410.09.

The Contractor shall obtain cores in the presence of the Engineer with a device
340 that shall produce a uniform 6.00 ±0.25 in. diameter pavement sample. Surface courses
shall be cored within one work day of placement. Damaged core shall be discarded
and replaced with a core from a location selected by adding 1 ft to the longitudinal
location of the damaged core using the same transverse offset.

The Contractor and the Engineer shall mark the core to define the course to be
tested. If the core indicates a course thickness of less than two times the maximum
particle size, the core will be discarded and a core from a new random location will be
selected for testing.

350 Cores shall not be obtained from areas placed with paving equipment in
accordance with 409.03(c)2 or 409.03(c)3. If a random location falls within this area,
the Engineer will randomly select another location within the sublot for coring. If an
entire sublot falls within this area, test results from the previous sublot will be used for
acceptance. If the previous sublot is not available, the subsequent sublot will be used
for acceptance.

The Engineer will take immediate possession of the cores. If the Engineer’s cores
are subsequently damaged, additional coring within a specific sublot or sublots will be
the responsibility of the Department. Subsequent core locations will be determined by
360 subtracting 1 ft from the random location using the same transverse offset.

The density of the mixture will be expressed as the percentage of maximum

specific gravity, % MSG, obtained by dividing the average bulk specific gravity by
the maximum specific gravity for the sublot, times 100. Samples for the bulk specific
gravity and maximum specific gravity will be dried in accordance with ITM 572. The
Engineer will determine the bulk specific gravity of the cores in accordance with
AASHTO T 166, Method A or AASHTO T 331, if required. The maximum specific
gravity will be mass determined in water in accordance with AASHTO T 209. The
target value for density of SMA mixtures of each sublot shall be 93.0%.
370
The densities of the sublots will be averaged to determine the density of the lot.

Within one work day of coring operations the Contractor shall clean, dry, and
refill the core holes with SMA of similar or smaller size particles or other approved
materials. The Contractor’s plan for refilling core holes shall be outlined in the QCP.

410.17 Pavement Corrugations

Pavement corrugations shall be in accordance with 606.
345
 410.18

380 410.18 Pavement Smoothness

The pavement smoothness will be evaluated and determined in accordance with
401.18.

410.19 Adjusted Points

When test results for mixture properties or density exceed the allowable
tolerances, adjustment points will be assessed. The adjustment points will be used to
calculate a quality assurance adjustment quantity, q, for the lot. Quality assurance
adjustment points for smoothness will be in accordance with 401.19(c).

390 The adjustment for mixture properties and density are calculated as follows:

q = 1.00 x (L x U x P/100)/MAF

where:

q= quality assurance adjustment quantity

L= lot quantity
U= unit price for the material, $/ton
P= total adjustment points

The total quality assurance adjustments is to be calculated as follows:

Q = Qs + ∑ (qm + qd)
400
where:

Q= total quality assurance adjustment quantity

Qs = quality assurance adjustment for smoothness as calculated in 401.19(c)
qm = lot adjustments for mixtures
qd = lot adjustments for density

If the total adjustment points for a lot are greater than 15, the pavement will be
evaluated by the Office of Materials Management. If the Contractor is not required to
remove the mixture, quality assurance adjustments of the lot will be assessed or other
corrective actions as determined by the Office of Materials Management.

(a) Mixture
410 When test results for the mixture furnished exceeded the allowable tolerances,
adjustment points will be assessed as follows:

346
 410.19

Adjustment Points for Gradation

Sieve Size
Adjustment Points 25.0 19.0 12.5 9.5 4.75 2.36 600 75
mm mm mm mm mm mm µm µm
For each 0.1% up to 1.0%
0.1 0.1 0.1 0.1 0.1 0.1 0.2 0.3
out of tolerance
For each 0.1% above 1.0%
0.1 0.1 0.1 0.1 0.1 0.2 0.3 0.6
out of tolerance

Gradation adjustment points for the lot shall be the sum of points calculated for
up to 1% out of tolerance and the points calculated for greater than 1% out of tolerance
in accordance with 410.09.

Binder content adjustment points for the lot shall be two points for each 0.1%
above the tolerance or four points for each 0.1% below the tolerance in accordance
420 with 410.09.

When test results for the mixture furnished exceed the allowable range in
accordance with 410.09, adjustment points will be assessed as follows:

Adjustment Points for Range

Sieve Size and Adjustment Points
Binder Content (For each 0.1% out of range)
No. 8 (2.36 mm) 0.1
No. 30 (600 µm) 0.1
No. 200 (75 µm) 0.1
%Binder 1.0

For mixtures produced during a certified HMA plant’s adjustment period,

adjustment points will not be assessed if the mixture produced is in accordance with
the following:

430 1. The gradation complies with 410.05 with the

allowable tolerance limits shown in 410.09.

2. The range for the binder content and gradation do not

exceed the limits shown in 410.09.

3. The binder content is within the tolerance

requirements of 410.09.

If the mixture is not in accordance with these requirements, adjustment points will
440 be assessed in accordance with 410.09 for variations exceeding the requirements
shown above.

347
 410.20

(b) Density
When the density of the lot is outside the allowable tolerances, adjustment points
will be assessed as follows:

Density
Percentages are
Pay Adjustments, %
based on %MSG
> 97.0 Submitted to the Office of Materials Management*
93.0 – 97.0 0.00
92.0 – 92.9 0.20 points for each 0.10% below 93.0
91.0 – 91.9 2.00 + 0.40 points for each 0.10% below 92.0
89.0 – 90.9 6.00 + 1.00 points for each 0.10% below 91.0
≤ 89.0 Submitted to the Office of Materials Management*
* Test results will be considered and adjudicated as a failed material in accordance with
normal Department practice as listed in 105.03.

410.20 Appeals
If the QC test results do not agree with the acceptance test results, a request, along
450 with the QC test results, may be made in writing for additional testing. Additional
testing may be requested for one or more of the following tests: binder content,
gradation, or MSG of the mixture samples and bulk specific gravity of the density
cores. The appeal request shall be submitted within seven calendar days of receipt of
the Department’s written results for that sublot. The request for the appeal for MSG,
BSG of the density cores or binder content and gradation shall be submitted within
seven calendar days of receipt of the Department’s written results for that sublot. The
sublot and specific tests shall be specified at the time of the appeal request. Only one
appeal request per sublot is allowed. Upon approval of the appeal, the Engineer will
perform additional testing.
460
The appeal results will replace all previous test results for acceptance of mixture
in accordance with 410.09 and density in accordance with 410.16. The results will be
furnished to the Contractor. The backup mixture samples or density cores will be tested
in accordance with the following:

(a) MSG
The backup MSG will be dried in accordance with ITM 572 and mass determined
in water in accordance with AASHTO T 209.

470 (b) Binder Content and Gradation

The backup binder content and gradation sample will be prepared and tested in
accordance with the test methods that were used for acceptance.

(c) BSG of the Density Core

Cores shall be taken within seven calendar days unless otherwise directed.
Additional core locations will be determined by adding 1 ft longitudinally of the cores
tested using the same transverse offset. The cores will be dried in accordance with
ITM 572 and tested in accordance with AASHTO T 166, Method A or AASHTO T
348
 410.22

331, if required. The Contractor shall clean, dry, and refill the core holes with SMA or
480 HMA surface materials within one work day of the coring operations.

410.21 Method of Measurement

SMA mixtures will be measured by the ton of the type specified, in accordance
with 109.01(b). The measured quantity will be divided by the MAF to determine the
pay quantity.

Joint adhesive will be measured by the linear foot in accordance with 109.01(a).

410.22 Basis of Payment

490 The accepted quantities for this work will be paid for at the contract unit price per
ton for QC/QA-HMA, of the type specified, – SMA, complete in place.

Payment for furnishing, calibrating, and operating the profilograph, and

furnishing profile information will be made in accordance with 401.22.

Joint adhesive will be paid for by the linear foot, complete in place.

Adjustments to the contract payment with respect to mixture, density, and

smoothness for mixture produced will be included in a quality assurance adjustment
500 pay item. The unit price for this pay item will be $1.00 and the quantity will be in units
of dollars. The quantity is the total calculated in accordance with 410.19. A change
order developed in accordance with 109.05 will be prepared to reflect contract
adjustments.

Payment will be made under:

Pay Item Pay Unit Symbol

Joint Adhesive, ____________ ................................................. LFT

510 course type
QC/QA-HMA, _____, _____, _____, ______ mm, - SMA ...... TON
(ESAL(1))(PG(2))(Course(3))(Mix(4))
Quality Assurance Adjustment .................................................. DOL
(1) ESAL Category as defined in 410.04
(2) Number represents the high temperature binder grade. Low
temperature grades are - 22
(3) Surface or Intermediate
(4) Mixture Designation
520
Preparation of surfaces to be overlaid shall be included in the cost of other pay
items within this section.

Coring and refilling of the pavement holes shall be included in the cost of other
pay items within this section.

349
 411.01

No payment will be made for additional anti-stripping additives, appeal coring or

related traffic control expenditures for coring operations.

530 Corrections for pavement smoothness shall be included in the cost of other pay
items within this section.

The price for profilograph, HMA will be full compensation regardless of how
often the profilograph is used or how many profilograms are produced.

SECTION 411 – WARRANTED MICRO-SURFACING

411.01 Description
This work shall consist of furnishing materials and the placement of warranted
micro-surfacing in accordance with 105.03. Multiple course micro-surfacing shall
consist of a surface course over a rut fill or leveling course. Single course micro-
surfacing shall consist of a surface course.

The Contractor shall be responsible for the warranted micro-surfacing in

10 accordance with 411.09.

411.02 Materials
Materials shall be in accordance with the following:

Asphalt Emulsion ........................................................ 902.01(b)1

Coarse Aggregates – Class B or Higher* .................... 904
Fine Aggregates** ....................................................... 904
Portland Cement, Type I.............................................. 901.01(b)
Water ........................................................................... 913.01
20
* The coarse aggregate angularity shall be a minimum of 95% in
accordance with ASTM D 5821. The coarse aggregate for rut
fill shall be limestone, dolomite, crushed gravel, sandstone,
ACBF, or SF. The surface application aggregate type shall be
based on the ESAL category in the Surface Aggregate Table
below.

** The fine aggregate for micro-surface shall be limestone,

dolomite, crushed gravel, sandstone, ACBF, or SF. The fine
30 aggregate angularity shall be a minimum of 45 in accordance
with AASHTO T 304 Method A. The clay content of the
blended aggregate material from the fine and coarse aggregates
shall meet a minimum sand equivalency of 65 in accordance
with AASHTO T 176. The surface leveling application
aggregate type shall be based on the ESAL category as follows:

350
 411.03

Surface Aggregate Table

Traffic ESALs
Coarse or Fine Aggregate Type
< 3,000,000 < 10,000,000 ≥ 10,000,000
Air-Cooled Blast Furnace Slag Yes Yes Yes
Steel Furnace Slag Yes Yes Yes
Sandstone Yes Yes Yes
Crushed Dolomite Yes Yes (Note 1)
Polish Resistant Aggregates Yes Yes (Note 1)
Crushed Stone No No No
Gravel No No No
Note 1: Polish resistant aggregate or crushed dolomite may be used when blended with
ACBF or sandstone but cannot exceed 50% of the coarse aggregate by weight, or
cannot exceed 40% of the coarse aggregate by weight when blended with SF.

411.03 Design Mix Formula

The Contractor shall submit a design mix formula, DMF, for the specific materials
40 to be used on the project to the District Testing Engineer one week prior to use. The
DMF shall state the following, where the percentages shown are based on the dry
weight of the aggregate:

(a) source of each individual material

(b) the aggregation gradation shall be in accordance with the
following:

Sieve Size Surface/Leveling, % Rut Fill, %*

3/8 in. (9.5 mm) 100 100
No. 4 (4.75 mm) 85 - 100 70 - 90
No. 8 (2.36 mm) 50 - 80 45 - 70
No. 16 (1.18 mm) 40 - 65 28 - 50
No. 30 (600 µm) 25 - 45 19 - 34
No. 50 (300 µm) 13 - 25 12 - 25
No. 100 (150 µm) 7 - 18 7 - 18
No. 200 (75 µm) 5 - 15 5 - 15
* If rut fill course is used as a surface application, the aggregates shall
be in accordance with the Surface Aggregate Table above.

50 (c) percentage of aggregate

(d) percentage of mineral filler, minimum and maximum
(e) percentage of water, minimum and maximum
(f) percentage of mix set additives, if required
(g) percentage of polymer modified CSS-1h emulsified asphalt
(h) state the quantitative effects of moisture content on the unit
weight of the aggregate
(i) results for the tests in the following:

351
 411.04

Characteristic Test Method ISSA* Requirement

Wet Cohesion TB-139**
30 minutes, min. (set time) 12 kg-cm
60 minutes, min. (traffic) 20 kg-cm
Wet Stripping, min. TB-114 > 90%
Compatibility Classification TB-144 11 pts min.
Wet Track Abrasion Loss TB-100
60 minutes soak, max. 538 g/sq m
6 day soak, max. 807 g/sq m
Mix Time @ 77°F (25°C) TB-113** controllable to 120 s
Mix Time @ 104°F (40°C) TB-113** controllable to 35 s
Excess Binder TB-109 538 g/sq m
Deformation, max TB-147 5%
* International Slurry Surfacing Association.
** The TB-139 (set time) and TB-113 (mix time) tests shall be checked at the highest
temperature expected during construction. For the TB-113 test at 104°F (40°C), all
ingredients and containers shall be preheated.

60 411.04 Equipment
The Contractor shall use self-contained, self-propelled, continuous loading units
designed for micro-surfacing.

Truck-mounted batch type machines will be allowed on projects with quantities

less than or equal to 50,000 sq yds. The Contractor shall provide a minimum of two
truck-mounted units at all times.

411.05 Pre-Paving Coordination

A pre-paving meeting will be held on-site prior to beginning work. The Contractor
70 shall furnish as a minimum:

(a) the Contractor’s detailed work schedule

(b) traffic control plan
(c) calibration of equipment
(d) design mix formula/job mix formula
(e) inspection and evaluation of the condition and adequacy of
equipment, including units for transport of materials
(f) Quality Control Plan in accordance with ITM 803.

80 CONSTRUCTION REQUIREMENTS

411.06 Preparation of Surfaces

The Contractor shall be responsible for all surface preparation necessary to meet
the performance requirements for warranted micro-surfacing. All castings and detector
housings shall be protected prior to the application of material in accordance with
404.07, except that raised pavement markers shall be removed.

352
 411.09

Any existing durable pavement markings shall be removed in accordance with

808.10 prior to placement of warranted micro-surfacing.
90
Cracks in the pavement in excess of 1/4 in. shall be filled in accordance with 408
prior to placement of warranted micro-surfacing.

The pavement surface shall have tack coat applied in accordance with 406 prior
to placement of warranted micro-surfacing.

411.07 Opening to Traffic

The micro-surface shall be capable of being opened to traffic within 1 h after
application. If the micro-surface is not stable under traffic loading within 1 h of
100 placement, the Contractor shall immediately cease operations. Prior to resuming
operations, the Contractor shall notify the Engineer of the cause and the corrective
action to be taken.

The micro-surface shall be cured a minimum of five days prior to applying

permanent pavement markings in accordance with 808.

411.08 Finished Pavement Properties

All finished surface irregularities in excess of 1/8 in. measured with a 10 ft
straightedge shall be corrected.
110
The longitudinal construction joints and lane edges shall coincide with the
proposed painted lane lines. Longitudinal joints shall be constructed with less than a
3 in. overlap on adjacent passes and no more than 1/4 in. overlap thickness measured
with a 10 ft straightedge in accordance with 409.03(f). If applicable, overlapping
passes shall be made to prevent ponding of water. Construct transverse joints with no
more than a 1/8 in. difference in elevation across the joint as measured with a 10 ft
straightedge. The lane edge shall have no more than 2 in. of horizontal variance in 100
ft.

120 411.09 Warranty

A warranty bond is to insure completion of required warranty work, including
payments for all labor, materials, equipment, and incidentals necessary or convenient
to the successful completion of the project and the carrying out of the duties and
obligations imposed by the contract used to remediate any warranted distresses.

The Contractor shall furnish to the Engineer a warranty bond at the

preconstruction conference or prior to beginning any work on the contract. The
warranty bond shall be equal to 100% of the contract total for the warranted micro-
surfacing pay items, and shall be properly executed by a surety satisfactory to the
130 Department, and shall be payable to the State of Indiana. The warranty bond shall be
in effect for three years from the date of substantial completion.

353
 411.10

Upon the final acceptance of the project, the contractual obligations of the
Contractor are satisfied as long as the micro-surfacing continues to meet or exceed the
warranted values as defined herein.

All warranty work shall be accomplished in accordance with 411.11. At the end
of the warranty period, the Contractor will be released from further warranty work or
responsibility, provided all previous warranty work has been satisfactorily completed
140 and approved by the Department.

411.10 Conflict Resolution Team

The scope of work for the conflict resolution team includes all issues concerning
the warranted pavement relative to the quality control plan, material selection,
warranted pavement evaluations, distress indicators, remedial action, and remediation
plans.

The team will consist of two Contractor representatives, two Department

representatives, and an additional person mutually agreed upon by both the
150 Department and the Contractor. All costs for the additional person will be equally
shared by the Department and the Contractor.

The team members will be identified in writing when needed and will be
knowledgeable in the terms and conditions of this warranty and the methods used in
the measurement and calculation of pavement distress. The team will render a final
recommendation to the Chief Engineer by a majority vote. Each member has an equal
vote.

411.11 Warranty Work

160 Elective work is performed by the Contractor at its discretion to meet the
performance requirements of warranted micro-surfacing prior to direction from the
Department for the Contractor to perform remedial work.

Remedial work is performed as a result of pavement distress surveys performed

by the Department.

During the warranty period, elective work and remedial work shall be performed
at no cost to the Department. Elective work shall be at the Contractor’s option. The
scope of all elective work or remedial work to be performed as well as materials to be
170 used shall be proposed by the Contractor and shall be subject to approval by the
Department. Prior to proceeding with any warranty work or monitoring, all necessary
permits shall be obtained from the Department.

Elective work during the warranty period will not be assessed a lane closure fee.
For remedial work, costs for closure periods will be as shown in the contract.

During the warranty period, the Contractor may monitor the warranted micro-
surfacing using non-destructive procedures.

354
 411.12

180 Coring, milling or other destructive procedures may not be performed by the
Contractor, without prior consent of the Department. The Contractor will not be
responsible for damages to the pavement as a result of coring, milling or other
destructive procedures conducted by the Department.

The Contractor has the first option to perform the remedial work. If, the problem
requires immediate attention, as determined by the Engineer, for safety of the traveling
public and the Contractor cannot perform the remedial work within 24 h of
notification, the Department will perform the remedial work. The Contractor shall be
responsible for all costs incurred by the Department for remedial work performed by
190 the Department. Remedial work performed by the Department will not alter the
requirements, responsibilities, or obligations of the warranty.

411.12 Pavement Distress Indicators, Thresholds, and Remedial Work

The Department will use the following pavement distress indicators throughout
the warranty period:

(a) Rutting – transverse displacement of the micro-surfacing.

(b) Delamination – physical separation of the micro-surfacing that
exposes the underlying surface.
200 (c) Raveling – wearing away of the micro-surfacing.
(d) Skid Resistance – friction number as measured by ASTM E 274
and E 524.

The pavement threshold values for the pavement distress indicators will be
evaluated for the entire length of the project for each lane. The threshold values for the
pavement distress indicators are listed below:

Distress Single Location Multiple Locations

Delamination or Raveling 1/2 sq yd 1 sq yd/mi
Rut Depth 1/4 in. average 1/4 in./mi
Friction Number* no less than 30 average 35
* Individual friction tests will be performed in each lane every 1/2 mi for
the length of the project.

The Department may evaluate the warranted micro-surfacing during the warranty
210 period. A final condition survey will be made by the Department and the Contractor
will be notified in writing of all sections exceeding the warranty threshold at least 90
days in advance of the expiration of the warranty period.

If the Department determines that any threshold level has been met or exceeded
and remedial work is required, the Contractor shall submit a work plan and schedule
to the Engineer for approval. The Contractor shall perform the remedial work within
30 calendar days of notification of approval by the Engineer.

355
 411.13

If, anytime during the warranty period, 30% or more of the project requires, or
220 has received remedial work, remedial work as determined by the Department shall be
performed on the entire project.

If remedial or elective work performed by the Contractor necessitates repair or

replacement of pavement markings, adjacent lanes or roadway shoulders, the required
work shall be the responsibility of the Contractor.

Warranty requirements for elective and remedial work will be limited to the life
of the original contract warranty.

230 411.13 Department Maintenance

The Department may perform routine maintenance operations during the warranty
period including, but not limited to, plowing, applying de-icing chemicals, repairs to
safety appurtenances, pavement markings, mowing and sign maintenance. The
Department, during the warranty period, will perform no routine pavement surface
maintenance activities.

411.14 Method of Measurement

Warranted micro-surfacing, of the type specified, will be measured by the square
yard of surface course.
240
Only the surface course will be measured for payment.

411.15 Basis of Payment

Warranted micro-surfacing, of the type specified, will be paid for at the contract
unit price per square yard of micro-surface, warranted, of the type specified, complete
in place.

Payment will be made under:

250 Pay Item Pay Unit Symbol

Micro-Surfacing, Warranted, for Approaches, Multiple Course .......... SYS

Micro-Surfacing, Warranted, for Approaches, Single Course .............. SYS
Micro-Surfacing, Warranted, Multiple Course ..................................... SYS
Micro-Surfacing, Warranted, Single Course ....................................... SYS

The cost of all incidentals including, but not limited to, surface preparation,
meeting smoothness requirements, and warranty bond shall be included in the cost of
the pay items.
260
411.16 Final Warranty Acceptance
The Engineer will review the project in the field for any defects not addressed in
the indicators and recommend a Final Warranty Acceptance. The Department will
issue the Contractor a Final Warranty Acceptance letter upon completion of the
warranty period and all remedial work.
356
 412.07

SECTION 412 – FOG SEAL

412.01 Description
This work shall consist of applying asphalt emulsion to the pavement surface in
accordance with 105.03.

MATERIALS

412.02 Materials
10 Materials shall be in accordance with the following:

Asphalt Emulsion, AE-F ............................................. 902.01(b)

Fine Aggregate ............................................................ 904.02

CONSTRUCTION REQUIREMENTS

412.03 Equipment
A distributor in accordance with 409.03(a) shall be used.

20 412.04 Weather Limitations

Fog seal operations shall not be conducted on a wet pavement, when the ambient
air or pavement temperature is below 60°F, or when other unsuitable conditions exist,
unless approved by the Engineer. Fog seal shall not be applied to travel or auxiliary
lanes before May 1 or after October 1.

412.05 Preparation of Surface

Surfaces shall be clean and free of any foreign or loose material.

All castings, detector housings, and snowplowable raised pavement markers shall
30 be covered to prevent coating with fog seal prior to application of the fog seal. These
coverings shall be removed prior to opening to traffic.

412.06 Application of Asphalt Material

The asphalt material shall be applied uniformly at the rate of 0.10 ±0.02 gal./sq
yd. Asphalt material shall be applied in such a way as to ensure even and uniform
coverage to the pavement surface.

412.07 Protection of Surface

Fine aggregate or other approved blotting material shall be applied to pedestrian
40 crosswalks, driveways or other areas as directed by the Engineer. Brooming of ponded
areas shall be required prior to opening to traffic on treated surfaces, as directed.

Traffic shall not be allowed on the freshly sealed surface until the asphalt material
has sufficiently cured to prevent tracking.

357
 412.08

412.08 Application of Pavement Markings

The fog seal shall be cured a minimum of five days prior to applying permanent
pavement markings in accordance with 808.

50 412.09 Method of Measurement

Fog seal will be measured by the square yard complete in place.

412.10 Basis of Payment

Fog seal will be paid for at the contract unit price per square yard.

Payment will be made under:

Pay Item Pay Unit Symbol

60 Fog Seal ..................................................................................... SYS

The costs of all asphalt materials, fine aggregate, surface preparation, and all other
necessary incidentals shall be included in the cost of the pay item.

SECTION 413 – BLANK

SECTION 414 - ULTRATHIN BONDED WEARING COURSE,

WARRANTED

414.01 Description
This work shall consist of furnishing materials and the placement of warranted
ultrathin bonded wearing course, UBWC, in accordance with 105.03. The UBWC
shall consist of surface preparation, application of asphalt emulsion and asphalt
mixture. Asphalt mixture shall be produced by a Certified Hot Mix Asphalt Producer.

10 The Contractor shall be responsible for the warranted UBWC in accordance with
414.14.

MATERIALS

414.02 Materials
Materials shall be in accordance with the following:

Asphalt Emulsion ........................................................ 902.01(b)2

Asphalt Materials
20 PG Binder, PG 64-22, PG 76-22 .......................... 902.01(a)
PG Binder Grade .................................................. 414.02(b)
Coarse Aggregates, Class A or Higher ........................ 904.03 and 414.02(c)
Fine Aggregates ........................................................... 904.02
Mineral Filler ............................................................... 904.02(f)
358
 414.04

(a) Blank

(b) Asphalt Materials

The PG binder grade shall be selected based on the following requirements:
30
PG Binder ESAL
64-22 < 10,000,000
76-22 ≥ 10,000,000

Additional requirements for the PG 76-22 binder as follows:

Characteristic Test Method Min. Max.

Separation, % prepared by ASTM D 7173 AASHTO T 53 6C
Elastic Recovery, @ 39F (4C), % AASHTO T 301 60

(c) Coarse Aggregates

Additional requirements for coarse aggregate shall also be as follows:

Characteristic Method Min. Max.

Coarse Aggregate Angularity ASTM D 5821 95/85*
Micro-Deval Abrasion, % loss AASHTO T 327 18
* Denotes two faced crush requirements.

414.03 Design Mix Formula

40 The design mix formula, DMF, shall be determined for each mixture prepared by
an Approved Mix Design Laboratory selected from the Department's list of approved
Mix Design Laboratories. The Contractor shall submit a DMF for each mixture to the
Engineer one week prior to use. The DMF shall state the maximum particle size in the
mixture, the mixture gradation, the total aggregate bulk specific gravity, the maximum
and bulk specific gravity of the UBWC mixture and the application rate for any anti-
stripping additives. No mixture will be accepted until the DMF is approved.

414.04 Mix Design

The binder content and the percentage of aggregate passing each sieve shall be in
50 accordance with the following requirements:

359
 414.04

Mixture Designation – Control Point (Percent Passing)

Sieve Size 12.5 mm 9.5 mm 4.75 mm
3/4 in. (19.0 mm) 100.0
1/2 in. (12.5 mm) 85.0 - 100.0 100.0
3/8 in. (9.5 mm) 55.0 - 80.0 85.0 - 100.0 100.0
No. 4 (4.75 mm) 22.0 - 38.0 22.0 - 38.0 40.0 - 55.0
No. 8 (2.36 mm) 19.0 - 32.0 19.0 - 32.0 20.0 - 32.0
No. 16 (1.18 mm) 15.0 - 24.0 15.0 - 24.0 15.0 - 24.0
No. 30 (600 µm) 11.0 - 18.0 11.0 - 18.0 11.0 - 18.0
No. 50 (300 µm) 8.0 - 14.0 8.0 - 14.0 8.0 - 14.0
No. 100 (150 µm) 5.0 - 10.0 5.0 - 10.0 5.0 - 10.0
No. 200 (75 µm) 4.0 - 5.5 4.0 - 5.5 4.0 - 5.5
Binder Content, %, 4.6 - 6.1 4.8 - 6.1 5.0 - 6.3
Plan Lay Rate (lb/sq yd)* 90 75 65
* Plan lay rates are based on 100 lb/sq yd/in. using a mixture with a specific
gravity of 2.5. Mixtures with different specific gravity will require an adjusted
equivalent lay rate.

The binder film thickness shall be a minimum of 0.4 mil. The binder content of
the mix shall be determined by calculating the binder film thickness in accordance
with ITM 589.

The maximum specific gravity of the UBWC mixture shall be mass determined
in water in accordance with AASHTO T 209.

60 The bulk specific gravity of the UBWC mixture shall be determined in accordance
with AASHTO T 331.

Draindown from the loose mixture shall not exceed 0.10% when tested in
accordance with AASHTO T 305.

The tensile strength ratio, TSR, shall meet or exceed 80% when tested in
accordance with AASHTO T 283(1). Specimens for AASHTO T 283 shall be 6 in. in
diameter by 3 3/4 ±1/4 in. height and compacted in accordance with AASHTO T 312,
except the specimens shall be compacted to 100 gyrations and resultant air voids
70 reported for information purposes only. The compaction temperatures shall be 300
±10°F.

(1) Follow AASHTO T 283 with the following exceptions:

(a) Condition the mixture for 4 h in accordance with AASHTO R

30, Section 7.1.
(b) Compact the Superpave Gyratory Compactor, SGC, specimens
to 100 gyrations.
(c) Extrude the samples as soon as possible without damage to the
80 sample.

360
 414.07

(d) Use AASHTO T 269 to determine the void content.

(e) Record the void content of the specimens.
(f) If less than 55% saturation is achieved, the procedure does not
need to be repeated unless the difference in tensile strength
between duplicate specimens is greater than 25 lbs/sq in.

414.05 Use of Recycled Materials

Recycled materials shall be in accordance with 401.06 for dense graded surfaces
except RAP for use in the UBWC mixture shall be 100% passing the 3/8 in. (9.5 mm)
90 sieve and 95 to 100% passing the No. 4 (4.75 mm) sieve.

414.06 Quality Control

The Contractor shall produce a mixture in compliance with the DMF within the
limits of the quality control tolerances. The Contractor shall maintain all quality
control documentation and make a copy available to the Engineer upon request or at
completion of work.

The Contractor shall sample the mix a minimum once per day in accordance with
ITM 580, section 8.6 Truck Samples, Dense Graded HMA Mixture. The sample shall
100 be tested for binder content and gradation prior to the next day’s production.

The Contractor shall take corrective action when the binder content exceeds
0.5% from that stated in the DMF as tested in accordance with ITM 586.

The Contractor shall take corrective action when the aggregate gradation exceeds
the following values from that stated in the DMF as tested in accordance with
AASHTO T 30.

Quality Control Tolerances (), %

Sieve Size Mixture Designation - Tolerances
12.5 mm 9.5 mm 4.75 mm
3/4 in. (19.0 mm)
1/2 in. (12.5 mm) 5.0
3/8 in. (9.5 mm) 5.0
No. 4 (4.75 mm) 4.0 4.0 5.0
No. 8 (2.36 mm) 4.0 4.0 4.0
No. 16 (1.18 mm) 4.0
No. 200 (75 µm) 1.0 1.0 1.0

110 CONSTRUCTION REQUIREMENTS

414.07 Equipment
The equipment shall be in accordance with 409.01, 409.02(a), 409.03(b) and
409.03(d)1 except as follows:

361
 414.08

The paver shall be self-priming, designed and built for applying the UBWC. The
paver shall have a receiving hopper, feed system, asphalt emulsion storage tank, a
calibrated metering system for measuring the emulsion volume applied, spray bar and
a heated, variable width, combination vibratory screed or a combination vibratory-
120 tamping bar screed. The paver shall be capable of spraying the asphalt emulsion,
applying the asphalt mix and leveling the surface of the mat in one pass. The screed
shall have the ability to crown the pavement at the center.

414.08 Preparation of Surface

The Contractor shall be responsible for all surface preparation to meet the
requirements for warranted UBWC. All castings and detector housings not identified
on the plans as being reset shall be protected prior to the application of material in
accordance with 404.07, except that raised pavement markers shall be removed.

130 414.09 Asphalt Emulsion

The asphalt emulsion shall be applied at a temperature recommended by the
emulsion supplier. The asphalt emulsion shall be applied uniformly across the entire
width of pavement to be overlaid. Equipment shall not operate on the applied asphalt
emulsion before the asphalt mix is placed.

The recommended plan application rates of the asphalt emulsion are as shown in
the table below. Determination of actual application rates shall be the responsibility of
the Contractor.

Recommended Asphalt Emulsion Application Rate

and Adjustment Factors for Surface Conditions
Mixture Designation 12.5 mm 9.5 mm 4.75 mm
General application rate, gal./sq yd 0.20 0.17 0.14
Recommended adjustment to
Existing Surface Condition
application rate, gal./sq yd
PCCP, smooth or polished -0.03 -0.03 -0.03
PCCP, broomed or textured 0 0 0
Flushed asphalt concrete surface -0.02 -0.03 -0.03
Dense, unaged asphalt concrete surface 0 0 0
Open textured, dry, aged or oxidized
+0.02 +0.01 +0.01
asphalt concrete surface
Milled asphalt concrete surface +0.02 +0.01 +0.01
140
414.10 Pre-Paving Meeting
A pre-paving meeting between the Engineer and Contractor will be held on-site
prior to beginning work. The following shall be reviewed:

(a) work schedule

(b) traffic control plan
(c) equipment calibrations and adjustments
(d) inspection and evaluation of the condition and adequacy of
equipment, including units for transport of materials
362
 414.14

150 (e) job mix formula

(f) Contractor’s proposed emulsion and mix application rates
(g) QCP in accordance with ITM 803
(h) Contractor’s authorized representative.

414.11 Mixture Placement

The UBWC shall be prepared and placed at temperatures recommended by the
binder supplier. Fracturing of aggregates shall be avoided.

414.12 Mixture Finishing

160 Three passes of rollers capable of exerting at least 150 lb/in. and in conformance
with 409.03(d)1 shall be applied to the UBWC before the material has cooled below
185F. A release agent may be added to the water system of the rollers to prevent
adhesion of the material to the roller drum. Rollers shall not operate in vibratory mode.

414.13 Smoothness
A straightedge in accordance with 409.03(f) will be used to determine
smoothness. The 16 ft straightedge will be used to accept smoothness along the
direction of mainline traffic and the 10 ft straightedge will be used to accept
smoothness transverse to the direction of mainline traffic. Smoothness correction shall
170 be in accordance with 401.18(c).

The lane edge shall have no more than 2 in. of horizontal variance in 100 ft.

414.14 Warranty
A warranty bond is to insure completion of required warranty work, including
payments for all labor, materials, equipment, and incidentals necessary or convenient
to the successful completion of the project and the carrying out of the duties and
obligations imposed by the contract used to remediate any warranted distresses.

180 The Contractor shall furnish to the Engineer a warranty bond at the
preconstruction conference or prior to beginning any work on the contract. The
warranty bond shall be equal to 100% of the contract total for the warranted UBWC
pay items, and shall be properly executed by a surety satisfactory to the Department,
and shall be payable to the State of Indiana. The warranty bond shall be in effect for
three years from the date of substantial completion.

Upon the final acceptance of the project, the contractual obligations of the
Contractor are satisfied as long as the UBWC continues to meet or exceed the
warranted values as defined herein.
190
All warranty work shall be accomplished in accordance with 414.16. At the end
of the warranty period, the Contractor will be released from further warranty work or
responsibility, provided all previous warranty work has been satisfactorily completed
and approved by the Department.

363
 414.15

414.15 Conflict Resolution Team

The scope of work for the conflict resolution team includes all issues concerning
the warranted pavement relative to the quality control plan, material selection,
warranted pavement evaluations, distress indicators, remedial action, and remediation
200 plans.

The team will consist of two Contractor representatives, two Department

representatives, and an additional person mutually agreed upon by both the
Department and the Contractor. All costs for the additional person will be equally
shared by the Department and the Contractor.

The team members will be identified in writing when needed and will be
knowledgeable in the terms and conditions of this warranty and the methods used in
the measurement and calculation of pavement distress. The team will render a final
210 recommendation to the Chief Engineer by a majority vote. Each member has an equal
vote.

414.16 Warranty Work

Elective work is performed by the Contractor at its discretion to meet the
performance requirements of warranted UBWC prior to direction from the Department
for the Contractor to perform remedial work.

Remedial work is performed as a result of pavement distress surveys performed

by the Department.
220
During the warranty period, elective work and remedial work shall be performed
at no cost to the Department. Elective work shall be at the Contractor’s option. The
scope of all elective work or remedial work to be performed as well as materials to be
used shall be proposed by the Contractor and shall be subject to approval by the
Department. Prior to proceeding with any warranty work or monitoring, all necessary
permits shall be obtained from the Department.

Elective work during the warranty period will not be assessed a lane closure fee.
For remedial work, costs for closure periods will be as shown in the contract.
230
During the warranty period, the Contractor may monitor the warranted UBWC
using non-destructive procedures.

Coring, milling or other destructive procedures may not be performed by the

Contractor, without prior consent of the Department. The Contractor will not be
responsible for damages to the pavement as a result of coring, milling or other
destructive procedures conducted by the Department.

The Contractor has the first option to perform the remedial work. If the problem
240 requires immediate attention, as determined by the Engineer, for safety of the traveling
public and the Contractor cannot perform the remedial work within 24 h of
notification, the Department will perform the remedial work. The Contractor shall be
364
 414.17

responsible for all costs incurred by the Department for remedial work performed by
the Department. Remedial work performed by the Department will not alter the
requirements, responsibilities, or obligations of the warranty.

414.17 Pavement Distress Indicators, Thresholds and Remedial Action

The Department will use the following pavement distress indicators throughout
the warranty period:
250
(a) Delamination - physical separation of the UBWC that exposes
the underlying surface.
(b) Rutting - transverse displacement of the UBWC.
(c) Raveling - wearing away of the UBWC.
(d) Skid Resistance - friction number as measured by ASTM E 274
and E 524.

The pavement threshold values for the pavement distress indicators will be
evaluated for the entire length of the project for each lane. The threshold values for the
260 pavement distress indicators are listed below:

Distress Single Location Multiple Locations

Delamination/Raveling 1/2 sq yd 1 sq yd/mi
Rut Depth 1/4 in. average 1/4 in./mi
Friction Number* no less than 30 average 35
* Individual friction tests will be performed in each lane every 1/2 mi for
the length of the project.

The Department may evaluate the warranted UBWC during the warranty period.
A final condition survey will be made by the Department and the Contractor will be
notified in writing of all sections exceeding the warranty threshold at least 90 days in
advance of the expiration of the warranty period.

If the Department determines that any threshold level has been met or exceeded
and remedial work is required, the Contractor shall submit a work plan and schedule
270 to the Engineer for approval. The Contractor shall perform the remedial work within
30 calendar days of notification of approval by the Engineer.

If, anytime during the warranty period, 30% or more of the project requires, or
has received remedial work, remedial work as determined by the Department shall be
performed on the entire project.

If remedial or elective work performed by the Contractor necessitates repair or

replacement of pavement markings, adjacent lanes or roadway shoulders, the required
work shall be the responsibility of the Contractor.
280
Warranty requirements for all elective and remedial work will be limited to the
life of the original contract warranty.

365
 414.18

414.18 Department Maintenance

The Department may perform routine maintenance operations during the warranty
period including, but not limited to, plowing, applying de-icing chemicals, repairs to
safety appurtenances, pavement markings, mowing and sign maintenance. The
Department, during the warranty period, will perform no routine pavement surface
maintenance activities.
290
414.19 Method of Measurement
Ultrathin bonded wearing course, of the type specified, will be measured by the
square yard in accordance with 109.01.

414.20 Basis of Payment

Ultrathin bonded wearing course, of the type specified, will be paid for at the
contract unit price per square yard.

Payment will be made under:

300
Pay Item Pay Unit Symbol

Ultrathin Bonded Wearing Course for Approaches, _____ ....... SYS

size
Ultrathin Bonded Wearing Course, _____ ................................ SYS
size

The cost of all incidentals including, but not limited to, surface preparation,
asphalt emulsion, meeting smoothness requirements, and warranty bond shall be
310 included in the cost of the pay items.

414.21 Final Warranty Acceptance

The Engineer will review the project in the field for any general defects not
addressed in the indicators and recommend a Final Warranty Acceptance. The
Department will issue the Contractor a Final Warranty Acceptance letter upon
completion of the warranty period and all required remedial work.

SECTION 415 – BASE SEAL

415.01 Description
This work shall consist of applying asphalt emulsion to the pavement surface in
accordance with 105.03.

MATERIALS

415.02 Materials
10 Base seal materials shall be in accordance with the following:

Asphalt Emulsion, SS-1h, AE-NT ............................... 902.01(b)

366
 416.01

CONSTRUCTION REQUIREMENTS

415.03 Equipment
A distributor in accordance with 409.03(a) shall be used.

415.04 Weather Limitations

20 Base sealing operations shall not be conducted on a wet pavement or when the
ambient air or pavement temperature is below 32°F.

415.05 Preparation of Surface

Surfaces shall be clean and free of any foreign or loose material.

415.06 Application of Asphalt Material

The base seal materials shall be applied to the pavement surface uniformly with a
distributor at an application rate of 0.22 ±0.02 gal./sq yd.

30 415.07 Protection of Surface

The base seal materials shall cure a minimum of two hours after application before
resuming paving operations.

415.08 Method of Measurement

The base seal will be measured by the ton complete in place.

415.09 Basis of Payment

The base seal will be paid for at the contract unit price per ton.

40 Payment will be made under:

Pay Item Pay Unit Symbol

Base Seal ................................................................................... TON

The costs of all asphalt materials, surface preparation and all other necessary
incidentals shall be included in the cost of the pay item.

SECTION 416 - COLD IN-PLACE RECYCLING, CIR

416.01 Description
This work shall consist of milling and pulverizing a portion of the existing asphalt
pavement to specified depth and maximum size, mixing asphalt emulsion, water and
additives to produce a recycled asphalt layer. This material shall then be placed and
compacted to the approved design properties in accordance with 105.03.

367
 416.02

416.02 Just-in-Time Training, JITT

10 The Engineer and the Contractor are required to attend a JITT course regarding
CIR and both shall mutually agree on the course instructor, course content and training
site. The training class shall be conducted at a project field location convenient for all
project construction personnel responsible for CIR operations and inspection to attend.

The JITT course shall be held during normal working hours and be completed not
more than 14 days prior to the start of CIR operations.

The Contractor shall provide a JITT instructor experienced in the construction

methods, materials and test methods associated with asphalt emulsion stabilized CIR.
20 A copy of the course syllabus, handouts and presentation materials shall be submitted
to the Engineer at least five business days before the course is to be taught.

416.03 Quality Control

A quality control plan, QCP, shall be submitted to the Engineer a minimum of
five calendar days prior to the JITT. The QCP shall include the proposed CIR mix
design, a start to finish process description to include discussion on corrective action
measures, a list of proposed equipment, a list of proposed QC tests and testing
frequencies, and the curing methods applied to the CIR. All QC test results shall be
maintained during the duration of the contract and made available to the Engineer upon
30 request.

The following table provides the type and minimum frequency for tests.

QC Testing
1,2
Test Frequency
Depth of Pulverization 1 per 500 ft
Pulverized Material Gradation 1 per 0.5 day of processing
Asphalt Emulsion Content 1 per 500 ft
Water Content 1 per 500 ft
Compacted In-Place Field Density 1 per 1,000 ft
Field Moisture Content for Curing 1 per each day of production
Notes:
1. The Contractor shall perform all QC tests within the first 500 ft after
startup and after any change in the mix design.
2. Testing frequency is based upon linear feet of CIR processing.

MATERIALS

416.04 Materials
CIR shall consist of a homogenous blend of reclaimed asphalt pavement, RAP,
combined with asphalt emulsion, water, and when required, recycling additives such
40 as corrective aggregate or cement. Cement recycling additives used in asphalt
emulsion stabilized CIR may be dry powder or slurry with a minimum dry solids
content of 60%. The actual materials used are dependent on the CIR mix design and
project requirements.
368
 416.06

Materials for use in CIR shall be in accordance with the following:

Asphalt Emulsion ...................................................................... 902.01(b)3

Corrective aggregate to adjust gradation or

50 supplement material volume:
1. Coarse or Dense Graded Aggregate,
Class C or Higher ........................................................ 904.03
2. Fine Aggregate ............................................................ 904.02
3. RAP shall be the product resulting from the cold
milling or crushing of an existing asphalt pavement.
The RAP coarse aggregate shall be processed so that
100% passes the 1 1/2 in. (37.5 mm) sieve.

Portland Cement, Type I............................................................ 901.01(b)

60 Water ......................................................................................... 913.01

Acceptance of the CIR will be in accordance with the Frequency Manual on the
basis of a type D certification in accordance with ITM 804.

416.05 Mix Design

The CIR mix design shall be in accordance with ITM 592 and shall be comprised
of existing RAP, asphalt emulsion and if necessary, recycling additives. The mix
design and all associated testing shall be performed, using samples of the existing
pavement material from the project site representing the recycling depth, by a design
70 laboratory that is AMRL accredited in HMA and asphalt emulsion. Additional mix
designs shall be performed when the in-place material changes significantly in order
to establish representative mixes for the entire job. The Contractor shall be responsible
for obtaining all samples required to develop the mix design. One sample per lane mile
of planned CIR shall be the minimum sampling frequency for mix design preparation.

The Contractor shall provide a mix design, or designs, for approval at least five
calendar days prior to the JITT. The mix design shall include all test results performed.
If new materials are added, a new mix design, including the updated test results, shall
be submitted at least one day prior to implementation.
80
CONSTRUCTION REQUIREMENTS

416.06 Roadway Preparation

Snowplowable raised pavement markers shall be removed in accordance with
808.11(e) prior to CIR operations.

Grass and other vegetation shall be removed from the edge of the existing
pavement to prevent contamination of the pulverized material during milling
operation.
90
369
 416.07

Grade adjustments of existing structures shall be made in accordance with 720.04

prior to CIR operations, except existing structures shall be lowered, properly covered
and filled with material compatible with the CIR mix design to maintain traffic.

All areas of soft or yielding subgrade, as shown on the plans, shall be corrected
prior to CIR operations.

416.07 Equipment
The recycling equipment shall be capable of milling the existing asphalt
100 pavement, sizing the resulting RAP and mixing the RAP with the materials stipulated
in the mix design. The recycling equipment shall be capable of meeting the specified
sizing requirement with either the milling process or with additional sizing equipment.
The recycling equipment shall be capable of producing a homogenous and uniformly
coated CIR mixture by mixing the RAP with the asphalt emulsion, water and any other
additives, either in the cold planer housing or in an additional mixing chamber. The
equipment used for placement of the CIR mixture shall be capable of the placement in
accordance with 105.03.

The CIR equipment shall consist of the following major components:

110
(a) Cold In-Place Recycler Equipment
The cold in-place recycling equipment will include either a single unit recycler or
a multi-unit recycler.

1. Single Unit Recycler

The single-unit recycler shall be a self-propelled cold milling machine/cold
recycling machine with a down cutting cutter head capable of pulverizing and
recycling the existing HMA pavement to the depth specified, incorporate the asphalt
emulsion and water and mix the materials to produce a homogenous mixture. The
120 machine shall have two systems for adding asphalt emulsion and water, with each
system having a full width spray bar with a positive displacement pump interlocked to
the machine’s ground speed to insure that the amount of asphalt emulsion and water
being added is automatically adjusted with changes to the machine’s ground speed.
Each additive system shall have its own spray bar equipped with two nozzles per foot
of spray bar and be capable of incorporating up to 7 gal./sq yd of asphalt emulsion or
water. Individual valves on the spray bar shall be capable of being turned off as
necessary to minimize asphalt emulsion and water overlap on subsequent passes.

2. Multi-Unit Recycler
130 A multi-unit recycler may be utilized instead of a single unit recycler. The multi-
unit train shall contain the following:

a. A self-propelled cold milling machine that is capable of

pulverizing the existing asphalt material in a single pass
to the depth shown on the plans and to a minimum
width of not less than 12 1/2 ft. The machine shall have
automatic depth controls to maintain the cutting depth
370
 416.07

to within ±1/4 in. of that shown on the plans, and shall

have a positive means for controlling cross slope
140 elevations. The use of a heating device to soften the
pavement will not be allowed.

b. A material sizing unit having screening and crushing

capabilities to reduce the cold pulverized material to the
appropriate size. The screening and crushing unit shall
have a closed circuit system capable of continuously
returning oversized material to the crusher. All of the
pulverized material shall be processed to the maximum
size requirements specified.
150
c. A mixing unit equipped with a belt scale for the
continuous weighing of the pulverized and sized
asphalt material and a coupled/interlocked computer
controlled liquid metering device. The mixing unit shall
be an on-board completely self-contained pugmill. The
liquid metering device shall deliver the amount of
asphalt emulsion to within ±0.25% of the required
amount by weight of the pulverized asphalt material.
The asphalt emulsion pump shall be sufficient capacity
160 to allow emulsion contents up to 4.0% by weight of
pulverized material. Also, automatic digital readings
shall be displayed for both the flow rate and total
amount of pulverized asphalt material and asphalt
emulsion in appropriate units of weight and time.

(b) Spreaders for Dry Cement

Spreaders used to apply dry cement recycling additives shall be non-pressurized
mechanical vane-feed, cyclone or screw type capable of providing a consistent,
accurate and uniform distribution of material while minimizing dust during
170 construction.

(c) Additive Slurry Storage and Supply Equipment

Slurry shall be produced using a batch or continuous-flow type stationary mixer
equipped with calibrated metering and feeding devices that introduce the cement,
water and additives into the mixer in the specified quantities. Additive slurry storage
and supply equipment shall have agitators or similar equipment to keep the slurry in
suspension when held in the slurry batch or storage tanks. Slurry shall be kept in
suspension during transport using agitator equipment.

180 (d) Spreading of Corrective Aggregate

Corrective aggregate, when required shall be placed with a mechanical spreader
or a conventional paver.

371
 416.08

(e) Water Truck

A water truck for supplying water to the milling equipment during CIR operation
shall be provided. The water truck system shall be able to supply the mixing chamber,
if necessary, so as to provide an independent source of water to properly disperse the
asphalt emulsion.

190 (f) Laydown Equipment

The processed CIR mixture shall be spread uniformly across the recycling width
using either a self-propelled paver in accordance with 409.03(c) or screed integral to
the recycling equipment.

In either case, the screed shall be controlled by electronic grade and cross slope
control. The equipment shall be of sufficient size and power to spread the recycled
material in one continuous pass, without segregation, in accordance with 105.03.
Heating of the screed will not be allowed.

200 In utilizing a self-propelled paver, material shall either be loaded directly into the
paver hopper from the recycling equipment or loaded by a pickup device from a
windrow.

If utilizing a pickup device, it shall be capable of removing and transferring the

entire windrow of recycled mix in a single pass. The pick-up machine shall be within
150 ft of the mixing unit throughout the treatment process.

(g) Compaction Equipment

Compaction equipment shall be in accordance with 409.03(d). The number,
210 weight, and types of rollers shall be as necessary to obtain required compaction. At a
minimum, the following rollers shall be used:

1. At least one pneumatic tired roller in accordance with

409.03(d)3 with a minimum weight of not less than 20 t.

2. At least one double drum vibratory roller in accordance

with 409.03(d)4 with a minimum weight of not less than
10 t.

220 416.08 Weather Limitations

CIR operations shall be performed when the RAP temperature, or pavement
surface temperature, is above 50ºF with ambient temperatures above 35ºF for seven
days. The Engineer may restrict work when the heat index is greater than 100°F. The
CIR shall not be performed before May 1 or after October 1.

416.09 Processing and Mixing Operation

For CIR mixtures, the pulverization shall produce a gradation that has 100%
passing the 1 1/2 in. (37.5 mm) sieve.

372
 416.10

230 Corrective aggregate, when required, shall be spread onto the existing surface
using a mechanical spreader or a conventional paver.

An additive used in asphalt emulsion stabilized CIR may be dry powder or slurry
and the Contractor shall address the application methods and fugitive dust control
procedures in the QCP when dry powder materials are used.

The pulverized material shall be processed through a mixing unit capable of

combining the pulverized material, asphalt emulsion, and any additives to produce a
homogenous recycled mixture. The asphalt emulsion shall be injected into the
240 pulverized asphalt material at the initial rate determined by the mix design and
approved by the Engineer. Sampling and mix design may determine different levels of
asphalt emulsion at various portions of the project.

When a paving fabric is encountered during the pulverization operation, the

Contractor shall make the necessary changes in equipment or operations so that
incorporation of shredded fabric into the CIR does not affect the performance
parameters or inhibit placement or compaction of the CIR. The Contractor shall be
required to remove and properly dispose of oversized pieces of paving fabric. The
Contractor shall make the necessary adjustments in equipment or operations so that
250 the shredded fabric in the recycled material is no more than 5 sq in. No fabric piece
shall have a dimension exceeding a length of 4 in.

Rubberized crack filler, durable pavement markings, loop wires, and other non-
pavement materials shall be removed as observed from the roadway during the CIR
process. Residual materials that cannot be completely removed may be incorporated
into the mixture if the Contractor can demonstrate that those added materials will not
adversely affect performance.

Any such materials retained in the mixture shall be appropriately sized and
260 blended so as to not adversely affect the strength of the CIR.

Asphalt emulsion shall have an application tolerance determined by adding

±0.25% to the percent total asphalt emulsion content recommended by the mix design.

The Contractor can request the asphalt emulsion percentage to exceed the upper
tolerance provided the mix design requirements are satisfied at the requested
percentage. The request will be subject to approval by the Engineer.

416.10 Control Strip and Compaction

270 A minimum 500 ft long control strip shall be conducted on the first day of
production to verify the construction process meets the requirements as specified. The
control strip shall allow the Contractor to:

(a) demonstrate the proposed equipment, materials and processes

can produce a CIR layer in accordance with specification
requirements, and;
373
 416.11

(b) determine the optimal rates for the asphalt emulsion, water and
any additives recommended for the reclaimed material, and;
280
(c) determine the sequence and manner of rolling necessary to
obtain specified density requirements.

The CIR density shall be achieved with the same equipment, materials,
construction methods and density requirements used on the accepted control strip. A
new control strip shall be constructed if changes are made outside of the tolerances of
the original mix design, equipment or construction methods.

A rolling pattern that produces the maximum obtainable density, or optimum field
290 density, shall be determined during the control strip. The Contractor shall provide a
sequence and manner of rolling by establishing a roller pass versus density chart that
shows the progress of densification from initial lay down through optimum field
density using a properly calibrated nuclear gauge in accordance to AASHTO T 310.
Production may continue after approval of the control strip.

The Contractor shall perform compaction testing in accordance with AASHTO T

310 during production to ensure compaction is between 97% and 102% of the
optimum field density established during the control strip. If two successive tests
indicate compaction is over 102% or below 97% of the optimum field density, a new
300 rolling pattern and roller pass versus density chart shall be established.

The QC technician shall be on site, observing all compaction efforts and

approving areas as they reach minimum relative compaction. Care shall be taken not
to over compact the mat.

Any type of rolling effort that causes cracking, displacement or other type of
pavement distress shall be discontinued until such time as the problem can be resolved
as approved by the Engineer.

310 Rollers shall not be started or stopped on recycled material except when changing
direction during the compaction process.

All tests shall be conducted at the stated QC testing frequencies throughout CIR
operations.

416.11 Opening to Traffic

Opening to traffic shall occur after sufficient cure time has been applied to the
CIR so traffic will not initiate raveling or permanent deformation. All loose particles
that may develop on the pavement surface shall be removed by a rotary power broom
320 in accordance with 409.

After opening to traffic, the surface of the recycled pavement shall be maintained
in a condition suitable for the safe movement of traffic.
374
 416.16

416.12 Maintenance
The Contractor shall maintain the recycled pavement in a manner satisfactory to
the Engineer until the surface course has been constructed.

Any damage to the completed recycled material shall be repaired by the

330 Contractor prior to the placement of new asphalt concrete or final surface sealing.
Patching shall be in accordance with 304. The excavated patch areas shall be filled and
compacted with HMA or CIR material as directed by the Engineer. No direct payment
will be made for damage or repair unless approved by the Engineer.

416.13 Curing
Before placing the final surfacing, the recycled surface shall remain in-place for
a minimum of three days and meet one of the following conditions:

(a) there is less than 3.0% moisture remaining in the mixture, or

340
(b) the material has remained in-place for a minimum of 10 days
without rainfall.

The planned method and duration of curing for CIR shall be in accordance with
the QCP. The specified surface course shall be placed within two weeks of the CIR
final cure, but no later than November 1.

416.14 Milling
The entire surface of the CIR shall be scarified in accordance with 306 to the
350 specified cross-slope in preparation for the overlay. Construction engineering in
accordance with 105.08(b) shall be provided.

416.15 CIR Surface Course

The surface course atop the CIR shall be as shown on the plans.

The CIR shall be swept of all loose material and standing water with a rotary
power broom in accordance with 409 immediately prior to placing the surface. The
CIR shall be swept lightly to avoid damage to the CIR.

360 A tack coat shall be required only for the HMA overlay and shall be applied to
the CIR in accordance with 406 immediately following sweeping operations.

Monuments shall be reestablished in accordance with 615.10.

416.16 Method of Measurement

The CIR will be measured by the square yard, complete in place. Asphalt
emulsion will be measured by the ton. Aggregate to adjust the CIR gradation will be
measured by the ton of material used. HMA Patching will be measured in accordance
with 304.06. Milling will be measured in accordance with 306.10. Re-established
370 monuments will be measured in accordance with 615.13. Grade adjustment of existing
375
 416.17

structures will be measured in accordance with 720.06. Removal of snowplowable

raised pavement markers will be measured in accordance with 808.12. Portland
cement will be measured by the ton.

416.17 Basis of Payment

The CIR will be paid for at the contract unit price per square yard, complete in
place. Asphalt emulsion will be paid for at the contract unit price per ton, complete in
place. Aggregate used to adjust the CIR gradation will be paid for at the contract unit
price per ton, complete in place. HMA patching will be paid for in accordance with
380 304.07, for the thickness shown on the plans. Milling will be paid for in accordance
with 306.11. Re-established monuments will be paid for in accordance with 615.14.
Grade adjustment of existing structures will be paid for in accordance with 720.07.
Removal of snowplowable raised pavement markers will be paid for in accordance
with 808.13.

Portland cement will be paid for in accordance with 104.03. The change order will
include direct material costs, delivery costs, and shall not include any other markups.

Payment will be made under:

390
Pay Item Pay Unit Symbol

Cold In-Place Recycling ............................................................ SYS

Corrective Aggregate, CIR ........................................................ TON
Stabilizing Material, Asphalt Emulsion..................................... TON
Stabilizing Material, Portland Cement ...................................... TON

The costs of the CIR mix design and QC testing shall be included in the cost of
the CIR.
400
The costs associated with removal of grass and vegetation, rubberized crack filler,
durable pavement markings, loop wires and other non-pavement materials shall be
included in the cost of the CIR.

The costs associated with stabilizing, compacting, curing and maintenance of the
CIR not related to failing subgrade shall be included in the cost of the CIR.

The cost associated with mixing water shall be included in the cost of the CIR.

410 The cost associated with aggregate when used to supplement material volume
shall be included in the cost of the corrective aggregate pay item.

When portland cement is a required stabilizing material, costs associated with

mixing, installation, compaction, curing, and maintenance shall be included in the cost
of the CIR.

376
 417.03

The cost associated with aggregate when used to adjust the CIR gradation shall
be included in the cost of the corrective aggregate pay item.

420 The cost of milling the asphalt emulsion stabilized CIR to maintain profile shall
be included in the cost of the milling.

In the locations of failing subgrade, removal of the CIR shall be included in the
cost of subgrade treatment.

SECTION 417 - COLD CENTRAL PLANT RECYCLING, CCPR

417.01 Description
This work shall consist of a mixture of sized Reclaimed Asphalt Pavement, RAP,
millings from existing asphalt pavement or existing stockpiles, asphalt emulsion,
water and other additives. The mixture shall be produced at a nearby location, then
placed and compacted to produce a recycled asphalt layer to the approved design
properties in accordance with 105.03.

10 417.02 Just-in-Time Training, JITT

The Engineer and the Contractor are required to attend a just-in-time training,
JITT, course regarding CCPR and both shall mutually agree on the course instructor,
course content and training site. The training class shall be conducted at a project field
location convenient for all project construction personnel responsible for CCPR
operations and inspection to attend.

The JITT course shall be held during normal working hours and be completed not
more than 14 days prior to the start of CCPR operations.

20 The Contractor shall provide a JITT instructor experienced in the construction

methods, materials and test methods associated with asphalt emulsion stabilized
CCPR. A copy of the course syllabus, handouts and presentation materials shall be
submitted to the Engineer at least five business days before the course is to be taught.

417.03 Quality Control

A quality control plan, QCP, shall be submitted to the Engineer a minimum of
five calendar days prior to the JITT. The QCP shall include the proposed CCPR mix
design, a start to finish process description to include discussion on corrective action
measures, a list of proposed equipment, a list of proposed QC tests and testing
30 frequencies, and the curing methods and procedures applied to the CCPR. All QC test
results shall be maintained during the duration of the contract and made available to
the Engineer upon request.

The following table provides the type and minimum frequency for tests:

377
 417.04

QC testing
Test Frequency1,2
Depth of Laydown 1 per 500 ft
Pulverized Material Gradation 1 per 1,000 tons of production
Pulverized Material Moisture Content 1 per 500 tons of production
Asphalt Emulsion Content3 1 per 500 tons of production
Water Content3 1 per 500 tons of production
Compacted In-Place Field Density 1 per 1,000 ft
Field Moisture Content for Curing 1 per each day of production
Notes:
1. The Contractor shall perform all QC tests within the first 500 ft after startup
and after any change in the mix design.
2. Testing frequency is based upon either linear feet of CCPR laydown or tons
of CCPR mixture processing.
3. Asphalt emulsion content and water content shall be taken from the readings
of the control settings of the mixing unit.

MATERIALS

417.04 Materials
40 CCPR shall consist of a homogenous blend of RAP combined with asphalt
emulsion, water, and when required, recycling additives such as corrective aggregate
or cement. Cement recycling additives used in asphalt emulsion stabilized CCPR may
be dry powder or slurry with a minimum dry solids content of 60%. The actual
materials used are dependent on the CCPR mix design and project requirements.

Materials for use in CCPR shall be in accordance with the following:

Asphalt Emulsion ...................................................................... 902.01(b)3

50 Corrective Aggregate to adjust gradation or

supplement material volume:
1. Coarse or Dense Graded Aggregate,
Class C or Higher ........................................................ 904.03
2. Fine Aggregate ............................................................ 904.02
3. RAP shall be the product resulting from the cold
milling or crushing of existing asphalt pavement and
processed so that 100% passes the 1 1/2 in. (37.5 mm)
sieve.

60 Portland Cement, Type I............................................................ 901.01(b)

Water ......................................................................................... 913.01

Acceptance of the CCPR will be in accordance with the Frequency Manual on the
basis of a type D certification in accordance with ITM 804.

378
 417.07

417.05 Mix Design

CCPR mix designs shall be in accordance with ITM 592 and shall be comprised
of existing RAP, asphalt emulsion and recycling additives, if necessary. The mix
design and all associated testing shall be performed using samples of each proposed
70 material. RAP samples shall either be collected from the existing pavement at the
project site representing the milling depth or from the RAP stockpile to be used during
construction. The mix design shall be completed by a design laboratory that is AMRL
accredited in HMA and asphalt emulsion. Additional mix designs shall be performed
when the proposed material changes significantly in order to establish representative
mixes for the entire job. The Contractor shall be responsible for obtaining all samples
required to develop the mix design. One sample per lane mile of planned CCPR shall
be the minimum sampling frequency for mix design preparation.

The Contractor shall provide a mix design or designs for approval at least five
80 calendar days prior to the JITT. The mix design shall include all test results performed.
If new materials are added, a new mix design, including the updated test results, shall
be submitted at least one day prior to implementation.

CONSTRUCTION REQUIREMENTS

417.06 Roadway Preparation

Snowplowable raised pavement markers shall be removed in accordance with
808.11(e) prior to CCPR operations.

90 Grass and other vegetation shall be removed from the edge of the existing
pavement to prevent contamination of the pulverized asphalt material during milling
operation.

All areas of soft or yielding subgrade shall be corrected prior to CCPR operations.

If the CCPR mix is to be placed on a prepared subgrade or aggregate base, the

Contractor shall ensure the subgrade soils and base have been properly prepared,
moisture treated and compacted to the minimum density according to plans or
specifications, immediately prior to placement of the CCPR mix, so as to create an
100 evenly graded, unyielding surface.

417.07 Pavement Removal

The existing asphalt pavement shall be milled in accordance with 306 to the
length, depth and width as shown on the plans or specifications. The RAP shall be free
of contamination of dirt, base, concrete or other deleterious materials such as silt and
clay.

When a paving fabric is encountered during the pulverization operation, the

Contractor shall make the necessary changes in equipment or operations so that
110 incorporation of shredded fabric into the CCPR does not affect the performance
parameters or inhibit placement or compaction of the CCPR. The Contractor shall be
required to remove and properly dispose of oversized pieces of paving fabric. The
379
 417.08

Contractor shall make the necessary adjustments in equipment or operations so that

the shredded fabric in the recycled material is no more than 5 sq in. No fabric piece
shall have a dimension exceeding a length of 4 in.

Rubberized crack filler, durable pavement markings, loop wires and other non-
pavement materials shall be removed as observed from the roadway. Residual
materials that cannot be completely removed may be incorporated into the mixture if
120 the Contractor can demonstrate that those added materials will not adversely affect
performance.

Any such materials retained in the mix shall be appropriately sized and blended
so as not to adversely affect the strength of the recycled pavement.

417.08 Equipment
The equipment shall consist of the following major components:

(a) Milling Machine/Pavement Cold Planer

130 Milling equipment shall be in accordance with 306.03(a). The equipment shall be
capable of pulverizing the existing asphalt material in a single pass to the depth shown
on the plans. The machine shall have automatic depth controls to maintain the cutting
depth to within ±1/4 in. of that shown on the plans. The milling operation shall not
disturb or damage the underlying material. The use of a heating device to soften the
pavement will not be allowed.

(b) Additive Slurry Storage and Supply Equipment

Slurry shall be produced using a batch or continuous-flow type stationary mixer
equipped with calibrated metering and feeding devices that introduce the cement,
140 water and additives into the mixer in the specified quantities. Additive slurry storage
and supply equipment shall have agitators or similar equipment to keep the slurry in
suspension when held in the slurry batch or storage tanks. Slurry shall be kept in
suspension during transport using agitator equipment.

(c) Sizing Equipment

A material sizing unit shall be capable of sizing using a scalping screen or
crushing capabilities to reduce RAP to a maximum size of 1 1/2 in. (37.5 mm) or to
the maximum size requirements specified prior to mixing with the asphalt emulsion.

150 (d) Mixing and Proportioning Equipment

The equipment shall be capable of processing sized RAP, asphalt emulsion, water
and any additives stipulated in the mix design to a homogenous and uniformly coated
CCPR mixture. The equipment shall be in accordance with 409.02(b) and display
automatic digital readings shall be displayed for flow rate of both the RAP and asphalt
emulsion in appropriate units of weight and time.

The mixing apparatus shall have cold feed hopper equipped with vibrators on the
hopper’s walls to assist the free flow of materials to a variable speed belt conveyor.
Control of the RAP shall be by mechanically adjustable gate valves at the point of
380
 417.10

160 discharge or a RAP belt scale for the continuous weighing of the RAP. The variable
speed belt conveyor or RAP belt scale shall be interlocked to the asphalt emulsion
metering device.

The asphalt emulsion metering device shall be capable of automatically adjusting

the flow of asphalt emulsion to compensate for any variation in the amount of RAP
introduced into the mixing apparatus. Asphalt emulsion shall be metered by weight of
RAP using a calibrated meter that will accurately measure the amount of asphalt
emulsion to within a tolerance of ±2.0% of the specified rate.

170 (e) Hauling Equipment

Hauling equipment shall be in accordance with 409.03(b).

(f) Laydown Equipment

Laydown equipment shall be in accordance with 409.03(c).

The paver screed shall be controlled by electronic grade and cross-slope control.
Heating of the screed shall not be allowed.

CCPR material shall either be loaded directly into the paver hopper from transport
180 trucks or loaded by a pickup device. If utilizing a pickup device, it shall be capable of
removing and transferring the entire windrow of recycled mix in a single pass.

The equipment used for placement of the CCPR mixture shall be capable of the
placement in accordance to 105.03.

(g) Compaction Equipment

Compaction equipment shall be in accordance with 409.03(d). The number,
weight, and types of rollers shall be as necessary to obtain required compaction. At a
minimum, the following rollers shall be used:
190
1. At least one pneumatic tired roller in accordance with
409.03(d)3 with a minimum weight of not less than 20 t.

2. At least one double drum vibratory roller in accordance

with 409.03(d)4 with a minimum weight of not less than
10 t.

417.09 Weather Limitations

CCPR operations shall be performed when the RAP temperature, or pavement
200 surface temperature, is above 50ºF with ambient temperatures above 35ºF for seven
days. The Engineer may restrict work when the heat index is greater than 100°F. The
CCPR shall not be performed before May 1 or after October 1.

417.10 Material Sizing and Stockpiling

The gradation of the RAP shall have 100% passing the 1 1/2 in. (37.5 mm) sieve,
or be sized to meet specific contract requirements.
381
 417.11

RAP that has been crushed and screened shall be stockpiled and maintained to
prevent reconsolidation. Water may be added to RAP as it is screened and crushed to
210 abate dust and mitigate reconsolidation.

Corrective aggregate, if required, shall either be mixed with RAP to create a

homogenous mixture during stockpiling or fed into the mixing apparatus at the rate
determined by the mix design.

417.11 Processing and Mixing Operation

The sized RAP shall be processed through a mixing unit capable of combining the
sized RAP, asphalt emulsion, and any additives to produce a homogenous recycled
mixture.
220
An additive used in asphalt emulsion stabilized CCPR may be dry powder or
slurry and the Contractor shall address the application methods and fugitive dust
control procedures in the QCP when dry powder materials are used.

The asphalt emulsion shall be injected into the CCPR materials at the initial rate
determined by the mix design and approved by the Engineer. Sampling and mix design
may determine different levels of asphalt emulsion at various portions of the project.

The asphalt emulsion shall have an application tolerance determined by adding

230 ±0.25% to the percent total asphalt emulsion content.

The Contractor can request the asphalt emulsion percentage to exceed the upper
tolerance provided the mix design requirements are satisfied at the requested
percentage. The request will be subject to approval by the Engineer.

417.12 Placement
The depth of CCPR shall be as indicated on the plans.

The hauling equipment shall deliver the blended CCPR material into the paver
240 within one hour of mixing or before the asphalt emulsion begins to break and set.

CCPR single lift thickness shall be a minimum compacted depth of 3 in. and shall
not exceed a maximum compacted depth of 5.5 in. Tack coat in accordance with 406
shall be applied between the lifts.

417.13 Control Strip and Compaction

A minimum 500 ft long control strip shall be conducted on the first day of
production to verify the construction process meets the requirements as specified. The
control strip shall allow the Contractor to:
250
(a) demonstrate the equipment, materials and processes proposed
to produce a CCPR layer in accordance with specification
requirements, and;
382
 417.14

(b) determine the optimal rates for the asphalt emulsion, water and
any additives recommended for the material, and;

(c) determine the sequence and manner of rolling necessary to

obtain specified density requirements in one uniformly
260 compacted layer.

The CCPR density shall be achieved with the same equipment, materials,
construction methods and density requirements used on the accepted control strip. A
new control strip shall be constructed if changes are made outside of the tolerances of
the original mix design, equipment or construction methods.

A rolling pattern that produces the maximum obtainable density, or optimum field
density, shall be determined during the control strip. The Contractor shall provide a
sequence and manner of rolling by establishing a roller pass versus density chart that
270 shows the progress of densification from initial lay down through optimum field
density using a properly calibrated nuclear gauge in accordance to AASHTO T 310.
Production may continue after approval of the control strip.

The Contractor shall perform compaction testing in accordance with AASHTO T

310 during production to ensure compaction is between 97% and 102% of the
optimum field density established during the control strip. If two successive tests
indicate compaction is over 102% or below 97% of the optimum field density, a new
rolling pattern and roller pass versus density chart shall be established.

280 The QC technician shall be on site, observing all compaction efforts and
approving areas as they reach minimum relative compaction. Care shall be taken not
to over compact the mat.

Any type of rolling effort that causes cracking, displacement or other type of
pavement distress shall be discontinued until such time as the problem can be resolved
as approved by the Engineer.

Rollers shall not be started or stopped on recycled material unless when changing
direction during the compaction process.
290
All tests shall be conducted at the stated QC testing frequencies throughout CCPR
operations.

417.14 Opening to Traffic

Opening to traffic shall occur after sufficient cure time has been applied to the
CCPR so traffic will not initiate raveling or permanent deformation. All loose particles
that may develop on the pavement surface shall be removed by a rotary power broom
in accordance with 409.

383
 417.15

300 After opening to traffic, the surface of the recycled pavement shall be maintained
in a condition suitable for the safe movement of traffic.

417.15 Maintenance
The Contractor shall maintain the recycled pavement in a manner satisfactory to
the Engineer until the surface course has been constructed.

Any damage to the completed recycled material shall be repaired by the

Contractor prior to the placement of new asphalt concrete or final surface sealing.
Patching shall be in accordance with 304. The excavated patch areas shall be filled and
310 compacted with HMA or CCPR material as directed by the Engineer. No direct
payment will be made for damage repair unless approved by the Engineer.

417.16 Curing
Before placing the final surfacing, the recycled surface shall remain in-place for
a minimum of three days and meet one of the following conditions:

(a) There is less than 3.0% moisture remaining in the mixture, or;

(b) The material has remained in-place for a minimum of 10 days

320 without rainfall.

The planned method and duration of curing for CCPR shall be in accordance with
the QCP. The specified surface course shall be placed within two weeks of the CCPR
final cure, but no later than November 1.

417.17 Milling and Pavement Smoothness

When the CCPR material is placed in a single lift, the entire surface of the CCPR
shall be scarified in accordance with 306 to the specified cross-slope in preparation for
the overlay. Construction engineering in accordance with 105.08(b) shall be provided.
330
Pavement smoothness of the cured CCPR mat shall meet the requirements of
401.18(b) The Contractor shall correct humps or depressions exceeding the tolerances
in accordance with 401.18(c).

417.18 CCPR Surface Course

The CCPR shall be swept of all loose material and standing water with a rotary
power broom in accordance with 409 immediately prior to placing the tack coat. A
tack coat shall be required and shall be applied to the CCPR in accordance with 406.

340 Monuments shall be reestablished in accordance with 615.10 after the surface
course is placed.

417.19 Method of Measurement

The CCPR will be measured by the square yard, complete in place. Asphalt
emulsion will be measured by the ton. Aggregate to adjust the CCPR gradation will
be measured by the ton of material used. HMA Patching will be measured in
384
 417.20

accordance with 304.06. Re-established monuments will be measured in accordance

with 615.13. Grade adjustment of existing structures will be measured in accordance
with 720.06. Removal of snowplowable raised pavement markers will be measured in
350 accordance with 808.12. Portland cement will be measured by the ton.

417.20 Basis of Payment

The CCPR will be paid for at the contract unit price per square yard, complete in
place. Asphalt emulsion will be paid for at the contract unit price per ton, complete in
place. Aggregate used to adjust the CCPR gradation will be paid for at the contract
unit price per ton, complete in place. HMA patching will be paid for in accordance
with 304.07, of the thickness specified on the plans. Re-established monuments will
be paid for in accordance with 615.14. Grade adjustment of existing structures will be
paid for in accordance with 720.07. Removal of snowplowable raised pavement
360 markers will be paid for in accordance with 808.13.

Portland cement will be paid for in accordance with 104.03. The change order will
include direct material costs, delivery costs, and shall not include any other markups.

Payment will be made under:

Pay Item Pay Unit Symbol

Cold Central Plant Recycling .................................................... SYS

370 Corrective Aggregate, CCPR .................................................... TON
Stabilizing Material, Asphalt Emulsion..................................... TON
Stabilizing Material, Portland Cement ...................................... TON

The costs associated with the CCPR mix design and quality control testing shall
be included in the cost of the cold central plant recycling.

The costs associated with the removal of grass and vegetation, rubberized crack
filler, durable pavement markings, loop wires and other non-pavement materials shall
be included in the cost of the cold central plant recycling.
380
The costs associated with pulverizing, stabilizing, compacting, curing and
maintenance of the CCPR not related to failing subgrade shall be included in the cost
of the cold central plant recycling.

The cost associated with mixing water for cold central plant material shall be
included in the cost of the cold central plant recycling.

The cost associated with aggregate when used to supplement material volume
shall be included in the cost of the corrective aggregate pay item.
390
When portland cement is a required stabilizing material, costs associated with
mixing, installation, compaction, curing, and maintenance shall be included in the cost
of the cold central plant recycling.
385
 417.20

The cost associated with aggregate when used to adjust the CCPR gradation shall
be included in the cost of the corrective aggregate pay item.

The costs of the asphalt emulsion stabilizing material shall be included in the cost
of the stabilizing material pay item.
400
In the locations of failing subgrade, removal of the CCPR shall be included in the
cost of subgrade treatment.

386
 501.04

DIVISION 500 – CONCRETE PAVEMENT

SECTION 501 – QC/QA PORTLAND CEMENT CONCRETE PAVEMENT,

PCCP

501.01 Description
This work shall consist of QC/QA portland cement concrete pavement, PCCP,
placed on a prepared subgrade or subbase in accordance with 105.03.

501.02 Quality Control

The mixture for PCCP shall be produced by an approved plant in accordance with
10 ITM 405, transported, and placed according to a Quality Control Plan, QCP, prepared
and submitted by the Contractor in accordance with ITM 803, for PCCP. The QCP
shall be submitted to the Engineer at least 15 days prior to commencing PCCP paving
operations.

An American Concrete Institute certified concrete field testing technician, grade I,

shall be on site to direct all sampling and testing.

A common testing facility shall be provided for both production control and
acceptance testing.
20
MATERIALS

501.03 Materials
Materials shall be in accordance with the following:

Admixtures .................................................................. 912.03

Coarse Aggregate, Class AP, Size No. 8* ................... 904
Fine Aggregate, Size No. 23* ...................................... 904
Fly Ash ........................................................................ 901.02
30 Ground Granulated Blast Furnace Slag ....................... 901.03
Portland Cement .......................................................... 901.01(b)
Rapid Setting Patch Materials ..................................... 901.07
Water ........................................................................... 913.01
* Or gradation as identified in the QCP

501.04 Concrete Mix Design

A concrete mix design submittal, CMDS, shall be in accordance with 501.05. The
CMDS shall be submitted to and approved by the DTE. The CMDS shall be submitted
a minimum of seven calendar days prior to the trial batch utilizing the Department
40 provided spreadsheet and shall include the following:

(a) a list of all ingredients

(b) the source of all materials
(c) the fine to total aggregate ratio
387
 501.04

(d) the gradation of the aggregates

(e) the absorption of the aggregates
(f) the SSD bulk specific gravity of the aggregates
(g) the specific gravity of pozzolan
(h) the batch weights
50 (i) the names of all admixtures
(j) the admixture dosage rates and the manufacturer’s
recommended range.

The CMDS is used to conduct a trial batch in accordance with 501.06. Upon
completion of the trial batch, the Contractor shall submit the concrete mix design for
production, CMDP. The CMDP shall be submitted to the DTE utilizing the
Department furnished spreadsheet a minimum of three work days prior to production.
Production shall not commence without an approved CMDP. Both the Contractor’s
and the Engineer’s test results from the trial batch will be included in the CMDP
60 submittal.

A CMDP may be changed or adjusted in accordance with the following:

(a) Change in Materials

A change in a previously approved CMDP, for a given contract, to any of the
following shall be submitted to the DTE as a CMDS, referencing the original CMDP.

1. cement source or type

2. pozzolan source or type
70 3. coarse aggregate source or type
4. admixture type.

A trial batch shall be conducted in accordance with 501.06, or verification of the

new CMDS may be made during the first day of production by tests conducted by the
Contractor and the Engineer. Acceptance test results may be used for the Engineer’s
verification tests. Production may continue until flexural strength tests are completed,
provided all other properties are in accordance with 501.06. The test results shall be
submitted to the DTE utilizing the Department spreadsheet no later than one day after
the flexural strength test results are complete. If the flexural strength is not in
80 accordance with 501.06, production shall stop and all PCCP constructed with the new
CMDS will be adjudicated as a failed material in accordance with normal Department
practice as listed in 105.03.

(b) Adjustments to Materials

An adjustment in a previously approved CMDP, for a given contract, to any of
the following shall be submitted to the DTE as a CMDS, referencing the original
CMDP.

1. admixture source
90 2. admixture product of the same type and from the same
source designated in the original CMDP
388
 501.05

3. fine aggregate source

4. target unit weight due to change in aggregate properties
5. fine to total aggregate ratio in excess of ±3% from the value
designated by the original CMDP
6. increase in cement content from the amount designated in
the original CMDP.

The new CMDS shall be submitted to the DTE utilizing the Department
100 spreadsheet a minimum of one work day prior to production. A trial batch or
verification testing is not required for approval. Production shall not commence
without an approved CMDP.

(c) Other Adjustments

Other adjustments in an approved CMDP, for a given contract, to any of the
following will be allowed and DTE notification and approval prior to use is not
required.

1. admixture dosage rate

110 2. fine aggregate to total aggregate ratio within ±3% of the
value designated by the original CMDP.

An approved CMDP from a previous contract may be used on additional

contracts. The CMDP shall be submitted to the DTE for review and approval prior to
use.

501.05 Concrete Mix Criteria

The CMD shall produce workable concrete mixtures having the following
properties:
120
Minimum portland cement content.............................. 400 lbs/cu yd
Maximum water/cementitious ratio ............................. 0.450
Minimum portland cement/fly ash ratio ...................... 3.2 by weight
Minimum portland cement/GGBFS ratio .................... 2.3 by weight
Target air content......................................................... 6.5%
Minimum flexural strength, third point loading .......... 570 psi at 7 days

The Contractor may elect to use fine and coarse aggregates in accordance
with 904, or may propose the use of alternate gradations. If alternate gradations are
130 proposed, the QCP shall specify the tolerances of material passing each sieve. In either
case, 100% of the coarse aggregate shall pass the 1 in. (25 mm) sieve. The combined
amount of fine and coarse aggregates passing the No. 200 (75 µm) sieve shall be from
0% to 2.0% for fine aggregate and gravel, and from 0% to 2.5% for fine aggregate and
crushed stone or crushed slag.

The fine aggregate shall be at least 35% but not more than 50% of the total weight
of the aggregate in each cubic yard. Proportions will be based upon saturated surface
dry aggregates.
389
 501.06

140 Absorption tests shall be performed on the fine aggregate in accordance with
AASHTO T 84 and on the coarse aggregate in accordance with AASHTO T 85.
Absorption test results for a particular size of aggregate that differ by more than 1.0
percentage point from the Department’s source value shall be investigated. The
Contractor shall report any differences that exceed 1.0% to the Department. The
Contractor’s results shall be used when calculating the water/cementitious ratio.

Fly ash or GGBFS used as an additive, or blended cements may only be

incorporated in the concrete mix between April 1 and October 15 of the same calendar
year. If type IP, type IP-A, type IS or type IS-A cements are to be used, the minimum
150 portland cement content shall be increased to 500 lbs/cu yd. The use of fly ash or
GGBFS as an additive will not be allowed when blended cement types IP, IP-A, IS, or
IS-A are used.

Water reducing admixture type A, or water reducing and retarding admixture

type D, may be used in PCCP. However, admixture type A shall not be used in
conjunction with admixture type D.

501.06 Trial Batch

A trial batch shall be produced and tested by the Contractor’s certified technician
160 to verify that the CMDS meets the concrete mix criteria. Concrete produced at a plant
shall be batched within the proportioning tolerances of 508.02(b). Concrete batched in
a laboratory shall be in accordance with ASTM C 192. The Engineer will test the trial
batch and provide the Contractor with the results. The trial batch shall be of sufficient
quantity to allow the Contractor and the Engineer to perform all required tests from
the same batch. Trial batch concrete shall not be used for more than one test, except
the concrete used for the unit weight may be used to conduct the air content test. The
air content shall be 5.0% to 10.0%. The plastic unit weight shall be within ±3.0% from
the target plastic unit weight of the CMDS. The water/cementitious ratio shall be
within ±0.030 of the target value of the CMDS and shall not exceed 0.450. The flexural
170 strength shall be determined by averaging a minimum of two beam breaks and shall
be a minimum of 570 psi.

Test results shall be added to the Department spreadsheet and submitted to the
DTE in accordance with 501.04. Adjustments to the target unit weight and the target
water/cementitious ratio may be made.

A trial batch is not required for a CMDS that has any of the following criteria:

(a) minimum cement content of 564 lbs/cu yd and a target

180 water/cementitious ratio of 0.420

(b) class C concrete in accordance with 702 using Class AP coarse

aggregate.

390
 501.10

501.07 Lots and Sublots

Lots will be defined as 7,200 sq yd of PCCP. Lots will be further subdivided into
sublots of 2,400 sq yd of PCCP within a lot. Partial sublots of 480 sq yd or less will
be added to the previous sublot. Partial sublots greater than 480 sq yd constitute a full
sublot. Partial lots of one or two sublots constitute a full lot.
190
Lots and sublots will be numbered and tested for a given pay item regardless of
the number of CMD’s used and will be closed out at the end of the paving season or
construction phase.

501.08 Acceptance
Acceptance of PCCP for flexural strength, air content, unit weight,
water/cementitious ratio, and thickness will be determined on the basis of tests
performed by the Engineer in accordance with 505. The Engineer will randomly select
the location within each sublot for sampling in accordance with ITM 802.
200
The random sample per sublot shall be of sufficient quantity to perform all
required tests and obtained in accordance with AASHTO R 60. Concrete and
necessary labor for sampling shall be furnished as required by the Engineer. The test
results of the sublots for each lot will be averaged and shall be in accordance with
501.05 and 501.06, except the lot average for thickness shall be in accordance with
501.26. Test results are to be shared in a timely manner.

Test or Determination Frequency Test Method Precision

7-Day Flexural Strength two beams per sublot AASHTO T 97 1 psi
AASHTO T 152
Air Content one per sublot 0.1
or ASTM C 173
Unit Weight one per sublot AASHTO T 121 1
Water/Cementitious Ratio one per two lots ITM 403 0.001
Thickness two per sublot ITM 404 0.1

Rounding will be in accordance with 109.01(a).

210
In the event that an acceptance sample is not available to represent a sublot, all
test results of the previous sublot will be used for acceptance. If the previous sublot is
not available, the subsequent sublot will be used for acceptance.

CONSTRUCTION REQUIREMENTS

501.09 General
Equipment for PCCP shall be in accordance with 508.

220 501.10 Preparation of Grade

The subgrade shall be shaped to the required grade and section, free from all ruts,
corrugations, or other irregularities, and uniformly compacted and approved in
accordance with 207.

391
 501.11

501.11 Preparation of Subbase

Subbase, if required, shall be placed and shaped to the required grade and section
in accordance with 302. Construction traffic shall not be allowed on the aggregate
drainage layer of the subbase, except where PCCP placement is restricted. Exceptions
shall be submitted for approval.
230
501.12 Placement
Placement of PCCP shall be by the slipformed or formed methods with equipment
specified in 508.04. The subgrade or subbase shall be uniformly moist at the time of
PCCP placement. Excessively dry subgrade or subbase shall be sprinkled with water.

501.13 Process Control

The Engineer and the Contractor will jointly review the operations to ensure
compliance with the QCP. Continuous violations of compliance with the QCP will
result in suspension of paving operations.
240
501.14 Concrete Mixing and Transportation
Concrete shall be mixed and delivered by one of the following:

(a) Central mixed concrete shall be completely mixed in a

stationary mixer and transported in a truck agitator, truck mixer
at agitating speed, or non-agitating equipment.

(b) Shrink mixed concrete shall be partially mixed in a stationary

mixer and the mixing completed during transportation in a truck
250 mixer.

(c) Transit mixed concrete shall be completely mixed in a truck

mixer.

The batch ticket for contract dedicated plants and delivery tickets for ready mix
plants shall include the approved CMDP number. The tickets shall be delivered to the
Engineer.

When the concrete temperature is 90°F or above, discharge from non-agitating

260 equipment shall be completed within 30 minutes of mixing the water, cement, and
aggregates. For concrete temperature below 90°F, discharge from non-agitating
equipment shall be completed within 45 minutes of mixing the water, cement, and
aggregates. The concrete temperature shall be measured in accordance with ASTM C
1064 at the point of delivery.

A watertight cover shall be used for a truck agitator and non-agitating equipment.
The concrete shall be incorporated into the paving equipment within 15 minutes of
discharge by the truck mixer, truck agitator, or non-agitating equipment.

392
 501.16

270 Discharge from a truck agitator or a truck mixer shall be completed within 90
minutes of mixing the water, cement, and aggregates.

Concrete shall be uniformly mixed when delivered to the job site. The Engineer
may conduct additional testing to verify uniformity of the mixture. Additional testing
will consist of slump tests taken in accordance with AASHTO T 119 at approximately
the 1/4 and 3/4 points of a load. If the slumps differ by more than 1 in. when the
average slump is 3 in. or less, or by more than 2 in. when the average slump is greater
than 3 in., paving operations may be suspended while the mixing process is jointly
reviewed and problems resolved by the Engineer and the Contractor.
280
Wash water shall not be used as a portion of the mixing water.

When concrete is delivered in transit mixers, additional water to increase the

workability of a load may be added within 45 minutes of initial mixing per the QCP.
Any addition of water shall be noted on the batch ticket and shall not occur as a
continuing operation.

501.15 Weather Limitations

PCCP shall not be placed on frozen subgrade or subbase. PCCP shall be placed
290 when the ambient temperature is 35°F and above, unless procedures outlined in the
QCP for lower temperatures are followed. Prior to attaining opening to traffic strengths
in accordance with 501.23, sufficient means shall be taken to prevent the PCCP from
freezing.

501.16 Placing Concrete

The batches shall be deposited so as to have a uniform mix and require as little
rehandling as possible. The plastic concrete shall not be segregated during placement.
Dowel bars and assemblies shall not be displaced during placement of concrete.

300 Concrete shall be thoroughly consolidated against the faces of all forms or
adjacent concrete surfaces. Hand placed concrete shall be thoroughly consolidated
with the use of a vibrator. Vibrators shall not operate in any one location so as to bring
excessive mortar to the surface, and shall not come in contact with a dowel bar
assembly, subgrade, subbase, or forms.

Concrete shall be placed around manholes or similar structures in accordance with

720.

The Contractor shall be responsible for the protection of the existing joints from
310 the intrusion of fresh concrete mortar, and for any damage to existing pavement caused
by the operation of mechanical equipment. Concrete materials that fall on or are
worked into the joints or surface tines of an existing slab, shall be removed
immediately.

Concrete shall not be mixed, placed, or finished when the natural light is
insufficient, unless an adequate and approved artificial lighting system is operated in
393
 501.17

accordance with the QCP.

The Contractor shall have available at all times sufficient materials for the
320 protection of unhardened PCCP from the effects of rain. Covering material such as
burlap or polyethylene sheeting shall be provided. When rain appears imminent,
paving operations shall stop. All available personnel shall be used to cover the PCCP.

501.17 Blank

501.18 Joints
Joints shall be in accordance with 503.

501.19 Finishing
330 PCCP shall be finished in accordance with 504.

501.20 Curing
PCCP shall be cured with an approved white pigmented liquid membrane forming
compound. Alternative methods of curing may be approved by the Engineer. Curing
shall be in accordance with 504. For formed PCCP, immediately after the forms are
removed, the sides of the PCCP shall be cured.

501.21 Form Removal

Forms may be removed as soon as the PCCP has hardened sufficiently to prevent
340 edge spalling or other damage. Form pullers shall not be supported on the PCCP during
form removal operations.

501.22 Pavement Inspection

The Contractor and the Engineer will conduct an inspection of the new PCCP for
any damage, including freezing or random cracks. The inspection and all necessary
repairs shall be completed prior to opening the pavement to non-construction traffic.
All random, full-depth cracks in the PCCP shall be corrected in accordance with
503.06. All other damage shall be repaired by approved methods.

350 501.23 Opening to Traffic

The Contractor shall be responsible for controlling the opening of the PCCP to
construction and non-construction traffic and include the procedures in the QCP.
Pavement inspection will be completed in accordance with 501.22.

(a) Construction
Construction vehicles or equipment will be allowed on the PCCP after 10 days or
when flexural tests indicate a modulus of rupture of 550 psi or greater. ITM 402 may
be used as an alternate method to determine the flexural strength. All construction
vehicles or equipment that may damage the PCCP shall not be used on the PCCP
360 unless adequate protection is provided. Approved joint cutting saws may be operated
on the PCCP.

394
 501.25

(b) Non-Construction
PCCP may be opened to traffic after 14 days. The PCCP may be opened earlier if
test beams or ITM 402 indicate a modulus of rupture of 550 psi or greater. If adequate
strengths are not met within 14 days, an investigation by the Engineer and the
Contractor will be conducted to determine if the PCCP is deficient. Resolutions for all
deficiencies will be developed at the completion of the investigation. Cracks and joints
shall be sealed in accordance with 503.05 and the PCCP cleaned prior to opening to
370 traffic.

501.24 Pavement Corrugations

Pavement corrugations shall be in accordance with 606.

501.25 Pavement Smoothness

Pavement smoothness will be accepted by means of a profilograph, a 16 ft long
straightedge, or a 10 ft long straightedge as described below.

(a) Profilograph
380 When a pay item for Profilograph, PCCP is included in the contract, the
Contractor shall furnish, calibrate, and operate an approved profilograph in accordance
with ITM 912 for the acceptance of longitudinal smoothness on the mainline traveled
way and ramps, including adjacent acceleration or deceleration lanes, where both of
the following conditions are met:

1. The design speed is greater than 45 mph.

2. The traveled way or ramp lane width is constant and is 0.1

mi in length or longer.
390
The profilogram produced shall become the property of the Department. The
profilograph shall remain the property of the Contractor.

The project area, less paving exceptions and areas exempt from profilograph
operation in accordance with ITM 912, will be divided into individual smoothness
sections measuring 0.1 mi in length for each lane. Partial length smoothness sections
adjacent to project limits, paving exceptions, or areas exempt from profilograph
operation will be considered in accordance with ITM 912.

400 If the posted speed limit for an entire smoothness section is less than or equal to
45 mph, the section will be exempt from profilograph operation and the smoothness
within the section will be accepted by a 16 ft straightedge.

If the posted speed limit is greater than 45 mph for a portion of a smoothness
section and is less than or equal to 45 mph for the remainder, the section smoothness
acceptance will be as follows:

395
 501.25

1. By profilograph for the portion of the section with a posted

speed limit greater than 45 mph.
410
2. By 16 ft straightedge for the portion of the section with a
posted speed limit less than or equal to 45 mph.

At locations where the profilograph is required, all high or low point deviations
which are greater than 0.30 in. shall be corrected. Corrections shall be made in
accordance with 501.25(c).

(b) 16 ft Straightedge and 10 ft Straightedge

The Department will furnish and operate 16 ft and 10 ft straightedges as described
420 below. The 16 ft straightedge is used to accept smoothness along the direction of
mainline traffic and the 10 ft straightedge is used to accept smoothness transverse to
the direction of mainline traffic. This includes longitudinal smoothness on public road
approaches and median crossovers.

For contracts which include the profilograph, PCCP pay item, the 16 ft long
straightedge will be used to accept longitudinal smoothness at the following locations:

1. All mainline traveled way lanes shorter than 0.1 mi.

430 2. All mainline traveled way lanes within smoothness

sections with posted speed limits less than or equal to 45
mph throughout the entire section length.

3. All mainline traveled way lanes at locations exempted from

profilograph operation in accordance with ITM 912.

4. All tapers.

5. All turn lanes, including bi-directional left turn lanes.

440
6. All ramps with design speeds of 45 mph or less.

7. All acceleration and deceleration lanes associated with

ramps with design speeds of 45 mph or less.

8. All shoulders.

For contracts where the profilograph is not used for smoothness acceptance, the
16 ft straightedge will be used to accept longitudinal smoothness at the above locations
450 and on all mainline traveled way lanes and ramps with design speeds greater than 45
mph. Smoothness acceptance on ramp acceleration or deceleration lanes will also be
accepted by the 16 ft straightedge.

396
 501.26

The 10 ft long straightedge shall be used for transverse slopes, approaches, and
crossovers.

As soon as the PCCP has cured sufficiently, the smoothness may be checked. The
Department may direct that the pavement profile be evaluated within 24 h following
placement. When profile testing is consistently outside pavement surface tolerances
460 the paving operation shall be discontinued until an amended QCP is submitted.

(c) Smoothness Correction

Pavement smoothness variations outside specified tolerances shall be corrected
by grinding with a groove type cutter or by replacement. Grinding will not be allowed
until the PCCP is 10 days old or the flexural strength test is 550 psi or greater. The
grinding of the pavement to correct the profile shall be accomplished in either the
longitudinal or the transverse direction. The PCCP texture after grinding shall be
uniform. If the grinding operation reduces the tining grooves to a depth of less than
1/16 in. and the longitudinal length of the removal area exceeds 15 ft, or two or more
470 areas are within 30 ft of each other, the PCCP shall be re-textured in accordance with
504.03.

At locations where the profilograph is used, all areas having a high or low point
deviation in excess of 0.30 in. shall be corrected. In addition, smoothness sections with
a deficient profile index in accordance with 501.28(d) shall be corrected. After the
corrective action is complete, the profilograph shall be operated throughout the entire
affected smoothness section to verify the adequacy of the corrective action.

At locations where the 16 ft straightedge is used, the pavement variations shall be

480 corrected to 1/4 in. or less. At locations where the 10 ft straightedge is used, the
pavement variations shall be corrected to 1/8 in. or less.

501.26 Pavement Thickness

PCCP thickness shall be determined after all corrective grinding. The Contractor
shall obtain cores at the locations determined by the Engineer in accordance with
ITM 802. Cores, 4 in. in diameter, shall be taken in the presence of the Engineer for
the full depth of the PCCP. The Engineer will take immediate possession of the cores.
Cores shall not be taken within 6 in. of the edge of pavement, within 3 in. of
longitudinal joints, within 2 ft of D-1 contraction joints, or within 5 ft of a transverse
490 construction joint. Cores shall be taken and measured in accordance with ITM 404.
All core holes shall be filled with PCC or rapid setting patch material within 24 h of
drilling.

The width of adjudicated PCCP shall be the width of pavement lane in which the
deficiency occurs. Pavement that has been replaced shall be investigated for thickness.

The thickness of the PCCP for each sublot shall be the average lengths of both
cores from the sublot. Calculations shall be to the nearest 0.1 in.

397
 501.27

500 501.27 Tolerance

Plastic unit weight, water/cementitious ratio, flexural beam, and air content tests
will be performed during PCCP operations.

(a) Plastic Unit Weight

Sublots shall not vary by more than ±3.0% from the target unit weight. A stop
paving order will be issued if the plastic unit weight exceeds ±3.0% from the target
plastic unit weight. Paving operations shall not resume until satisfactory changes are
made or an alternate CMDP is used.

510 Calculations for the plastic unit in lbs/cu yd will be made and reported to the
nearest figure in the tenth.

(b) Water to Cementitious Ratio

The weekly water to total cementitious materials ratio shall not vary more than ±
0.030 of the target value or exceed 0.450. A stop paving order will be issued if the test
results exceed these values. Paving operations shall not resume until satisfactory
changes are made or an alternate CMDP is used.

Calculations for water to cementitious ratio will be made and reported to the
520 nearest figure in the third decimal place.

(c) Flexural Strength

Average lot values of 570 psi and above shall be achieved. Price adjustments for
values outside the tolerance limits will be in accordance with 501.28.

Calculations for flexural strength in psi will be made and reported to the nearest
whole unit.

(d) Air Content

530 The average lot air content values shall not vary more than - 0.8% to + 2.4% from
the 6.5% target air content. The range of sublot air content values shall not exceed
2.5%. Price adjustments for values outside the tolerance limits or range will be in
accordance with 501.28.

Calculations for air content percentage will be made and reported to the nearest
figure in the first decimal place.

501.28 Pay Factors

When the PCCP test results for flexural strength, air content, air content range,
540 smoothness, and thickness exceed the allowable tolerances, pay factors will be
determined. The pay factors will be used to calculate a quality assurance adjustment
quantity for the lot.

398
 501.28

The adjustment for flexural strength, air content, air content range, thickness, and
smoothness will be calculated as follows:

q = L x U x (P – 1.00)

where:
q= quality assurance adjustment quantity
L= lot quantity
U= unit price for QC/QA-PCCP, $/sq yd
P= pay factor.
550
For sublot thickness determination:

qT = lT x U x (P – 1.00)

where:
qT = quality assurance adjustment quantity
lT = sublot quantity for thickness
U= unit price for QC/QA-PCCP, $/sq yd
P= pay factor.

The quality assurance adjustment points for smoothness, Qs, will be calculated in
accordance with 501.28(d).

560 The total quality assurance adjustments will be calculated as follows:

QT = Σ (qT1 + qT2 + qT3), and

Q = Σ (qF + qA + qR + QT) + QS

where:
Q= total quality assurance adjustment quantity
QS = quality assurance adjustment for smoothness
qF = lot quality assurance adjustments for flexural strength
QT = lot quality assurance adjustments for thickness
qA = lot quality assurance adjustments for air content
qR = lot quality assurance adjustments for range.

If the Contractor is not required to remove the pavement or take other corrective
actions, quality assurance adjustments of the lot will be assessed as determined by the
570 Office of Materials Management.

(a) Flexural Strength

When test results for flexural strength exceed the allowable tolerance, a pay factor
will be assessed as follows:

399
 501.28

1. Lots
Lot Average Flexural Strength
Psi Pay Factors
570 and above 1.00
565 – 569 0.98
560 – 564 0.96
555 – 559 0.94
550 – 554 0.92
545 – 549 0.89
540 – 544 0.86
535 – 539 0.83
525 – 534 0.78
515 – 524 0.72
514 or less *
* The PCCP will be adjudicated as a failed material in accordance with normal
Department practice as listed in 105.03. The PCCP may be subject to removal
and replacement or left in place with reduced or no payment.

2. Sublots
If a sublot value is less than 500 psi, the PCCP will be adjudicated as a failed
580 material in accordance with normal Department practice as listed in 105.03. For a
sublot completely removed, the sublot test value from the replacement sublot will
replace the original test value.

(b) Air Content

When test results for air content exceed the allowable tolerance or range, a pay
factor will be assessed as follows:

1. Lots
Lot Average Air Content
Percent, % Pay Factors
> 9.8 *
9.7 − 9.8 0.80
9.5 – 9.6 0.90
9.3 – 9.4 0.95
9.0 – 9.2 0.99
5.7 – 8.9 1.00
5.6 0.93
5.5 0.90
5.4 0.85
5.3 0.79
< 5.3 *
* The PCCP will be adjudicated as a failed material in accordance with
normal Department practice as listed in 105.03. The PCCP may be subject
to removal and replacement or left in place with reduced or no payment.

400
 501.28

Lot Range for Air Content

Percent, % Pay Factors
0.0 – 2.5 1.00
2.6 – 3.0 0.99
3.1 – 3.5 0.97
> 3.5 *
* The PCCP will be adjudicated as a failed material in accordance with
normal Department practice as listed in 105.03. The PCCP may be subject
to removal and replacement or left in place with reduced or no payment.
590
2. Sublots
If a sublot value is less than 5.0% or greater than 10.0%, the PCCP will be
adjudicated as a failed material in accordance with normal Department practice in
accordance with 105.03. For a sublot completely removed, the sublot test value from
the replacement sublot will replace the original test value.

(c) Thickness
When test results for pavement thickness do not meet the specified thickness, a
pay factor will be assessed as follows:
600
Sublot Pay Factors for Thickness
Average core depth, ACD
Design depth, DD
ACD minus DD Pay Factor
> +0.5 in. 1.05
+0.3 in. to +0.5 in. 1.02
±0.2 in. 1.00
−0.3 in. to −0.5 in. 0.96
−0.6 in. to −0.7 in. 0.90
−0.8 in. to −1.0 in. 0.80
< −1.00 in. *
* The PCCP will be adjudicated as a failed material in accordance with normal
Department practice as listed in 105.03. The PCCP may be subject to
removal and replacement or left in place with reduced or no payment.

(d) Smoothness
When the pavement smoothness is tested with a profilograph, pavement will be
based on a zero blanking band on the final profile index. A Quality Assurance Pay
Factor, PFs, for smoothness will apply to the planned thickness of the PCCP. The
quality assurance adjustment for each section will include the total area of each
pavement lane measured by the profilograph for 0.1 mi long section represented by
the profile index calculated by the following formula:

610 qs = (PFs – 1.00) x A x U

where:

401
 501.29

qs = quality assurance adjustment for smoothness for one section

PFs = pay factor for smoothness
A= area of the section, sq yd
U= unit price for the material $/sq yd.

For smoothness sections that are less than 0.1 mi in length or require profilograph
operation along both lane edges, the profile index used to obtain the smoothness pay
factor used in the above formula will be determined in accordance with ITM 912.

The quality assurance adjustment for smoothness, Qs, for the contract will be the
total of the quality assurance adjustments for smoothness, qs, on each section by the
620 following formula:

Qs = Σ qs

Regardless of the tabulated value, the maximum pay factor for a smoothness
section where corrective action has been performed will be 1.00.

Pay Factors for Smoothness

(PI0.0) Zero Blanking Band
Design Speed greater than 45 mph
Profile Index, in./0.1 mi. Pay Factor, PFs
over 0.00 to 1.40 1.06
over 1.40 to 1.60 1.05
over 1.60 to 1.80 1.04
over 1.80 to 2.00 1.03
over 2.00 to 2.40 1.02
over 2.40 to 2.80 1.01
over 2.80 to 3.60 1.00
over 3.60 to 3.80 0.96
All pavements with a Profile Index, PI0.0, greater than 3.80 in.
shall be corrected to a profile index less than or equal to 3.80 in.

501.29 Appeals
If the Contractor does not agree with the acceptance test results, a request may be
630 made in writing for additional tests for a sublot or lot. The basis of the appeal shall
include applicable QC test results showing acceptable quality results and shall be
submitted within five calendar days of receipt of the Department’s written results for
that lot. Upon review of the appeal, the Engineer may accept the PCCP in accordance
with 105.03 or accept the appeal.

(a) Flexural Strength

Appeals will not be considered unless QC test results indicate greater than a 50 psi
difference between the Department’s and the Contractor’s tests. Upon approval for the
additional testing, the Contractor shall obtain cores, as directed, in the presence of the
640 Engineer.

402
 501.29

The Engineer will determine the location of the cores within the appealed and
adjacent sublots using the same CMD. The location of the cores will be at the center
of a lane at the acceptance sample location. Cores shall not be taken over dowels or
within 5 ft of a header. Two cores shall be taken in each sublot for the full depth of
pavement and shall be 4 in. in diameter. All core holes shall be filled with portland
cement concrete within 24 h of drilling. If adjacent sublots were produced using
different CMDs, the matter will be adjudicated as a failed material in accordance with
normal Department practice.
650
Each core will be tested for split tensile strength in accordance with ASTM C 496.
The cores will be submerged in lime saturated water prior to testing for a minimum of
40 h.

The average core split tensile strength will be determined for the appealed and
adjacent sublots. Flexural strength will be calculated as follows:

F F 
FD  SD x  A1  A 2 
 2SA1 2SA 2 
660 where:
FD = flexural strength of the appealed sublot
FA1 = flexural strength of the previous adjacent sublot
FA2 = flexural strength of the subsequent adjacent sublot
SD = split tensile strength of the appealed sublot
SA1 = split tensile strength of the previous adjacent sublot
SA2 = split tensile strength of the subsequent adjacent sublot.

(b) Air Content

Appeals will not be considered unless QC test results indicate greater than a 0.5%
difference between the Department’s and the Contractor’s tests. Upon approval for the
additional testing, the Contractor shall obtain core as directed in the presence of the
Engineer.

The Engineer will determine the location of the core within the appealed sublot.
The location of the core will be at the center of a lane at the acceptance sample location.
670 A core shall not be taken over dowels or within 5 ft of a header. One 4 in. diameter
full depth core shall be taken from the pavement for each sublot appealed. All core
holes shall be filled with PCC or rapid setting patch material within 24 h of drilling.

The air content for a sublot will be the hardened concrete air content determined
from the core in accordance with ITM 401. When ACBF aggregates are used, the
hardened concrete air content will be determined in accordance with ASTM C 457.

403
 501.30

501.30 Method of Measurement

QC/QA-PCCP will be measured by the square yard of the thickness specified. The
680 area of QC/QA-PCCP will be the planned width of the pavement multiplied by the
length of the pavement, or as directed in writing. The width of the pavement will be
as shown on the typical cross section of the plans. The length of the pavement will be
measured parallel to the surface of the pavement along the centerline of the roadway
or ramp, excluding paving exceptions as shown on the plans.

Milled pavement corrugations will be measured in accordance with 606.02.

501.31 Basis of Payment

The accepted quantities of QC/QA-PCCP will be paid for at the contract unit price
690 per square yard for the thickness specified, complete in place.

Payment for furnishing, calibrating, and operating the profilograph, and

furnishing profile information will be made at the contract lump sum price for
profilograph, PCCP.

Adjustments to the contract payment with respect to flexural strength, thickness,

air content, range and smoothness will be included in a quality assurance adjustment
pay item in accordance with 109.05.1.

700 Milled pavement corrugations will be paid for in accordance with 606.03.

Payment for pavement thickness determinations will be made at the contract lump
sum price for coring, PCCP. A change order in accordance with 109.05 will be
developed to adjust the cost of coring when the final QC/QA-PCCP quantity differs
from the bid quantity by more than 2,400 sq yd. This adjustment covers the cost of
cores for the adjusted quantity of QC/QA-PCCP. The adjustment, plus or minus, will
be based on the difference in the number of sublots, rounded to the nearest full sublots,
times $100.

710 Payment will be made under:

Pay Item Pay Unit Symbol

Coring, PCCP ............................................................................ LS

Profilograph, PCCP ................................................................... LS
QC/QA-PCCP, __________ in.................................................. SYS
thickness

The cost of trial batch demonstrations shall be included in the cost of PCCP.
720
The price of profilograph, PCCP will be full compensation regardless of how
often the profilograph is used or how many profilograms are produced.

404
 502.03

The cost of corrections for pavement smoothness and re-texturing shall be

included in the cost of QC/QA-PCCP.

The cost of coring and refilling of the pavement holes for appeals shall be included
in the cost of QC/QA-PCCP.

730 Traffic control for appeals shall be supplied with no additional payment.

Removal and replacement of QC/QA-PCCP damaged by freezing shall be with

no additional payment.

SECTION 502 – PORTLAND CEMENT CONCRETE PAVEMENT, PCCP

502.01 Description
This work shall consist of portland cement concrete pavement, PCCP, placed on
a prepared subgrade or subbase in accordance with 105.03.

MATERIALS

502.02 Materials
10 Materials shall be in accordance with the following:

Admixtures .................................................................. 912.03

Coarse Aggregate, Class AP, Size No. 8 ..................... 904
Fine Aggregate, Size No. 23........................................ 904
Fly Ash ........................................................................ 901.02
Ground Granulated Blast Furnace Slag ....................... 901.03
Portland Cement .......................................................... 901.01(b)
Rapid Setting Patch Materials ..................................... 901.07
Water ........................................................................... 913.01
20
502.03 Concrete Mix Design
A concrete mix design submittal, CMDS, shall be in accordance with 502.04. The
CMDS shall be submitted one week prior to production and approved by the Engineer.
The CMDS shall be submitted utilizing the Department provided spreadsheet and shall
include the following:

(a) a list of all ingredients

(b) the source of all materials
(c) the fine to total aggregate ratio
30 (d) the absorption of the aggregates
(e) the SSD bulk specific gravity of the aggregates
(f) the specific gravity of pozzolan
(g) the batch weights
(h) the names of all admixtures

405
 502.04

(i) the admixture dosage rates and the manufacturer’s

recommended range.

Production may commence once the DTE approves the submission as a CMDP.

40 Any of the following changes or adjustments to an existing CMDP shall require a

new CMDS to be submitted to the DTE.

(a) cement source or type

(b) pozzolan source or type
(c) aggregate source or type
(d) admixture source or type
(e) addition or deletion of an admixture
(f) proportioning of the concrete in accordance with 502.04 as
follows:
50
1. cement content or cement reduction
2. pozzolan to cement substitution ratio
3. target water/cementitious ratio
4. proportion of aggregate by weight exceeding ±2%.

A CMDP in accordance with 501.05 or a CMDP in accordance with 502.04 from

a previous contract may be submitted for use upon the approval to the DTE.

502.04 Concrete Mix Criteria

60 The fine aggregate shall be at least 35% but not more than 45% of the total weight
of the aggregate in each cubic yard. Proportions will be based upon saturated surface
dry aggregates.

(a) Portland Cement Concrete

The CMD shall produce workable concrete mixtures, with the minimum amount
of water, and having the following properties.

Portland cement content ................................................. 564 lbs/cu yd

Maximum water/cementitious ratio ................................ 0.450
70 Maximum cement reduction for GGBFS replacement ... 30%
Fly Ash/portland cement substitution ratio ..................... 1.25 by weight
Maximum cement reduction for fly ash replacement ..... 20%
GGBFS/portland cement substitution ratio..................... 1.00 by weight
Slump, formed ................................................................ 2 to 6 in.
Slump, slipformed .......................................................... 1.25 to 3 in.
Air ................................................................................... 5.0% to 8.0%
Minimum flexural strength, third point
loading, with fly ash ................................................ 550 psi at 28 days
Relative yield .................................................................. 0.98 to 1.02
80

406
 502.05

Class C concrete in accordance with 702 using Class AP coarse aggregate may be
substituted in PCCP.

Chemical admixtures type A, type B, type C, type D, type E, and type F may be
allowed with prior written approval.

Fly ash or GGBFS used as an additive, or blended cements may only be

incorporated in the concrete mix between April 1 and October 15 of the same calendar
year. If type IP, type IP-A, type IS or type IS-A cements are to be used, the portland
90 cement content shall be increased to 598 lbs/cu yd. The use of fly ash or GGBFS as an
additive will not be allowed when blended cement types IP, IP-A, IS, or IS-A are used.

(b) High-Early Strength Concrete

The Contractor shall submit, along with the CMDS, all supporting test results for
approval to the DTE prior to placing concrete. Testing shall be conducted by an
American Concrete Institute, ACI, certified concrete field testing technician, grade 1.
The supporting test results shall be signed by the technician and include air content,
slump, relative yield, water cement ratio, and the flexural strengths at 1 day, 2 days,
and 7 days.
100
The CMD shall produce workable concrete mixtures, with the minimum amount
of water, and having the following properties.

Minimum portland cement content (types I, IL or III) ... 564 lbs/cu yd

Maximum fly ash addition .............................................. 10% of cement content
Maximum water/cementitious ratio (types I or IL)......... 0.42
Maximum water/cementitious ratio (type III)................. 0.45
Maximum GGBFS addition............................................ 15% of cement content
Slump, formed ................................................................ 2 to 6 in.
110 Slump, slipformed .......................................................... 1.25 to 3 in.
Air content ...................................................................... 5.0% to 8.0%
Minimum flexural strength, third point loading ............. 550 psi at 2 days
Relative yield .................................................................. 0.98 to 1.02

Fly ash or GGBFS used as an additive may only be incorporated in the concrete
mix between April 1 and October 15 of the same calendar year.

Chemical admixtures type A, type B, type C, type D, type E, and type F may be
allowed with prior written approval.
120
502.05 Job Control
Control of PCCP for air content, slump, or relative yield will be determined on
the basis of tests performed by the Engineer in accordance with 505. Concrete and
necessary labor for sampling shall be furnished as required by the Engineer. Testing
will be in accordance with the Frequency Manual.

407
 502.06

The Engineer will notify the Contractor when test results for air content, slump,
or relative yield are outside the requirements of 502.04. Rounding will be in
accordance with 109.01(a). The Contractor shall adjust the mixture such that it is in
130 accordance with 502.04.

CONSTRUCTION REQUIREMENTS

502.06 General
Equipment for PCCP shall be in accordance with 508.

Aggregate stockpiles shall be located in well drained areas to prevent the soil from
pumping into and contaminating the aggregate that is to be used in PCCP. Stockpiles
shall be built in layers not to exceed 6 ft. Upper layers shall be prevented from spilling
140 onto the lower layers.

Aggregate stockpiles shall be worked to minimize segregation and maintain

uniform moisture content. Aggregates which have become contaminated shall not be
used.

The water measuring device will be checked under actual working conditions or
at any other time deemed necessary. All labor and equipment required for calibrating
and checking shall be furnished.

150 The volume of the batched concrete shall not exceed the manufacturer’s standard
rating for the concrete mixer.

502.07 Preparation of Grade

The subgrade shall be shaped to the required grade and section, free from all ruts,
corrugations, or other irregularities, and uniformly compacted and approved in
accordance with 207. Surfaces on which a mixture is placed shall be free from
objectionable or foreign materials at the time of placement.

502.08 Preparation of Subbase

160 Subbase, if required, shall be placed and shaped to the required grade and section
in accordance with 302. Construction traffic shall not be allowed on the aggregate
drainage layer of the subbase, except where PCCP placement is restricted. Exceptions
shall be submitted for approval.

502.09 Placement
Placement of PCCP shall be by the slipformed or formed methods with equipment
specified in 508.04. The subgrade or subbase shall be uniformly moist at the time of
PCCP placement. Excessively dry subgrade or subbase shall be sprinkled with water.

170 If the slip-form method is used the subgrade or subbase shall firmly support the
paving equipment to construct the specified alignment and grade. The slip-form paver
shall be operated with as nearly a continuous forward movement as possible. If it is

408
 502.10

necessary to stop the forward movement of the paver, the vibratory and tamping
elements shall also be stopped. Edge slump of PCCP shall not exceed 1/4 in.

When the slip-form method is used, the Contractor shall have metal or wood
forms available for protection of the PCCP edges should excessive edge slump occur.

If forms are used they shall be firmly supported by the subbase or subgrade for
180 the entire length of the form at the specified alignment and grade. The alignment of
the forms shall not deviate more than 1/4 in. in the horizontal direction from the
planned PCCP width for tangent sections.

Forms shall be staked into place with a minimum of three pins for each 10 ft
section. A pin shall be placed at each side of every joint. Form sections shall be locked
tightly and be free from play or movement in any direction. No excessive settlement
or springing of forms under the finishing machine will be allowed. Forms shall be
cleaned and oiled prior to the placing of concrete.

190 Forms shall be kept a minimum of 500 ft ahead of concrete placement when
distance allows. Any material displaced during form setting operations shall be
thoroughly compacted. If material under the forms becomes unstable before concrete
is placed, the forms shall be removed, the grade corrected, and the forms reset.

502.10 Concrete Mixing and Transportation

Concrete mixing and transportation shall be completed by central mixed, shrink
mixed, or transit mixed methods. The minimum batch of concrete shall be 2 cu yd.
When the concrete temperature is 90°F or above, discharge from non-agitating
equipment shall be completed within 30 minutes of mixing the water, cement, and
200 aggregates. For concrete temperature below 90°F, discharge from non-agitating
equipment shall be completed within 45 minutes of mixing the water, cement, and
aggregates. The concrete temperature will be measured in accordance with ASTM C
1064 at the point of delivery. Discharge from a truck agitator or a truck mixer shall be
completed within 90 minutes of mixing the water, cement, and aggregates.

Concrete shall be uniformly mixed when delivered to the job site. Batch tickets
for each load of PCC shall indicate the weight of cement, pozzolan, and aggregates,
volume or weight of water, and the type and volume of admixtures. The weight of the
cement shall be within 1% of the CMDP, the saturated surface dry weight of the
210 aggregates shall be within 2% of the CMDP, and the volume or weight of water shall
be within 1% of the required amount.

The Engineer may conduct additional testing to verify uniformity of the mixture.
Additional testing will consist of slump tests taken in accordance with AASHTO
T 119 at approximately the 1/4 and 3/4 points of a load. If the slumps differ by more
than 1 in. when the average slump is 3 in. or less, or by more than 2 in. when the
average slump is greater than 3 in., paving operations may be suspended while the
mixing process is jointly reviewed and problems resolved by the Engineer and the
Contractor.
409
 502.11

220
Wash water shall not be used as a portion of the mixing water.

When concrete is delivered in transit mixers, additional water to increase the

workability of a load may be added within 45 minutes of initial mixing. Any addition
of water shall be noted on the batch ticket and shall not occur as a continuing operation.

Stationary mixers shall be operated at the manufacturer’s recommended drum

speed. Batches shall not exceed the nominal capacity of the mixer. A maximum
overload of 10% may be allowed provided strength and consistency remain
230 satisfactory and no spillage of concrete takes place.

(a) Central Mixed Concrete

Central mixed concrete shall be completely mixed in a stationary mixer and
transported in a truck agitator, truck mixer at agitating speed, or non-agitating
equipment.

Mixing for central mixed concrete shall be no less than 60 s per batch. The mixing
time shall be measured from the time all cement and aggregates are in the drum. The
batch shall be so discharged into the mixer that some of the water enters in advance of
240 the cement and aggregates. All required water shall be in the drum by the end of the
first quarter of the specified mixing time.

If a truck mixer or truck agitator is used for transportation, the concrete shall be
agitated at the agitation speed designated by the manufacturer.

(b) Shrink Mixed Concrete

Shrink mixed concrete shall be partially mixed in a stationary mixer and the
mixing completed at the plant in a truck mixer.

250 The time in a stationary mixer for shrink mixed concrete may be reduced to
approximately 30 s. Mixing shall then be completed in a truck mixer at the plant by 50
to 100 revolutions of the drum at the mixing speed designated by the manufacturer.
Agitation during transportation shall be at the agitation speed designated by the
manufacturer.

(c) Transit Mixed Concrete

Transit mixed concrete shall be completely mixed and transported in a truck
mixer.

260 Mixing for a truck mixer loaded to rated capacity shall be 70 to 100 revolutions
of the drum at the mixing speed, but not less than the number of revolutions
recommended by the manufacturer. Discharge shall be completed prior to 300
revolutions of the drum.

502.11 Weather Limitations

PCCP shall not be placed on a frozen subgrade or subbase. PCCP operations shall
410
 502.12

not begin until the ambient temperature is 35°F and rising. PCCP operations shall be
discontinued when the ambient temperature is descending and is 40°F or below. PCCP
operations may occur outside these temperatures when authorized in writing.
270 Regardless of placement temperature, sufficient means shall be taken to prevent the
PCCP from freezing prior to attaining opening to traffic strengths in accordance with
502.18. Any PCCP damaged by freezing shall be removed and replaced.

When concreting is authorized during cold weather, the aggregates may be heated
by either steam or dry heat prior to being placed in the mixer. The apparatus used shall
heat the mass uniformly and prevent the occurrence of overheated areas which might
damage the materials. Unless authorized, the temperature of the mixed concrete shall
not be less than 50°F and not more than 80°F at the time of placement.

280 When the water or the aggregates are heated, they shall be a minimum of 70°F or
a maximum of 150°F. When either aggregates or water are heated to above 100°F,
they shall be combined in the mixer before the cement is added.

502.12 Placing Concrete

The batches shall be deposited so as to have a uniform mix and require as little
rehandling as possible. The plastic concrete shall not be segregated during placement.
Rakes shall not be used to handle plastic concrete. Dowel bars and assemblies shall
not be displaced during placement of concrete. Plastic concrete shall not be
contaminated with earth or other foreign matter.
290
Concrete shall be thoroughly consolidated against the faces of all forms or
adjacent concrete surfaces. Hand placed concrete shall be thoroughly consolidated
with the use of a vibrator. Vibrators shall not operate in any one location so as to bring
excessive mortar to the surface, and shall not come in contact with a dowel bar
assembly, subgrade, subbase, or forms.

Concrete shall be placed around manholes or similar structures in accordance with

720.

300 The Contractor shall be responsible for the protection of the existing joints from
the intrusion of fresh concrete mortar, and for all damage to existing pavement caused
by the operation of mechanical equipment. Concrete materials that fall on or are
worked into the joints or surface tines of an existing slab, shall be removed
immediately.

Concrete shall not be mixed, placed, or finished when the natural light is
insufficient, unless an adequate and approved artificial lighting system is operated.

The Contractor shall have available at all times sufficient materials for the
310 protection of unhardened PCCP from the effects of rain. Covering material such as
burlap or polyethylene sheeting shall be provided. When rain appears imminent,
paving operations shall stop. All available personnel shall be used to cover the PCCP.

411
 502.13

502.13 Joints
Joints shall be in accordance with 503.

502.14 Finishing
PCCP shall be finished in accordance with 504.

320 502.15 Curing

PCCP shall be cured with an approved white pigmented liquid membrane forming
compound. Alternative methods of curing may be approved by the Engineer. Curing
shall be in accordance with 504. For formed PCCP, immediately after the forms are
removed, the sides of the PCCP shall be cured.

502.16 Form Removal

Forms may be removed as soon as the PCCP has hardened sufficiently to prevent
edge spalling or other damage. Form pullers shall not be supported on the PCCP during
form removal operations.
330
502.17 Pavement Inspection
The Contractor and the Engineer will conduct an inspection of the new PCCP for
any damage, including freezing or random cracks. The inspection and all necessary
repairs shall be completed prior to opening the pavement to non-construction traffic.
All random, full-depth cracks in the PCCP shall be corrected in accordance with
503.06. All other damages shall be repaired by approved methods.

502.18 Opening to Traffic

When fly ash, GGBFS, or cement type IP, type IS, type IP-A, or type IS-A is
340 incorporated into the PCCP, traffic shall not be allowed on the PCCP until the test
beams indicate a modulus of rupture of 550 psi or greater. Opening to traffic of PCCP
not containing the above additives shall be based on the following.

(a) Construction
Construction vehicles or equipment may be allowed on the PCCP after 10 days or
when the test beams indicate a modulus of rupture of 550 psi or greater. Any
construction vehicle or equipment that may damage the PCCP shall not be used on the
PCCP unless adequate protection is provided. Approved joint cutting saws may be
operated on the PCCP as determined by the Contractor.
350
(b) Non-Construction
PCCP may be opened to traffic after 14 days or when test beams indicate a
modulus of rupture of 550 psi or greater. Prior to opening to traffic, cracks and joints
shall be sealed in accordance with 503.05 and the PCCP shall be cleaned.

502.19 Pavement Corrugations

Pavement corrugations shall be in accordance with 606.

412
 502.21

502.20 Pavement Smoothness

360 Pavement smoothness will be in accordance with 501.25 except profilograph
requirements will not apply.

502.21 Pavement Thickness

PCCP thickness shall be determined after all corrective grinding. The Contractor
shall obtain cores at the locations determined by the Engineer in accordance with
ITM 802. Cores, 4 in. in diameter, shall be taken in the presence of the Engineer for
the full depth of the PCCP. The Engineer will take immediate possession of the cores.
Cores shall not be taken within 2 ft of the edge of PCCP, over dowels, or within 5 ft
of a transverse construction joint. Cores shall be taken and measured in accordance
370 with ITM 404. All core holes shall be filled with PCC or rapid setting patch material
within 24 h of drilling.

If a core measurement reveals that the pavement is more than 1/2 in. deficient in
thickness, additional cores shall be drilled at 20 ft intervals on each side of the original
core. These additional cores shall be on a line which passes through the original core
and parallel to the centerline of the pavement. The drilling shall continue in both
directions at 20 ft intervals until two successive cores indicate a thickness deficiency
of 1/2 in. or less, or where cores can no longer be drilled in the new PCCP.

380 If a core indicates a thickness deficiency of more than 1 in. and two cores drilled
adjacent at 20 ft intervals indicate a thickness deficiency of not more than 1 in.,
additional cores shall be drilled at 5 ft intervals on each side of the initial core. The
drilling shall continue in both directions at 20 ft intervals until two successive cores
indicate a thickness deficiency of 1/2 in. or less, or where cores can no longer be drilled
in the new PCCP.

When a single core indicates a thickness deficiency of more than 1 in., or if two
or more adjacent cores indicate a thickness deficiency of more than 1/2 in., the
investigation will be expanded to include adjoining PCCP. The additional cores shall
390 be taken from the adjoining traffic lanes or shoulders at the same station at which the
first core or cores indicated the deficiency, whether the lane was paved at the same
time or not.

The width of adjudicated PCCP shall be the width of pavement lane in which the
deficiency occurs. Pavement that has been replaced shall be investigated for thickness.

(a) Sections
The quantity of PCCP for each pay item will be defined as a section. The section
will be divided into subsections of 1,200 sq yd. Sections less than 1,200 sq yd shall
400 not be cored. A minimum of one core shall be drilled at a random location within each
subsection. A section greater than or equal to 1,200 sq yd shall have a minimum of
four cores drilled. Partial subsections shall not be cored unless otherwise directed.
Widening of 3 ft or less shall not be cored unless otherwise directed. Formed drives
shall not be cored unless otherwise directed. Verification of the required pavement

413
 502.21

depth on formed drives shall be checked in the presence of the Engineer prior to
pouring, by making stringline measurements every 10 ft across the width of the drive.
Any location deficient in thickness by 1/4 in. or more shall be corrected prior to placing
PCCP.

410 (b) Average PCCP Thickness

The thickness of the PCCP for each section shall be the average lengths of all
cores from the section. However, no cores shall be included from areas for which no
payment will be made. Where PCCP has been removed and replaced the initial core
lengths will be discarded and the core lengths of the replaced PCCP will be substituted.
Any core measurements exceeding the specified PCCP thickness by more than 1/2 in.
will be recorded as the specified PCCP thickness plus 1/2 in. Calculations shall be to
the nearest 0.1 in.

(c) PCCP Adjusted Payment

420 If the average PCCP thickness is equal to or greater than the specified thickness,
no adjustments will be made. If an average PCCP thickness is less than the specified
thickness by up to 1/2 in., payment for that section will be adjusted in accordance with
the following:

QT = Q x U x (1 – M2/S2)

where:
QT = quality assurance assessment for thickness
Q = placed quantity of the PCCP section
M = average PCCP thickness of the section
S = specified PCCP thickness of the section
U = unit bid price.

(d) PCCP Non-Payment

430 Where two adjacent cores indicate a thickness deficiency of more than 1/2 in., no
payment will be made unless the PCCP is removed and replaced. Payment for PCCP
with non-adjacent cores indicating a thickness deficiency of more than 1/2 in. will be
in accordance with 502.21(c).

The limits of non-payment shall extend from deficient core to the transverse joint
location nearest the first additional core indicating a thickness deficiency of less than
1/2 in.

(e) PCCP Removal

440 Where two adjacent cores indicate a thickness deficiency of more than 1 in. the
PCCP shall be removed and replaced. Non-adjacent cores indicating a thickness
deficiency of more than 1 in. do not require removal and replacement.

The limits of removal and replacement shall extend from the deficient core to the
transverse joint location nearest the first additional core indicating a thickness
deficiency of less than 1/2 in.
414
 502.23

502.22 Method of Measurement

PCCP will be measured by the square yard of the thickness specified. The area of
450 PCCP will be the planned width of the pavement multiplied by the length of the
pavement, or as directed in writing. The width of the pavement will be as shown on
the typical cross section of the plans. The length of the pavement will be measured
parallel to the surface of the pavement along the centerline of the roadway or ramp,
excluding paving exceptions as shown on the plans.

Milled pavement corrugations will be measured in accordance with 606.02.

502.23 Basis of Payment

The accepted quantities of PCCP will be paid for at the contract unit price per
460 square yard for the thickness specified, complete in place.

Milled pavement corrugations will be paid for in accordance with 606.03.

Payment will be made for portland cement content of more than 564 lbs/cu yd
when ordered in writing. Additional payment for the quantity used will be at the net
unit price of portland cement as shown by certified vouchers for the quantity used in
accordance with 109.05.

The quality assurance adjustment quantity for thickness will be determined in

470 accordance with 502.21(c).

An adjustment to the contract payment with respect to thickness will be made

utilizing the quality assurance adjustment pay item. The unit price for this pay item
will be $1.00. The quantity is the total calculated in accordance with 502.21(c). A
change order developed in accordance with 109.05 will be prepared to reflect contract
adjustments.

Payment for pavement thickness determinations will be made at the contract lump
sum price for coring, PCCP in accordance with 501.31. A change order in accordance
480 with 109.05 will be developed to adjust the cost of PCCP when the final PCCP quantity
differs from the bid quantity by more than 2,400 sq yd. This adjustment covers the
cost of cores for the adjusted quantity of PCCP. The adjustment, plus or minus, will
be based on the difference in the number of subsections, rounded to the nearest full
subsection, times $100.

Payment will be made under:

Pay Item Pay Unit Symbol

490 PCCP, __________, in. ............................................................. SYS

thickness
Quality Assurance Adjustment .................................................. DOL

415
 503.01

No additional payment will be made for PCCP which has an average thickness
above that shown on the plans.

The cost of trial batch demonstrations shall be included in the cost of PCCP.

The cost of corrections for pavement smoothness and re-texturing shall be

500 included in the cost of PCCP.

Removal and replacement of PCCP found to be deficient or damaged by freezing

shall be completed with no additional payment.

The cost of coring and refilling of the pavement holes for appeals shall be included
in the cost of PCCP.

SECTION 503 – PCCP JOINTS

503.01 Description
This work shall consist of the construction of joints in PCC pavements, placing
dowel bar assemblies and joint sealing operations in accordance with 105.03.

MATERIALS

503.02 Materials
10 Materials shall be in accordance with the following:

Chemical Anchor System ............................................ 901.05

Dowel Bars .................................................................. 910.01(b)10
Epoxy Coated Reinforcing Bars .................................. 910.01(b)9
Joint Filler ................................................................... 906.01
Joint Materials ............................................................. 906
PCC Sealer/Healers ..................................................... 901.06
Reinforcing Bars.......................................................... 910.01

20 Tie bars shall be epoxy coated reinforcing bars.

Bent tie bars shall be deformed billet steel in accordance with 910.01 and ASTM
A 615, grade 40.

The epoxy coating on the bent and straight tie bars shall be protected in
accordance with 703.04.

CONSTRUCTION REQUIREMENTS

30 503.03 Joints
Joints shall be constructed in accordance with the type and dimensions and at the
416
 503.03

locations shown on the plans or as directed. All joints shall be perpendicular to the
subgrade.

Longitudinal joints shall be parallel to the centerline. The longitudinal joint shall
not deviate from the true line shown on the plans by more than 1/4 in. Transverse joints
shall be at right angles to the centerline and be continuous for the full width of the
pavement.

40 All joints shall be cut to the required dimensions and sealed. All sawed joints shall
be made by sawing equipment in accordance with 508.07 and shall be in accordance
with the following.

(a) Type D-1 Contraction Joint

Type D-1 contraction joints shall be created by sawing slots in the pavement
unless alternative methods are approved. The sawed contraction joint spacing shall be
as shown on the plans or as directed, but shall not exceed 18 ft.

Sawed contraction joints shall be cut in two operations. The initial saw cut shall
50 commence as soon as the concrete has hardened sufficiently to enable sawing without
raveling, usually 2 to 12 h after placement. All joints shall be saw cut through the
edges of the pavement to the required depth before uncontrolled shrinkage cracking
takes place. The sawing operations shall be carried on during day and night, regardless
of weather conditions. The sawing of a joint shall be omitted if a crack occurs at or
near the joint location prior to the time of sawing. Sawing shall be discontinued if a
crack develops ahead of the saw. Formed contraction joints may be used where
conditions make sawing impractical.

The second saw cut shall be made after the concrete has sufficiently cured, but
60 before opening the pavement to non-construction traffic. Slurry or saw residue
remaining in the slot shall be immediately flushed with water. Construction traffic
shall not be allowed on the PCCP after the second saw cut until the joint is sealed.

The sawed slot shall be cleaned to remove all foreign matter from the entire depth
of cut. Joint sealing shall be in accordance with 503.05.

(b) Longitudinal Joint

Longitudinal joints shall be created by sawing slots in the pavement unless
alternative methods are approved. The longitudinal joint spacing shall be as shown on
70 the plans or as directed, but shall not exceed 16 ft. Tie bars shall be placed by
mechanical equipment in accordance with 508.04(a), or rigidly secured in place.

Longitudinal joints shall be cut to the depth, width, and line shown on the plans.
The longitudinal joint slots shall be sawed concurrently with the initial D-1 contraction
joint slots. If random cracking occurs ahead of sawing, the sawing operations shall be
discontinued in that area. A second saw cut shall be made when construction traffic
uses the PCCP prior to sealing. Joint sealing shall be in accordance with 503.05.

417
 503.03

Longitudinal joints may be replaced with longitudinal construction joints when

80 approved by the Engineer.

(c) Transverse Construction Joints

Transverse construction joints shall be constructed when there is an interruption
of more than 30 minutes in the PCCP placement operations. A transverse construction
joint located at a D-1 contraction joint shall be in accordance with 503.03(a), except
the initial saw cut shall be omitted. All other transverse construction joints shall be
located at least 6 ft from an adjacent D-1 contraction joint.

Tie bars for transverse construction joints may be placed in the plastic or hardened
90 concrete. A header board with openings for tie bars shall be used when placing tie bars
in plastic concrete. The header board shall be rigid and accurately set to grade. Tie
bars placed in hardened concrete shall be retrofitted in accordance with 503.03(g).

(d) Longitudinal Construction Joint

The longitudinal construction joint spacing shall be as shown on the plans or as
approved. Tie bars shall be placed by mechanical equipment in accordance with
508.04(a) or other approved methods. Longitudinal construction joint saw cuts may
be made as soon as the PCCP has sufficiently hardened.

100 Longitudinal construction joints shall be cut to the depth, width, and line shown
on the plans. Construction traffic shall not be allowed on the PCCP after the saw cuts
are made until the joints are sealed. Joint sealing shall be in accordance with 503.05.

Bent tie bar spacing shall be adjusted to prevent interference with the D-1
contraction joints. Bent tie bars shall not be omitted. Bent tie bars shall be replaced
with retrofitted tie bars when more than one tie bar breaks within 30 ft during
straightening.

The longitudinal construction joint for shoulder widths less than 6 ft may be
110 replaced by a longitudinal joint or be eliminated by extending the type D-1 contraction
joint through the shoulder. If either option is used, the mainline and shoulder shall be
constructed at the same time.

(e) Terminal Joints

Terminal joints shall consist of a sleeper slab, polyethylene bond breaker, and
HMA mixtures. The polyethylene bond breaker shall be an approved polyethylene
sheeting having a thickness of 6 mils or greater. HMA mixtures shall consist of type
B surface and intermediate mixtures in accordance with 402.04. A MAF in accordance
with 402.05 will not apply. Aggregate requirements of 904.03(d) do not apply. The
120 portion of the sleeper slab on which the polyethylene bond breaker is to be placed shall
be finished to a smooth trowel finish.

418
 503.04

(f) Expansion Joints

Expansion joints shall be constructed at the locations shown on the plans and shall
consist of joint filler.

The joint filler shall be shaped to the subgrade, parallel to the surface, and be full
width of the pavement. Damaged or repaired joint filler shall not be used.

130 The joint filler shall be held in a position which is normal to the surface. Finished
joints shall deviate no more than 1/4 in. in the horizontal alignment from a straight
line. There shall be no offsets between adjacent sections when the joint filler consists
of more than one section. No plugs of concrete shall be within the expansion joint.

(g) Retrofitted Tie Bars

Retrofitted tie bars shall be secured at right angles to the pavement with a chemical
anchor system in accordance with the manufacturer’s recommendation. The chemical
anchor system shall be injected to the back of the hole to eliminate air pockets prior to
inserting the bar. The quantity of material injected shall be sufficient to disperse the
140 material along the entire length of the bar and completely fill the annular space. After
the anchor system has been injected, the bar shall be fully inserted using a back-and-
forth twisting motion, leaving the proper length exposed. If it is necessary to use a
hammer to seat the bar, the exposed end shall be protected with a wood block.

When a capsule type chemical anchor system is used, the capsules shall be
conditioned as per the manufacturer’s installation instructions, if required, and placed
at the back of the hole. The number of capsules shall be sufficient to disperse the
material along the entire length of the bar and completely fill the annular space. After
the capsules have been placed the bar shall be fully inserted in accordance with the
150 manufacturer’s installation instructions.

503.04 Dowel Bar Assemblies

The dowel bar assemblies shall be in accordance with the following:

(a) The dowel bars shall be supported by an approved welded wire

assembly which shall hold the bars rigid during placement of
the PCCP. The wire for the welded assembly shall be in
accordance with ASTM A 82. The maximum angle of deviation
shall not exceed 1 in 48 units during placement.
160
(b) The assembly shall have two continuous parallel spacer bars
and two continuous parallel bearing members of size W 7.5 or
greater. One spacer bar shall be located at or near each end of
the dowel. Alternate ends of dowels shall be welded to a spacer
bar so that the dowels remain parallel to each other and enable
sliding movement in the joint. The free ends of each dowel shall
be retained securely in place by means of wire loops.

419
 503.05

(c) Suitable struts or tie wires shall be provided to hold the

170 assembly in correct position during installation. The tie wires
shall be size W 7.5 or smaller and there shall be a maximum of
five tie wires for each dowel bar assembly.

(d) The assembly shall have an upright support welded to the spacer
bar and a continuous bearing member at the end of each dowel.

(e) If the upright support consists of a single vertical wire, the

support shall be size W 7.5 or greater wire. Otherwise, the
support shall be 1/4 in. or greater in diameter.
180
(f) At the time of placement, dowel bars shall be free of dirt, loose
rust, or scale. If the Engineer suspects the epoxy coating has
been damaged by exposure to ultraviolet light, a sample will be
obtained and will be tested in accordance with 910.01(b)9.

(g) The dowel bar assembly shall be held securely in place during
placing, consolidating, and finishing the PCCP by means of
metal pins. Pins used on granular subbase shall penetrate a
minimum of 12 in. below the dowel bar assembly. Pins shall be
190 size W 7.5 or greater wire and shall be provided with a hook or
arm welded to the pin so that it shall secure the assembly in
place. A minimum of eight pins shall be used for each 10, 11,
or 12 ft section of assembly. A minimum of 10 pins shall be
used for assembly sections greater than 12 ft and less than or
equal to 16 ft.

(h) Dowel bars shall be coated with a bond breaking material and
the coating shall be evident at the time of placement of the
PCCP.
200
(i) Dowel bars shall be placed 6 in. from the edges of the pavement
and spaced at 1 ft on center across the joint.

503.05 Sealing Cracks and Joints

Cracks and joints in the PCCP shall be cleaned and sealed in accordance with the
sealant manufacturer’s recommendations. Water blasting shall not be applied under
pressure which may damage the concrete. All cracks and joints shall be sealed prior to
discontinuing work for the winter.

210 When preformed elastomeric joint seals are used, the material shall be installed in
one continuous piece by means of an approved machine. The seal shall not be stretched
more than 5% while being placed and show no twisting, rollover, folding, cutting, or
excess lubricant-adhesive on the top of the seal. Elastomeric joint seal may be installed
in two separate pieces for phased construction with the splice point occurring at the

420
 503.08

highest point of the joint. The splicing method used shall be in accordance with the
seal manufacturer’s recommendations.

503.06 Random Crack Remediation

Random cracks shall be corrected.
220
(a) Transverse
Random transverse cracks shall be corrected by PCCP replacement. The
replacement shall be full lane width and a minimum of 6 ft in length. Transverse PCCP
removal limits shall be perpendicular to the centerline and shall include the entire
random crack. Load transfer for the replacement PCCP shall be obtained by using
dowel bars and retrofit epoxy coated tie bars. PCCP replacement areas shall have
dowel bars which match contraction joints in any adjacent panels. All remaining
panels shall be a minimum of 6 ft in length.

230 (b) Longitudinal

Random longitudinal and skewed cracks within 18 in. of a longitudinal joint shall
be routed and sealed. All longitudinal saw cuts in areas of random cracks shall be
sealed with a sealer/healer or a bonding agent in accordance with ASTM C 881, grade
1.

Random longitudinal and skewed cracks outside 18 in. of a longitudinal joint shall
be corrected by PCCP replacement in accordance with 503.06(a).

503.07 Method of Measurement

240 D-1 contraction joints and terminal joints will be measured by the linear foot as
measured along the centerline of the joint.

Retrofitted tie bars will be measured by the number of units installed.

503.08 Basis of Payment

D-1 contraction joints and terminal joints will be paid for at the contract unit price
per linear foot, complete in place.

Retrofitted tie bars will be paid for at the contract unit price per each, complete in
250 place.

Payment will be made under:

Pay Item Pay Unit Symbol

D-1 Contraction Joint ................................................................ LFT

Retrofitted Tie Bars ................................................................... EACH
Terminal Joint............................................................................ LFT

421
 504.01

260 The cost of furnishing and placing all materials, not specified as a pay item, shall
be included in the cost of PCCP.

The cost of dowels, dowel bar assemblies, backer rod, joint sealants and all
necessary incidentals shall be included in the cost of D-1 contraction joints.

The cost of the sleeper slab, reinforcing bars, bond breaker, and HMA mixtures
shall be included in the cost of the terminal joint.

The cost of retrofitted tie bars or PCCP replacement used to repair damaged PCCP
270 due to fault or negligence, remediation of random cracking, or the replacement of
broken deformed bars shall be included in the cost of the PCCP.

SECTION 504 – PCCP FINISHING AND CURING

504.01 Description
All PCCP surfaces shall be finished and cured in accordance with the following.

MATERIALS

504.02 Materials
The materials shall be in accordance with the following:
10
Curing Materials .......................................................... 912.01

CONSTRUCTION REQUIREMENTS

504.03 Finishing
PCCP shall be finished with equipment in accordance with 508.04. The operations
shall be controlled so that an excess of mortar and water is not worked to the top. Long
handled floats may be used to smooth and fill in open textured areas in the PCCP.

20 Hand methods of finishing may be used when finishing equipment breaks down
or in tight working areas where field conditions limit the use of mechanical devices.
Hand placed concrete shall be further finished by means of a longitudinal float or an
approved transverse smoothing float in accordance with 508.08(a).

The edges of formed PCCP adjacent to HMA or compacted aggregate shall be

tooled. A continuous radius with a uniform smooth dense mortar finish shall be
produced.

The PCCP surface shall be textured with a double thickness burlap drag or a
30 minimum 4 ft wide turf drag.

422
 504.04

The textured surface of PCCP shall be tined, unless otherwise specified. Tining
shall consist of transverse grooves that are between 3/32 and 1/8 in. in width, between
1/8 and 3/16 in. in depth, and be spaced as follows: 5/8 in., 1 in., 7/8 in., 5/8 in., 1 1/4
in., 3/4 in., 1 in., 1 in., 1 in., 1 in., 3/4 in., 7/8 in., 1 3/4 in., 7/8 in., 3/8 in., 1 in., 1 in.,
1 1/4 in., 1 1/2 in., 7/8 in., 3/4 in., 7/8 in., 1 in., 7/8 in., 1 in. The grooving pattern shall
be repeated across the pavement. The grooves shall be formed in the plastic concrete
without tearing the surface and without bringing pieces of the coarse aggregate to the
top of the surface.
40
Texturing and curing operations may be performed by a single machine subject
to satisfactory performance.

Areas of PCCP which are not finished in accordance with these requirements shall
be corrected by retexturing.

Retexturing shall consist of cutting longitudinal or transverse grooves in the PCCP

surface by means of saw blades or other approved devices. The grooves shall be spaced
3/4 in. center to center and be 1/8 in. in width and depth. Alternative patterns may be
50 used, subject to approval. The PCCP surface, after cutting, shall not be polished.

504.04 Curing
Curing materials shall be applied to exposed surfaces and sides of newly placed
PCCP within 30 minutes after the finishing operations have been completed, or as soon
as marring of the concrete does not occur. Paving operations shall be immediately
suspended if sufficient curing materials are not available on site.

When forms are used, the edges of the pavement shall be cured immediately upon
removal of the forms. The edge shall be covered with curing materials equal to the
60 material used on the surface or banked with soil 12 in. wide or greater.

When conditions arise which prevent immediate application of curing materials,

the paving operation shall be suspended and the PCCP shall be kept wet with a fine
spray of water. The fine spray of water shall continue until application of curing
materials resumes.

Curing shall be continuous for 96 h unless a longer period is ordered and shall be
in accordance with the following.

70 (a) Liquid Membrane Forming Compounds

Immediately after surface water has disappeared, a uniform coating of the liquid
membrane forming curing compound shall be applied.

The compound shall be applied in a continuous uniform film at a rate not less than
1 gal./150 sq ft. It shall be applied in two applications. The curing compound may be
warmed in a water bath during cold weather at a temperature not exceeding 100°F.
Thinning with solvents will not be allowed. Non-uniform film rates will result in the
discontinuance of that application method.
423
 504.05

80 A new coat of curing compound shall be applied to areas damaged by rain or other
means during the curing period. The recoating shall be applied as soon as possible and
at a rate equal to that specified for the original coat.

(b) Double Burlap

The PCCP shall be covered with wet burlap, laid directly on the surface, and kept
wet with a fine spray of water. This initial burlap shall receive an additional covering
of wet burlap no later than 9:00 a.m. the day following its placement. The two layers
of burlap shall be kept wet for the required curing period.

90 (c) Waterproof Covers

The PCCP shall be kept wet with a fogged spray of water, or be covered with wet
burlap laid directly on the surface and kept wet with a fine spray of water. The PCCP
shall receive a cover no later than 9:00 a.m. the day following its placement. If white
burlap polyethylene sheets are used, the burlap side shall be wet or the surface of the
concrete thoroughly wetted just prior to the blanket being placed.

The covers shall be weighted down on each edge and shall be as wide as the full
width of the pavement being cured. Adjoining covers shall overlap 12 in. or more and
the laps held securely in place.
100
Covers may be reused provided they are airtight. All torn covers shall be repaired
with patches. All units not in accordance with these requirements shall not be used.

The covers shall remain in place for the required curing period.

(d) Straw
The PCCP shall be covered with wet burlap, laid directly on the surface, that is
kept wet with a fine spray of water. The burlap shall be removed by 9:00 a.m. the day
following its placement and the surface immediately covered with straw no less than
110 3 in. deep. The straw shall be thoroughly saturated immediately after being placed,
and kept wet for the required curing period. After the cure period, the straw shall be
removed from the pavement and disposed of properly.

Straw curing shall not be used in cities or towns unless written permission is
obtained.

504.05 Method of Measurement

Finishing and curing operations will not be measured for payment.

120 504.06 Basis of Payment

The cost of finishing and furnishing and placing curing materials shall be included
in the cost of the PCCP.

424
 505.01

SECTION 505 – TESTS AND PROCEDURES

505.01 Test Methods and Procedures

The following test methods and procedures shall be used with exceptions as listed
below.

Air Test ........................................................................ AASHTO T 152* or

ASTM C 173**
Flexural Strength ......................................................... AASHTO T 97*
10 Making and Curing Specimens.................................... AASHTO T 23*
Sampling Fresh Concrete ............................................ AASHTO R 60
Sieve Analysis of Aggregates ...................................... AASHTO T 27
Slump .......................................................................... AASHTO T 119
Specific Gravity and
Absorption, Coarse Aggregate.............................. AASHTO T 85
Specific Gravity and
Absorption, Fine Aggregate.................................. AASHTO T 84
Thickness of PCCP ...................................................... ITM 404
Unit Weight and Relative Yield .................................. AASHTO T 121*
20 Water-Cementitious Ratio ........................................... ITM 403

* The concrete shall be consolidated by the method of internal vibration

in beam forms or in an aluminum measure or air meter bowl, as
appropriate for the test.

** If slag aggregate is used, the method and procedure for the test shall be
in accordance with ASTM C 173.

The chosen method of concrete consolidation shall be the same for all concrete
30 test specimens.

(a) Exceptions to AASHTO T 23

The exceptions to AASHTO T 23 for making and curing specimens in the field
shall be as follows:

1. Non-watertight beam forms, molds, will be allowed.

2. After 24 h the molded specimens are taken to the storage
location and removed from the molds.
3. Field stored beams will not require 24 ±4 h lime water soak
40 prior to time of testing.

(b) Exceptions to AASHTO T 97

The exceptions to AASHTO T 97 for conducting a flexural test on concrete beams
shall be as follows:

1. The beam size shall be measured to the nearest 1/16 in.

425
 506.01

2. The test result shall be discarded when the break occurs

outside the middle 1/3 of the beam.

50 (c) Exceptions to AASHTO T 121

The exceptions to AASHTO T 121 for determining the unit weight of concrete
shall be as follows:

1. Weight shall be determined to the nearest 0.01 lb.

(d) Exceptions to AASHTO R 60

The exceptions to AASHTO R 60 for sampling fresh concrete shall be as follows:

1. Where job conditions dictate, the entire sample may be

60 obtained from one portion of the load.

(e) Exceptions to AASHTO T 152

The exceptions to AASHTO T 152 for determining the air content in portland
cement concrete shall be as follows:

1. The sample for aggregate correction factor shall be

prepared in accordance with 6.0. The aggregate correction
factor shall be determined in accordance with 8.3 and read
directly from the meter.
70 2. The aggregate correction factor test shall be re-run for
confirmation if the test results for gravel is greater than
0.4% or if the test results for crushed stone is greater than
0.6%.
3. For aggregates indicating a high correction factor, the
aggregate may be washed from the concrete sample and
used to determine the correction factor.

SECTION 506 – PCCP PATCHING

506.01 Description
This work shall consist of the removal and replacement of PCCP in accordance
with 105.03.

MATERIALS

506.02 Materials
10 Materials shall be in accordance with the following:

Admixtures .................................................................. 912.03

Calcium Chloride, Type L ........................................... 913.02
Chemical Anchor System ............................................ 901.05

426
 506.03

Coarse Aggregate, Class A or Higher, Size No. 11 ..... 904

Coarse Aggregate, Class AP, Size No. 8 ..................... 904
Dowel Bars .................................................................. 910.01(b)10
Fine Aggregate, Size No. 23........................................ 904
Portland Cement .......................................................... 901.01(b)
20 Water ........................................................................... 913.01

Coarse aggregate for partial depth patching shall be size No. 11. Coarse aggregate
for full depth patching shall be size No. 8. Coarse aggregate for patching shall be stone
or gravel.

A bonding agent shall be selected from the Department’s list of approved

Non-Vapor Barrier Type Bonding Agents.

Dowel bars and dowel bar assemblies shall be in accordance with 503.04.
30
506.03 Concrete Mix Design
A concrete mix design submittal, CMDS, shall be in accordance with 506.04. The
CMDS shall be submitted to and approved by the DTE. The CMDS shall be submitted
a minimum of seven calendar days prior to the trial batch utilizing the Department
provided spreadsheet and shall include the following:

(a) a list of all ingredients

(b) the source of all materials
(c) the fine to total aggregate ratio
40 (d) the absorption of the aggregates
(e) the SSD bulk specific gravity of the aggregates
(f) the batch weights
(g) the names of all admixtures
(h) the admixture dosage rates and the manufacturer’s
recommended range.

The CMDS is used to conduct a trial batch in accordance with 506.05. Upon
completion of the trail batch, the Contractor shall submit the concrete mix design for
production, CMDP. The CMDP shall be submitted to the DTE utilizing the
50 Department furnished spreadsheet a minimum of three work days prior to production.
Production shall not commence without an approved CMDP. Both the Contractor’s
and Engineer’s test results from the trial batch will be included in the CMDP submittal.

A CMDP may be changed or adjusted in accordance with the following:

(a) Change in Materials

A change in a previously approved CMDP, for a given contract, to any of the
following shall be submitted to the DTE as a CMDS, referencing the original CMDP.

60 1. cement source or type

427
 506.03

2. pozzolan source or type

3. coarse aggregate source or type
4. admixture type.

A trial batch shall be conducted in accordance with 506.05, or verification of the

new CMDS may be made during the first day of production by tests conducted by the
Contractor and the Engineer. Production may continue until flexural strength tests are
completed, provided all other properties are in accordance with 506.04. The test results
shall be submitted to the DTE utilizing the Department spreadsheet no later than one
70 day after the flexural strength test results are complete. If the flexural strength is not
in accordance with 506.04, production shall stop and all PCCP patching constructed
with the new CMDS will be adjudicated as a failed material in accordance with normal
Department practice as listed in 105.03.

(b) Adjustments to Materials

An adjustment in a previously approved CMDP, for a given contract, to any of
the following shall be submitted to the DTE as a CMDS, referencing the original
CMDP.

80 1. admixture source
2. admixture product of same type and from same source
designated in the original CMDP
3. fine aggregate source
4. fine to total aggregate ratio in excess of ±3% from the value
designated by the original CMDP
5. Increase in cement content from amount designated in the
original CMDP.

The new CMDS shall be submitted to the DTE utilizing the Department
90 spreadsheet a minimum of one work day prior to production. A trial batch or
verification testing is not required for approval. Production shall not commence
without an approved CMDP.

(c) Other Adjustments

Other adjustments in previously approved CMDP, for a given contract, to any of
the following will be allowed and DTE notification and approval prior to use is not
required.

1. admixture dosage rate

100 2. fine aggregate to total aggregate ratio within ±3% of the
value designated by the original CMDP.

An approved CMDP, from another contract in the current or previous calendar

year may be used on additional contracts. The CMDP shall be submitted to the DTE
for review and approval prior to use.

428
 506.06

506.04 Concrete Mix Criteria

The fine aggregate shall be at least 35% but not more than 45% of the total weight
of the aggregate in each cubic yard. Proportions will be based upon SSD aggregates.
110
The CMD shall produce workable concrete mixtures, with the minimum amount
of water, having the following properties:

Minimum portland cement content.............................. 658 lbs/cu yd

Maximum water/cement ratio...................................... 0.45
Minimum slump .......................................................... 2 in.
Air Content .................................................................. 6.5% ±1.5%
Minimum Flexural strength, third point loading ......... 300 psi at 24 h
Minimum flexural strength, third point loading .......... 500 psi at 3 days
120
When calcium chloride solution is added, a maximum of 2%, by weight of
cement, shall be used. The percentage shall be reduced to 1 if the ambient temperature
is above 80°F. If the mixture is used in an 805 application, calcium chloride shall not
be used.

506.05 Trial Batch

A trial batch shall be produced and tested to verify that the CMD is in accordance
with the concrete mix criteria. An American Concrete Institute certified concrete field
testing technician, grade 1 shall be on site to direct all sampling and testing. The trial
130 batch shall be produced at the plant prior to production. The Engineer will test the
concrete’s air content and determine the water/cement ratio, and prepare and test
flexural beams. The flexural strength will be determined by averaging a minimum of
two beam breaks. The Engineer will provide the Contractor the results of the tests.

A trial batch will not be required when the total quantity of partial depth patching
or full depth patching will require less than 10 cu yd of material per contract.

The trial batch shall be of sufficient quantity to allow the Engineer to perform all
required tests from the same batch. Trial batch concrete shall not be used for more than
140 one test.

506.06 Job Control

Control of PCCP for air content and flexural strength beams will be determined
on the basis of tests performed by the Engineer in accordance with 505. Concrete and
necessary labor for sampling shall be furnished as required by the Engineer. Testing
for air content will be on the first load of the day and once per every 50 cu yd. Beams
will be made once per every 150 cu yd and tested for compliance with 3 day flexural
strength requirements.

150 The Engineer will notify the Contractor when test results for air content or flexural
strength are outside the requirements of 506.04. Rounding will be in accordance with
109.01(a).

429
 506.07

CONSTRUCTION REQUIREMENTS

506.07 PCCP Removal

PCCP removal areas will be marked. Vertical saw cuts around the perimeter of
the removal areas shall be made in the PCCP. Transverse cuts shall be perpendicular
to the centerline of the PCCP.
160
PCCP removal areas shall not remain open overnight. Shoulders or adjacent
PCCP damaged during the removal shall be repaired as directed.

(a) Partial Depth Removal

The saw cut shall be a minimum of 1 in., to a maximum of 3 in. Removal of all
unsound concrete to a minimum depth of 1 in. shall be by hand chipping tools or
handheld mechanically driven equipment. Mechanical hammers shall not be heavier
than a nominal 45 lb class. Mechanically driven tools shall be operated at a maximum
angle of 45° from the PCCP surface. If the saw cut face is damaged, a parallel saw cut
170 1 in. outside the initial saw cut shall be made and the concrete in this area shall be
removed by hand chipping.

Reinforcing bars encountered during the removal operation shall be cause for a
full depth patch in accordance with 506.07(b). Wire mesh reinforcement exposed
during the removal operations shall be removed.

Exposure of unsound concrete below 3 in. shall be cause for a full depth patch in
accordance with 506.07(b).

180 The partial depth cavities shall be thoroughly sandblasted and, just prior to placing
new concrete, cleaned of all dust, chips, and water. The air lines for sandblasting and
air cleaning shall be equipped with oil traps to prevent contamination of the surfaces.

(b) Full Depth Removal

The saw cut shall be full lane width and thickness of the PCCP. After the full
depth saw cut is completed, vehicle mounted removal equipment may be used to
remove the concrete provided this equipment does not damage the adjacent sound
concrete.

190 Removal areas in the same lane which are closer than 10 ft shall require the PCCP
between these areas to be removed and replaced. If a transverse joint is located within
the removal area, the limits of removal shall be increased to a minimum of 1 ft beyond
the joint.

Full depth removal shall be extended until sound PCCP is encountered to allow
dowel bars to be firmly anchored.

All subbase material disturbed during the removal operation shall be recompacted
as directed.

430
 506.10

200
506.08 Concrete Mixing and Transportation
Concrete mixing and transportation shall be completed by central mixed, shrink
mixed, or transit mixed methods. Discharge from non-agitating equipment shall be
completed within 30 minutes of mixing the water, cement, aggregates, and calcium
chloride solution. Discharge from a truck agitator or a truck mixer shall be completed
within 90 minutes of mixing the water, cement, and aggregates or within 30 minutes
of the addition of calcium chloride solution. If the location of the plant is such that this
time limit cannot be met, the calcium chloride solution shall be added to the concrete
in a transit mixer at the site and the concrete shall then be mixed for an additional 40
210 revolutions prior to discharge.

Concrete shall be uniformly mixed when delivered to the job site. Tickets for each
load of PCC shall indicate the weight of cement, and aggregates, volume of water, and
the type and volume of admixtures. The weight of the cement shall be within 1% of
the CMDP and the saturated surface dry weight of the aggregates shall be within 2%
of the CMDP.

Wash water shall not be used as a portion of the mixing water.

220 When concrete is delivered in transit mixers, additional water to increase the
workability of a load may be added within 45 minutes of initial mixing. Any addition
of water shall be noted on the ticket and shall not occur as a continuing operation.

(a) Central Mixed Concrete

Central mixed concrete shall be in accordance with 502.10(a).

(b) Shrink Mixed Concrete

Shrink mixed concrete shall be in accordance with 502.10(b).

230 (c) Transit Mixed Concrete

Transit mixed concrete shall be in accordance with 502.10(c).

506.09 Weather Limitations

Placement of PCCP patches in continuous reinforced concrete pavement shall be
after 1:00 p.m. when the next day’s forecasted ambient temperature is 70°F or greater,
unless otherwise directed.

PCCP patches shall not be placed on frozen subgrade, subbase, or PCCP.

240 506.10 Placing Concrete

The concrete shall be placed level to the adjacent PCCP and consolidated by
internal vibration. The concrete shall be hand finished in accordance with 504.
Texturing and tining are not required if the PCCP is to be resurfaced with HMA or
diamond ground in accordance with 507.06.

431
 506.11

The PCCP patch shall be cured in accordance with 504.04(a). In addition,

polyethylene film shall be placed over the patch and covered with a 4 in. layer of rigid
or flexible insulation and firmly anchored. Small dimension lumber weighted with
sandbags may be used, but large objects such as rocks or concrete blocks shall not be
250 used.

The PCCP patch shall be inspected in accordance with 502.17.

For patches which are not to be overlaid and have a length greater than 20 ft,
pavement smoothness will be in accordance with 501.25 except profilograph
requirements will not apply.

(a) Partial Depth

A non-vapor barrier type bonding agent shall be applied to the vertical and
260 horizontal surfaces prior to placing concrete. Coated surfaces shall be protected from
contaminants such as dust and dirt. Contaminated surfaces shall be recleaned and
recoated. The bonding agent and concrete shall be placed in accordance with the
bonding agent manufacturer’s recommendations. The recommended time limits will
be strictly enforced.

Existing joint openings within the patch shall be maintained for the full depth of
the patch by preformed joint fillers or forms. After the patch has cured, these joints
shall be sawed and sealed in accordance with 503.

270 (b) Full Depth

Patches shall be anchored with dowel bars to the adjacent PCCP as shown on the
plans. Dowel bars shall be installed using a chemical anchoring system.

Patches constructed adjacent to transverse contraction joints or random cracks that

are to remain in place shall be constructed with type D-1 contraction joints. The joint
shall be made continuous across the width of the PCCP to match the existing joint or
random crack. Patches greater than 18 ft shall have type D-1 contraction joints in
accordance with 503.

280 Concrete shall be placed around manholes or similar structures in accordance with
720.

Sawing and sealing of transverse joints may be omitted when the existing PCCP
is to be overlaid as part of the contract.

506.11 Opening to Traffic

A patch may be opened to traffic in accordance with the following when calcium
chloride is used.

432
 506.13

T H HT T H HT
40 - 42°F 30 26 61 - 63°F 14 9
43 - 45°F 27 23 64 - 66°F 14 9
46 - 48°F 24 21 67 - 69°F 14 8
49 - 51°F 21 19 70 - 72°F 14 7
52 - 54°F 19 16 73 - 75°F 14 6
55 - 57°F 16 14 above 75°F 14 5
58 - 60°F 16 11
T = Lowest ambient temperature during placement, or the
temperature of concrete at time of delivery, whichever is lower
H = Time in hours to open to traffic
HT = Time in hours to open to traffic when the average daily traffic is
less than 10,000
290
PCCP patches with calcium chloride may be opened to traffic sooner than
specified in the above table if test beams indicate a modulus of rupture of 300 psi or
greater. ITM 402 may be used as an alternative method to determine the flexural
strength.

When other admixtures or admixture systems are used, the PCCP patches may be
opened to traffic when flexural strength tests indicate a modulus of rupture of 300 psi
or greater. ITM 402 may be used as an alternate method to determine the flexural
strength.
300
506.12 Method of Measurement
Partial depth patching and full depth patching will be measured by the square
yard.

D-1 contraction joints and retrofitted tie bars used in PCCP patching will be
measured in accordance with 503.07.

PCCP removal, subbase, and subgrade excavation, when required, subbase and
subgrade recompaction, non-vapor barrier bonding agent, individual dowel bars,
310 chemical anchor system, concrete, finishing, curing, and sawing and sealing of joints
will not be measured for payment.

506.13 Basis of Payment

PCCP patching will be paid for at the contract unit price per square yard for the
type of patching required.

D-1 contraction joints and retrofitted tie bars used in PCCP patching will be paid
for in accordance with 503.08.

320 Partial depth patches which have been directed to be full depth will be paid for at
the contract unit price per square yard for PCCP patching, partial depth, plus 80% of
the contract unit price per square yard for PCCP patching, full depth.

433
 507.01

Payment will be made under:

Pay Item Pay Unit Symbol

PCCP Patching, Full Depth ......................................... SYS

PCCP Patching, Partial Depth ..................................... SYS
330
The cost of PCCP removal, subbase, and subgrade excavation, when required,
subbase and subgrade recompaction, non-vapor barrier bonding agent, individual
dowel bars, chemical anchoring system, concrete, finishing and curing, and sawing
and sealing of joints shall be included in the cost of PCCP patching.

The cost of corrections for pavement smoothness and re-texturing shall be

included in the cost of PCCP patching.

Repair or replacement of adjacent PCCP or shoulder damaged by the Contractor

340 shall be made at no additional cost to the Department.

SECTION 507 – PCCP RESTORATION

507.01 Description
This work shall consist of cleaning and sealing of joints and cracks, patching,
profiling, underseal, and retrofit load transfer in accordance with 105.03.

MATERIALS

507.02 Materials
10 Materials shall be in accordance with the following:

Asphalt Binder, PG 64-22 ........................................... 902.01(a)

Dowel Bars .................................................................. 910.01(b)10
Fine Aggregates, Size No. 23 or 24 ............................. 904
Joint Sealing Materials ................................................ 906.02
Rapid Setting Patch Materials ..................................... 901.07

Dowel bars and dowel bar assemblies shall be in accordance with 503.04.

20 CONSTRUCTION REQUIREMENTS

507.03 Cracks
Sealing and filling operations shall not be conducted on a wet surface, when the
ambient temperature is below 40°F, or when other unsuitable conditions exist, unless
approved by the Engineer.

434
 507.04

(a) Routing, Cleaning and Sealing

Cracks in PCCP shall be routed and cleaned when specified. Cracks shall be
routed with a routing machine capable of cutting a uniform shape to form a reservoir
30 not exceeding 3/4 in. wide with a minimum depth of 3/4 in. The operation shall be
coordinated such that routed materials do not encroach on pavement lanes carrying
traffic and all routed materials are disposed of in accordance with 104.07. The cracks
shall be cleaned with compressed air or by other suitable means. Air compressors shall
be capable of producing a minimum air pressure of 100 psi. Water blasting shall not
be utilized.

Cracks shall be sealed with hot poured joint sealant in accordance with the
manufacturer’s recommendations within 1/4 in. below the surface. A distributor in
accordance with 409.03 shall be used with an indirect-heat double boiler kettle and
40 mechanical agitator. The hot poured joint sealant shall be placed utilizing a “V” shaped
wand tip, to allow the penetration of the materials into the cracks.

Application of hot poured joint sealant shall be completed without covering

existing pavement markings. When traffic is to be maintained within the limits of the
section, temporary traffic control measures in accordance with 801 shall be used.
Treated areas shall not be opened to traffic until the hot poured joint sealant has set.

(b) Cleaning and Filling

The cracks shall be cleaned by blowing with compressed air or by other suitable
50 means when specified. Air compressors shall be capable of producing a minimum air
pressure of 100 psi. Water blasting shall not be utilized.

Cracks shall be filled with asphalt material. The cracks shall be completely filled
or overbanded not to exceed 5 in., or as required. Asphalt material shall be placed
utilizing a “V” shaped wand tip, to allow the penetration of the materials into the
cracks. The filled cracks shall be covered with sufficient fine aggregate or other
suitable material to prevent tracking of the asphalt material. All excess cover material
shall be removed from the pavement within 24 h, when directed.

60 Application of asphalt material shall be completed without covering existing

pavement markings. When traffic is to be maintained within the limits of the section,
temporary traffic control measures in accordance with 801 shall be used. Treated areas
shall not be opened to traffic until the asphalt material has set.

507.04 Joints
Sealing and filling operations shall not be conducted on a wet surface, when the
ambient temperature is below 40°F, or when other unsuitable conditions exist, unless
approved by the Engineer.

70 (a) Sawing, Cleaning and Sealing

Joints in PCCP shall be sawed, cleaned and sealed when specified. Air
compressors shall be capable of producing a minimum air pressure of 100 psi. Water

435
 507.05

blasting shall not be applied under pressure which may damage the concrete. The
existing joints shall be sawed to the width and depth as shown on the plans. Slurry or
saw residue remaining in the slot shall be immediately flushed with water. Traffic may
be allowed on the PCCP for up to seven calendar days after the saw cutting prior to
sealing.

Joints shall be sealed with joint sealing materials in accordance with the sealant
80 manufacturer’s recommendations. Transverse joints shall be sealed with hot poured
joint sealant, silicone sealant or preformed elastomeric joint sealant. Longitudinal
joints shall be sealed with hot poured joint sealant or silicone sealants.

Application of asphalt materials shall be completed without covering existing

pavement markings. When traffic is to be maintained within the limits of the section,
temporary traffic control measures in accordance with 801 shall be used. Treated areas
shall not be opened to traffic until the asphalt material has set.

(b) Cleaning and Filling

90 Joints in PCCP shall be cleaned and filled when specified. Cleaning shall include
removal of old sealant and backer rod. Air compressors shall be capable of producing
a minimum air pressure of 100 psi. Water blasting shall not be utilized.

Joints shall be filled with hot poured joint sealant in accordance with the
manufacturer’s recommendations within 1/4 in. below the surface. A distributor in
accordance with 409.03 shall be used with an indirect-heat double boiler kettle and
mechanical agitator. The hot poured joint sealant shall be placed utilizing a “V” shaped
wand tip, to allow the penetration of the materials into the joints.

100 507.05 PCCP Patching

(a) Full Depth Patching

PCCP patching shall be in accordance with 506.

(b) Partial Depth Patching

Partial depth patching shall be constructed at locations shown on the plans.
Existing joints directed to be patched partial depth, shall be milled to a depth of 3 in.
the full width of the lane. The minimum length of milling is 6 in. beyond the map-
cracked area. The milled area shall be cleaned of all loose material prior to patching.
110 Cleaning shall be by blowing the milled areas with compressed air at a minimum
pressure of 100 psi. When the milled areas are satisfactorily cleaned, the milled areas
shall be tacked with asphalt material in accordance with 406 and patched with HMA.

The milled areas shall be filled with HMA partial depth patching. Partial depth
patches shall consist of HMA Surface, type B in accordance with 402.04. MAF in
accordance with 402.05 will not apply. The mixture shall be compacted by a vibratory
roller in accordance with 409.03(d). A minimum of four passes of the rollers shall be
completed. Partial depth patches shall be completed during work hours and opened to

436
 507.08

traffic at the close of the workday. Mixtures will be accepted in accordance with
120 402.09.

507.06 Profiling
Profiling consists of the diamond grinding of the pavement. The grinding shall be
completed by mechanical grinding equipment in accordance with 508.08(c). Grinding
shall be completed in a longitudinal direction and shall begin and end at lines normal
to the pavement centerline in any ground section. The operation shall be coordinated
such that the slurry or residue materials are continuously removed from the pavement.
The slurry shall not encroach into adjacent pavement lanes carrying traffic, or flow
into gutters or other drainage facilities and shall be immediately and directly deposited
130 into a tanker truck and removed from the jobsite. Final disposal of the material shall
be in an approved manner and in accordance with 104.07. Pavement smoothness will
be measured and adjusted in accordance with 501.25 and 501.28(d) after the cracks
are routed, cleaned, and sealed in accordance with 507.03 and joints are sawed,
cleaned, and resealed in accordance with 507.04.

507.07 Undersealing
Undersealing shall be in accordance with 612.

507.08 Retrofit Load Transfer for PCCP

140 Retrofit load transfer consists of diamond saw slot cutting and placing dowel bar
assemblies in the PCCP, parallel to the centerline of the roadway without damaging
adjacent PCCP. The diamond-sawed slot shall be cut using two diamond saw blades
per slot to cut the edges of the slot. The PCC within the slot and the burrs and bumps
remaining in the base of the slots after cutting shall be removed with hand or
mechanical chipping hammers which shall not exceed a nominal 15 lb in weight and
shall be operated at a maximum angle of 45° from the pavement surface.

All surfaces of the slots shall be thoroughly cleaned by sand blasting and all cracks
in the slots shall be sealed with a silicone sealer. The slots shall be cleaned and blown
150 dry with compressed air.

Dowel bar assemblies shall be as shown on the plans. Prior to placement, the
assemblies shall be coated with a bond breaking material and placed on non-metallic
supports in the slots. Dowel bars shall be parallel to the pavement surface.

Rapid setting patch material shall be mixed and cured in accordance with the
manufacturer’s recommendations. The material shall be placed in the slots and
troweled to match existing adjoining PCCP. Excess material removed during placing
and troweling shall not be reused.
160
Transverse contraction joints with retrofitted load transfers shall be sawed for the
full lane width and sealed in accordance with 503.03(a) except the joint shall be cut in
one operation. Transverse random cracks with retrofitted load transfer slots shall be
routed and sealed for the full lane width in accordance with 503.05.

437
 507.09

PCCP damaged outside the area of the slots due to the Contractor’s operations
shall be repaired in an acceptable manner or replaced.

507.09 Method of Measurement

170 Routing and sealing of cracks, filling of cracks, sawing and sealing of joints, and
filling of joints will be measured by the linear foot, complete in place. Retrofit load
transfer will be measured by each dowel bar assembly installed, complete in place.
PCCP patching will be measured in accordance with 506.12. Profiling, regardless of
depth, will be measured by the square yard. Asphalt material and drilled holes for
undersealing will be measured in accordance with 612.07.

HMA partial depth patching will be measured by the ton, in accordance with
109.01(b).

180 Construction activities for the cutting, cleaning of the PCCP, dowel bars, dowel
bar supports, dowel bar end caps, foam core board, patching material and all other
incidentals will not be measured.

Routing of cracks or sawing of joints will not be measured. Routing and sealing
of transverse random cracks at retrofitted load transfer assemblies will not be
measured.

Temporary traffic control measures for routing, sealing or filling of cracks or

sawing, sealing, or filling of joints, and profiling will be measured in accordance with
190 801.17.

507.10 Basis of Payment

Routing and sealing of cracks, filling of cracks, sawing and sealing of joints and
filling of joints will be paid for by the linear foot, complete in place. The accepted
quantities of retrofit load transfer will be paid for at the contract unit price per each
assembly installed, compete in place. PCCP patching will be paid for in accordance
with 506.13. Profiling will be paid for by the square yard. Undersealing and drilled
holes will be paid for in accordance with 612.08. The accepted quantities for HMA
partial depth patching will be paid for at the contract unit price per ton, complete in
200 place.

The cost of temporary traffic control measures for routing, sealing or filling of
cracks or joints, and profiling will be paid for in accordance with 801.18.

Payment will be made under:

Pay Item Pay Unit Symbol

Cracks in PCCP, Filled .............................................................. LFT

210 Cracks in PCCP, Rout and Seal ................................................. LFT

438
 508.02

HMA Partial Depth Patch .......................................................... TON

Joints in PCCP, Filled................................................................ LFT
Joints in PCCP, Saw and Seal ................................................... LFT
Profiling PCCP .......................................................................... SYS
Retrofit Load Transfer ............................................................... EACH

The cost of milling, cleaning, tacking, and all incidentals shall be included in the
cost of the pay item, partial depth patching.

220 The cost of cutting of slots, cleaning, dowel bars, dowel bar supports, dowel bar
end caps, foam board, mortar, and curing materials shall be included in the cost of the
pay item retrofit load transfer.

The cost of cleaning, sealing materials, and all incidentals shall be included in the
cost of the pay item cracks in PCCP, filled or joints in PCCP, filled.

The cost of routing, cleaning, sealant materials, and all incidentals shall be
included in the cost of the pay item cracks in PCCP, rout and seal. The cost of sawing,
cleaning, sealant materials, and all incidentals shall be included in the cost of the pay
230 item joints in PCCP, saw and seal.

The cost of all grinding, diamond cutting heads, and cleaning of the pavement,
shall be included in the cost of the pay item for profiling.

SECTION 508 – EQUIPMENT

508.01 Production, Transportation, and Placement of PCC Mixtures

The Contractor shall provide and calibrate all equipment necessary for the mixing,
transportation, and placement operations for PCCP.

508.02 Mixing Plant

(a) Plant Inspection

10 The concrete production equipment shall be capable of producing a uniform
mixture. A plant inspection in accordance with 106.03 will be made by the Engineer
annually, after a plant is moved, or as deemed necessary.

(b) Proportioning System

Batching plants shall be equipped to proportion aggregates and bulk cement by
weight by means of automatic and interlocked proportioning devices. PCCP produced
in accordance with 501 and 502 shall document each ingredient in each batch.

All scales shall be accurate to within ±0.5% throughout their range unless
20 otherwise approved. For applied loads less than 1,000 lb on the cement scale and 4,000
lb on the aggregate scale, the scales shall be accurate to 2.0% or 1 gradation.

439
 508.02

Meters for both admixtures and water shall be accurate to within 1.0%.

Means of control shall be provided so that as the quantity desired in the weighing
hopper is approached, the materials may be added at a slower rate and shut off with
precision. The following proportioning tolerances shall be used for batching:

1. admixtures ....................................... ±3%

30 2. aggregates........................................ ±2%
3. cementitious materials ..................... ±1%
4. water, volume or weight .................. ±1%.

The plant shall be equipped with a recording device capable of producing a ticket
to permanently record the batch number, time of day, weight of all materials in the
mix, volume or weight of mixing water added, and admixture quantities or equipped
with a suitable non-resettable batch counter which will indicate correctly the number
of batches produced. The CMD number shall be included on the ticket.

40 (c) Material Storage

The plant shall have separate storage bins or tanks for each material in the mixture.
Each compartment shall discharge efficiently and freely into the weighing hopper or
feed through a meter.

1. Aggregates
The aggregate storage area shall be well drained. All stockpiles shall be
sufficiently separated and identified by signs or other approved methods.

2. Cementitious Materials
50 The storage bins shall be sealed and vented to preclude dusting during operation
and have a sampling port.

3. Admixtures
Separate tanks for each admixture shall be provided.

(d) Hoppers
Weighing hoppers shall be constructed to eliminate accumulation of materials and
to discharge fully. The fine aggregate and coarse aggregate shall be weighed separately
into a weigh hopper in the respective amounts defined in the CMD. Separate scales
60 and hoppers shall be used for weighing the cement. Pozzolans may be weighed into
the cement hopper in one cumulative operation provided that the portland cement is
weighed in first.

(e) Mixing System

The concrete mixing system shall be either a central stationary mixer or a transit
truck mixer. Each mixer shall have attached in a prominent place a manufacturer’s
plate showing the capacity of the drum in terms of volume of mixed concrete, the

440
 508.04

speed of rotation of the mixing drum or blades, and the manufacturer’s name and
address.
70
The mixer shall be capable of combining the ingredients of the concrete within
the specified time into a thoroughly mixed and uniform mass.

1. Central or Stationary Mixers

Stationary mixers shall be equipped with a timing device which does not enable
the batch to be discharged until the specified mixing time has elapsed.

2. Truck Mixers
Truck mixers shall be equipped with means by which the number of revolutions
80 of the drum at mixing speed may be verified.

508.03 Transportation

(a) Truck Mixers and Truck Agitators

Truck mixers and agitators shall be capable of maintaining and discharging the
concrete at a satisfactory rate and degree of uniformity. The haul units shall be
examined daily for accumulations of hardened concrete or mortar and compared to the
manufacturer’s standard for wear of blades.

90 (b) Non-Agitator Trucks

Bodies of non-agitating hauling equipment shall be smooth, mortar tight, metal
containers. They shall be capable of discharging the concrete at a controlled rate. The
bodies shall be examined daily for accumulations of hardened concrete, mortar, or
foreign matter.

508.04 Placement Equipment

(a) Slipform
The paver shall spread, consolidate, and shape the freshly placed concrete in one
100 complete pass to provide a dense and homogeneous pavement. The paver shall be of
sufficient weight and power to construct the specified PCCP, at an adequate variable
forward speed, and without transverse, longitudinal, or vertical instability. The paver
shall be equipped with an automated steering and elevation control system.

The paver shall consolidate by vibrating the concrete for the full width and depth
of the PCCP. Vibration shall be accomplished by internal vibrators, which have a
variable frequency range of 7,000 to 12,000 vibrations per minute. The amplitude of
vibration shall be between 0.025 in. and 0.06 in. The vibrators shall be spaced and
operated to achieve acceptable consolidation. The paver shall include a handheld
110 tachometer or other suitable device for measuring the frequency of the vibrators. The
automated vibrator control shall be capable of stopping vibration when forward
movement ceases.

441
 508.04

Mechanical tie bar inserters shall be rigidly attached to the paver and may be
operated manually or automatically controlled.

A mechanical belt placer, if used, shall have a re-combining deflector plate

mounted on the end of the discharge belt.

120 (b) Form Riding Equipment

The finishing machine shall be supported by forms and be equipped with two or
more oscillating type transverse screeds and a transverse smoothing float.

Forms for riding equipment shall be of sufficient thickness to maintain the true
cross section and shall be furnished in sections no less than 10 ft in length. Forms shall
have a minimum depth equal to the prescribed edge thickness of the concrete pavement
without a horizontal joint, and a minimum base width equal to the depth of the forms.
Flexible or curved forms shall be of an acceptable design. Forms shall be provided
with adequate devices for secure setting so that when in place they can withstand,
130 without visible spring or settlement, the impact and vibration of the consolidating and
finishing equipment. Flange braces shall extend outward on the base a minimum of
2/3 of the height of the form. The top face of the form shall not vary from a true plane
by more than 1/8 in. in 10 ft and the upstanding leg shall not vary by more than 1/4 in.
The forms shall contain provisions for locking the ends of abutting form sections
together tightly for secure setting.

The transverse screed and transverse smoothing float shall be suspended from and
guided by a rigid frame. The frame shall have a maximum effective wheel base of 14
ft. The length of the float shall be approximately 2 in. less than the normal width of
140 the pavement and have an adjustable crown section. The forward speed of the float
shall be adjustable.

The vibration equipment shall consolidate the full width and depth of the strip of
PCCP being placed. Vibrators may be either the surface pan type or the internal type
with either immerse tube or multiple spuds. Vibrators may be attached to the spreader
or the finishing machine or mounted on a separate carriage. The frequency of the
surface pan type shall be 3,500 impulses per minute or greater. The frequency of the
internal type shall have no less than 5,000 impulses per minute for tube vibrators and
spud vibrators shall have a frequency of from 10,000 to 12,000 impulses per minute
150 in air. The paver shall include a device, such as a handheld tachometer for measuring
the frequency of the vibrators. Vibrators shall have automatic controls, which stop
vibration when forward motion ceases. The maximum spacing of spud vibrators shall
be 2 ft. A warning device shall be connected to each vibrator circuit to indicate a failure
of any individual vibrator and shall be visible from the ground.

(c) Hand Placement

1. Steel Forms
Steel forms shall be 10 ft or greater in length. Forms shall be capable of being

442
 508.04

160 staked in three locations or more for each 10 ft section and shall be equipped to
interlock. Forms shall support finishing equipment without deflection in either the
vertical or horizontal direction. The top face of the form shall not vary from a true
plane by more than 1/8 in. in 10 ft.

2. Wood Forms
Wood forms shall support finish equipment without deflection in either vertical
or horizontal direction.

3. Finishing Equipment
170 The finish device or machine shall be capable of producing a uniform surface free
of voids and in accordance with the planned profiles and cross section.

A mechanical tube finisher shall consist of a single or multiple rotating

strike-off/finish tubes setting approximately transverse to the longitudinal movement
of the machine. The length of finish tubes shall be a minimum of 2 ft longer than the
planned PCCP width. The forward speed of the machine as well as the rate of the finish
tube rotation shall be variable and it shall be reversible to allow for multiple finish
passes.

180 A vibratory screed finisher shall consist of a truss frame with a minimum base
width of 1 ft, which extends across the transverse width of the PCCP. The frame shall
extend 2 ft beyond the width of the PCCP and shall hold its shape when moved
forward. The screed shall move forward with either hydraulic or manual wenches,
which are capable of maintaining the screed at a right angle to the direction of travel.
The screed shall be vibrated as it moves forward and the vibration shall stop when
forward motion ceases. Vibration shall be accomplished with mechanical driven
eccentric weights or with auxiliary driven pneumatic vibrators.

A mechanical bridge deck finishing machine shall consist of a single or multiple

190 rotating cylinders setting approximately parallel to the longitudinal movement of the
machine and operating transversely. The forward motion of the machine as well as the
transverse movement of the finish cylinders shall be variable.

A hand operated strike off shall be rigid and shall hold its shape when moved
forward with a combined longitudinal and transverse motion.

A mechanical belt placer, if used, shall have a re-combining deflector plate

mounted on the end of the discharge belt.

200 4. Vibrators
Hand spud vibrators shall be capable of transmitting 7,000 to 10,800 impulses per
minute in air. The diameter of the head shall be 1 1/4 to 2 1/2 in.

443
 508.05

508.05 Curing
Mechanical equipment shall be self-supported and ride on wheels or tracks located
outside the paving lane. The mechanical sprayer shall be capable of applying a
continuous uniform film at a minimum rate of 1 gal./150 sq ft and shall be of the fully
atomizing type. The equipment shall provide adequate agitation of the compound
during application.
210
Hand spraying equipment shall be of the fully atomizing type.

508.06 Texturing Equipment

Mechanical texturing equipment shall be capable of forming transverse grooves
of uniform depth and alignment in the plastic PCCP, without tearing the surface. The
texturing comb shall have steel tines spaced as specified.

Hand tools consisting of fluted floats, rakes with spring steel tines, or finned floats
with a single row of fins shall produce grooves which conform to the same
220 requirements as those specified for the grooves formed by the mechanical equipment.

508.07 Sawing Equipment

Sawing equipment shall be self-propelled single or gang-mounted units. The saw
shall be capable of maintaining the specified alignment and depth of cut without
damaging the PCCP.

508.08 Miscellaneous Equipment

(a) Hand Tools

230 Long handled floats used to smooth and fill in open texture areas in the pavement
shall have blades no less than 5 ft in length and 6 in. in width. Equipment made of or
coated with aluminum or aluminum alloys shall not be used.

Straightedges shall be 10 ft in length and mounted on a long handle. The handle

shall be 3 ft longer than 1/2 of the width of the pavement being placed.

(b) Joint Sealing

Joint sealant material shall be installed using manufacturer’s recommended
equipment.
240
Air compressors shall be capable of producing a minimum air pressure of 80 psi.

Water blasting equipment shall be capable of operating at 1,500 psi without

damaging the PCCP.

(c) Grinding
Grinding shall be completed by mechanical grinding equipment using diamond
tipped saw blades mounted on a power driven, self-propelled machine containing
transverse and longitudinal grade controls. The cutting head shall be no less than 36 in.

444
 508.09

250 wide to produce a uniform texture per the full width of the cutting head shaft. The
pavement surface after cutting shall have a uniform texture but shall not be smooth or
polished. Tearing or dislodging of aggregates will not be allowed.

508.09 Testing Facility and Equipment

(a) Testing Facility

Testing facility shall be capable of maintaining a controlled curing environment
in accordance with AASHTO T 23 and contain sufficient storage tanks with curing
solution to cure both production control and acceptance test beams. Water shall be
260 conveniently available for cleaning testing equipment and for serving other tasks at
the facility. Office space, having suitable heat and air conditioning, shall be provided
to the Department within the testing facility. A telephone shall be provided in the
testing facility. Floor space shall be provided for a Department furnished beam
breaker.

A current set of AASHTO’s Standard Specifications for Transportation Materials

and Methods of Sampling and Testing, Part 2 Tests, and ASTM C 173 shall be
provided.

270 (b) Testing Equipment

Testing equipment shall be provided to perform production control testing and
shall be maintained in suitable working order. The equipment shall be in accordance
with AASHTO requirements where applicable. The Contractor shall provide a spud
vibrator with power source in suitable working order.

(c) Profilograph
The profilograph shall be in accordance with ITM 912.

(d) Straightedge – 16 ft
280 A 16 ft straightedge shall be a rigid beam mounted on two solid wheels on axles
16 ft apart. The straightedge has a mounted push bar to facilitate propelling the device
along or across the pavement. Tolerance points are located at the 1/4, 1/2, and 3/4
points and may be composed of threaded bolts capable of being adjusted to the
tolerance required.

(e) Straightedge – 10 ft
A 10 ft straightedge is the same as a 16 ft straightedge except that the wheels are
mounted 10 ft apart. A handheld rigid beam may be substituted.

445
THIS PAGE INTENTIONALLY LEFT BLANK

446
 601.02

DIVISION 600 – INCIDENTAL CONSTRUCTION

SECTION 601 – GUARDRAIL

601.01 Description
This work shall consist of the fabrication, assembly, and installation of guardrail,
guardrail transitions, and guardrail end treatments, in accordance with these
requirements, and as shown on the plans. This work may also consist of the extension
of existing guardrail with new guardrail, the removal of existing guardrail, or adjusting
the height of existing guardrail.

10 MATERIALS

601.02 Materials
Materials shall be in accordance with the following:

Alternate Material Blockouts....................................... 926.03

Guardrail Posts ............................................................ 910.10
Rail Accessories, Fittings, and Hardware .................... 910.11
Steel Thrie-Beam Rail ................................................. 910.09
Steel W-Beam Rail ...................................................... 910.09
20 Timber Posts and Blockouts ........................................ 911.02(f)

All guardrail, post, accessories, fittings, and hardware shall be supplied from a
source listed on the Department’s list of Certified Guardrail Suppliers in accordance
with 910.09. Guardrail end treatments shall be selected from the Department’s list of
approved Guardrail End Treatments in accordance with 601.07 and impact attenuators
shall be selected from the Department’s list of Approved Impact Attenuators in
accordance with 601.08.

PCC in anchors and in pads or bases for impact attenuators shall be class A and
30 in accordance with 702. Sheet signs and sign posts shall be in accordance with 802.

Barrels used in impact attenuators shall be yellow with black lids. The aggregate
used in the barrels shall be uncrushed gravel, class F or higher, in accordance with 904
and the following gradation requirements.

Sieve Size % Passing

1/2 in. (12.5 mm) 100
No. 50 (300 µm) 0-5
No. 100 (150 µm) 0-2

All other impact attenuators shall have end reflectorization as shown on the plans
or attached to the nose of the attenuator in accordance with the attenuator
manufacturer’s recommendation.

447
 601.03

40
Thrie-beam guardrail elements shall be steel and shall be in accordance with the
applicable requirements for steel beam guardrail shown in 910.09, 910.10, and 910.11.

W-beam or Midwest Guardrail System, MGS, W-beam guardrail, components,

assembly, post spacing, post lengths, and installation for each location shall be as
shown on the plans. Double-facing of the guardrail will be required at the locations
shown on the plans. For W-beam guardrail, in locations where conditions will not
allow the use of 7 ft posts, 6 ft posts may be substituted when approved. Timber posts
may be used within a run of MGS W-beam guardrail as shown on the plans. Timber
50 posts shall not be used within a run of W-beam guardrail.

The base metal thickness of the steel W-beam rail element for a curved guardrail
system shall be 0.105 in. The base metal thickness of the steel W-beam terminal
connector shall be 0.138 in. The controlled released terminal, CRT, timber breakaway
posts shall be S4S timber and shall otherwise be in accordance with 911. The curved
rail timber posts shall be in accordance with 911. All structural tubing shall be in
accordance with ASTM A 500. The remaining steel components shall be in accordance
with 910.

60 CONSTRUCTION REQUIREMENTS

601.03 General Requirements

Posts shall be installed plumb at the spacing and embedment depth shown on the
plans. Posts shall be driven where subsurface conditions enable the use of normal
driving equipment. Where subsurface conditions prohibit driving the posts, a 12 in.
diameter hole shall be bored to the required embedment depth. The hole shall be
backfilled with suitable material in 6 in. maximum lifts, compacted as directed, and
then the posts driven.

70 Posts damaged during installation shall be repaired or replaced as directed with

no additional payment.

When new guardrail is being installed to replace existing guardrail and traffic is
to be maintained during the work, the installation of the new guardrail shall follow the
removal of the existing guardrail as closely as practical. Adequate safety protection
shall be provided as directed between the time that the existing guardrail is removed
and the time that the installation of the new guardrail is completed.

When new guardrail is being installed where there is no existing guardrail and
80 traffic is to be maintained during the work, the mounting of the blockouts and the rail
elements to the posts shall be completed as soon as practical after the posts are
installed. The time between the installation of the posts and the mounting of the
blockouts and rail elements shall not exceed 24 h. Drums shall be placed to mark all
installed guardrail posts left bare overnight. The spacing of these devices shall be
numerically equal to the worksite speed limit, but not less than 20 ft.

448
 601.06

All damaged galvanized surfaces shall be coated in accordance with 910.11(a)4.

W-beam guardrail shall be installed as shown on the plans with the W-beam rail
90 element splice at the post. MGS W-beam guardrail shall be installed as shown on the
plans with the W-beam rail element splice at midspan. MGS W-beam guardrail
installed with half or quarter post spacing shall be spliced as shown on the plans.

The nested W-beam guardrail element shall consist of two rail elements, one set
inside the other. The length of nested guardrail placed over a culvert shall not be
spliced.

601.04 Guardrail Erection

Blockouts and rail elements shall be erected in a manner resulting in a smooth,
100 continuous installation. All bolts shall be of sufficient length to extend beyond the nuts
and shall be drawn tight. Rail installed along a radius of 150 ft or less shall be shop
curved. Rail elements shall be lapped as shown on the plans.

601.05 Curved W-Beam Guardrail Systems

This work shall consist of the fabrication, assembly, and installation of specified
types of curved W-beam guardrail connector system or curved W-beam guardrail
terminal system in accordance with the requirements herein and as shown on the plans.

The installation of the terminal end buffer may utilize an alternate single piece
110 having similar dimensional shape to the terminal end buffer as shown on the plans,
and which mates with the W-beam guardrail.

Where the W-beam terminal connector is lapped on the outside of the guardrail,
a galvanized 1 in. inside diameter, 2 in. outside diameter, 0.134 in. thick, narrow plain
washer shall be placed under the splice bolt heads.

Nuts for the anchor cable assembly shall be hand tightened, plus one complete
turn at the anchor plate end. All other nuts shall be torqued to 50 ft lb.

120 The installation of the type 5 anchor shall include tightening the cable with the
swaged end to eliminate all slack.

The W-beam rail in the type 5 anchor shall be attached to the steel pipe with 5/8 in.
diameter by 1 1/4 in. button head bolt with no washer. Connection to the post will not
be required.

601.06 Guardrail Transitions

Guardrail transitions shall be required to connect guardrail to bridge rail, guardrail
to piers, and new W-beam guardrail to existing rub rail type guardrail. The required
130 type of guardrail transition shall be as shown on the plans.

449
 601.07

An MGS guardrail transition, with or without curb, shall be required to connect

guardrail to bridge rail, guardrail to piers. An MGS height transition shall be required
to connect MGS W-beam guardrail to existing W-beam or existing rub rail type
guardrail. The required type of guardrail transition shall be as shown on the plans.

The fabrication, assembly, and installation of thrie-beam rail, W-beam rail

components, and posts and blockouts for guardrail transitions will be required for the
locations shown on the plans.
140
601.07 Guardrail End Treatments
Guardrail end treatments shall be required to terminate guardrail installations at
the locations shown on the plans. The type I guardrail end treatment shall be either as
shown on the plans, or shall be selected from the Department’s list of approved
Guardrail End Treatments. The type II guardrail end treatment shall be as shown on
the plans. The type OS or MS guardrail end treatments shall be selected from the
Department’s list of approved Guardrail End Treatments. The reflectorization of
guardrail end treatments, and the grading requirements shall be as shown on the plans.

150 For contracts letting prior to July 1, 2018 the following applies. When a 31 in.
guardrail end treatment is required to terminate MGS W-beam guardrail, a 27 3/4 in.
guardrail end treatment with an MGS height transition may be substituted when
approved by the Engineer.

Double facing of guardrail end treatment type I will be required when it is used in
conjunction with double faced guardrail.

Each unit shall be installed in accordance with the manufacturer’s

recommendations. A copy of the manufacturer's FHWA eligibility letter stating that
160 its product complies with the requirements of NCHRP 350 or MASH test level 3 shall
be provided.

Assembly and installation shall be supervised or performed at all times by an

installer trained and certified by the unit’s manufacturer, and shall be in accordance
with the manufacturer’s recommendations at the locations shown on the plans. The
installer shall be included on the Department’s list of Certified Guardrail End
Treatment and Impact Attenuator Installers prior to the start of work.

The Contractor shall provide the Department with original copies of all necessary
170 current manufacturer’s installation manuals and working drawings in accordance with
105.02.

When installing end treatments to existing rub rail type guardrail, the rub rail, if
not spliced at the last existing post, shall be cut and the end repositioned behind the
flange of the post. If the rub rail is spliced at the last existing post, the existing splice
material shall be removed and the end of the rub rail repositioned behind the flange of
the post. In both cases, the rub rail shall be connected to the post as shown on the plans.

450
 601.09

Guardrail end treatments shall be installed within 24 h of the completion of the

180 guardrail installation to which they are to be attached. Drums in accordance with
801.09 shall be placed for overnight marking of the bare end of the guardrail when the
installation of the guardrail end treatment will not be completed until the day following
the completion of the guardrail installation to which it is to be attached.

601.08 Impact Attenuators

Impact attenuators shall be placed or reset to obtain the proper height where
shown on the plans. The unit for each new location shall be of the width recommended
by the manufacturer and for the test level specified and shall be chosen from those
shown on the Department’s list of approved Impact Attenuators. Each unit shall be
190 placed in accordance with the manufacturer’s recommendations, on a PCC pad. A
copy of the manufacturer's FHWA eligibility letter stating that its product complies
with the requirements of NCHRP 350 or MASH test level 3 shall be provided.

Assembly and installation or resetting shall be supervised or performed at all

times by an installer trained and certified by the unit’s manufacturer, and shall be in
accordance with the manufacturer’s recommendations at the locations shown on the
plans. The installer shall be included on the Department’s list of Certified Guardrail
End Treatment and Impact Attenuator Installers prior to the start of work.

200 The Contractor shall provide the Department with original copies of all necessary
current manufacturer’s installation manuals and working drawings in accordance with
105.02.

Transition panels and all other necessary hardware shown in the manufacturer’s
recommendations to be required for bi-directional traffic protection shall be included
in the installation or resetting, if the unit is installed at a location where traffic is
passing the unit on both sides in opposite directions.

601.09 Extension of Existing Guardrail

210 Extension of existing rub rail type guardrail with new W-beam guardrail shall
require adjusting the post heights in the last 25 ft of existing rub rail type guardrail
adjacent to the extension as shown on the plans. Guardrail transition type VH shall be
used to make this adjustment. The post spacing of the guardrail transition type VH
shall equal that of the last 25 ft of existing rub rail type guardrail adjacent to the
extension. The rub rail shall be terminated at the last existing post in the transition in
accordance with 601.06.

Extension of existing rub rail type or W-beam guardrail with new MGS W-beam
guardrail shall require adjusting the splice location and post height in the last 37 ft 6
220 in. of the existing rub rail type or W-beam guardrail as shown on plans. MGS height
transition shall be used to make this adjustment. The rub rail shall be terminated at the
last existing post in the transition in accordance with 601.06.

451
 601.10

601.10 Removal of Existing Guardrail

Removal of existing guardrail shall be in accordance with the applicable
requirements of 202 and these requirements. The locations shall be as shown on the
plans. When it is specified that the removed guardrail is to become the property of the
Department, the rail elements, posts, and blockouts shall be removed without being
damaged. The removed material shall be stored as directed.
230
601.11 Adjusting Existing Guardrail Height
The height of the existing guardrail shall be adjusted by the use of moveable
blockouts as shown on the plans. The height shall be measured to the top of the rail
element along the face of the rail. Existing fixed blockouts shall be replaced with
moveable blockouts installed at the proper height. Existing moveable blockouts shall
be disconnected from the posts and re-mounted at the proper height.

601.12 Resetting Guardrail

This work shall consist of the removal of existing guardrail and, and if necessary,
240 storing it, and then re-erecting it where shown on the plans or as directed.

601.13 Method of Measurement

Guardrail, guardrail with rub rail, shop curved guardrail, adjusting guardrail
height, guardrail removal, and resetting guardrail will be measured by the linear foot
along the top of the rail element, complete in place. Nested guardrail will be measured
per each 100 lft run placed. Modified posts for nested guardrail will be measured per
each, complete in place. MGS structure top-mounted posts will be measured per each,
complete in place. Long span MGS W-beam guardrail will be measured per each for
the type specified and corresponding run length between outermost CRT posts.
250 Guardrail transitions, W-beam and MGS W-beam guardrail cable terminal anchors,
and guardrail end treatments will be measured per each, complete in place. Guardrail
buried end treatments type II will be measured per each. Impact attenuators and
resetting impact attenuators will be measured per each for the type and width and test
level, complete in place. The curved W-beam guardrail connector system and the
curved W-beam guardrail terminal system will be measured per each for the type
specified. Grading at guardrail end treatments, the reflectorization of guardrail end
treatments, and concrete used in anchoring guardrail end treatments will not be
measured for payment.

260 601.14 Basis of Payment

W-beam and MGS W-beam guardrail will be paid for at the contract unit price
per linear foot for the specified post spacing. Thrie-beam and thrie-beam double faced
guardrail will be paid for at the contract unit price per linear foot for guardrail, thrie-
beam and guardrail, thrie-beam, double faced, complete in place. Nested guardrail will
be paid for at the contract unit price per each 100 lft run, complete in place for
guardrail, W-beam, nested. Long span MGS guardrail will be paid for at the contract
unit price per each type specified and corresponding run length between outermost
CRT posts, complete in place for guardrail, MGS, long span. W-beam and MGS W-
beam guardrail cable terminal anchor will be paid for at the contract unit price per

452
 601.14

270 each, complete in place. Modified posts for nested guardrail will be paid for at the
contract unit price per each for modified posts, nested guardrail. Structure top-
mounted posts will be paid for at the contract unit price per each for guardrail, MGS,
structure top-mounted posts.

W-beam guardrail with rub rail will be paid for at the contract unit price per linear
foot for guardrail, WR-beam complete in place. Shop curved guardrail, adjusting
guardrail height, guardrail removal, and resetting guardrail will be paid for at the
contract unit price per linear foot. Guardrail transitions and guardrail end treatments
will be paid for at the contract unit price per each for the type specified. Guardrail
280 buried end treatments type II will be paid for at the contract unit price per each,
complete in place.

Impact attenuators and resetting impact attenuators will be paid for at the contract
unit price per each for the type and width, and test level specified. The curved W-beam
guardrail connector system and curved W-beam guardrail system will be paid for at
the contract unit price per each for the type specified, complete in place.

Where existing guardrail height is adjusted, such work will be paid for at the
contract unit price per linear foot. The cost of removal, all necessary storage, new
290 adjustable post brackets, attachment of rail section, and miscellaneous nuts and bolts
as required shall be included in the cost of adjust guardrail height.

Payment will be made under:

Pay Item Pay Unit Symbol

Guardrail Connector System, W-Beam, Curved, _____ ........... EACH

type
Guardrail End Treatment, _____ ............................................... EACH
300 type
Guardrail Height Transition, MGS ............................................ EACH
Guardrail Height Transition, VH, ____ ft ____ in. Spacing ...... EACH
Guardrail Transition, _____ ...................................................... EACH
type
Guardrail Transition, MGS, _____ ............................................ EACH
type
Guardrail, Adjust Height ........................................................... LFT
Guardrail, MGS W-Beam, ____ ft ____ in. Spacing................. LFT
Guardrail, MGS W-Beam, Cable Terminal Anchor .................. EACH
310 Guardrail, MGS W-Beam, Double Faced,
_____ ft _____ in. Spacing ................................................ LFT
Guardrail, MGS W-Beam, Shop Curved,
_____ ft _____ in. Spacing ................................................. LFT
Guardrail, MGS, Long Span, _____ .......................................... EACH
type

453
 601.14

Guardrail, MGS, Structure Top-Mounted Posts ........................ EACH

Guardrail, Remove .................................................................... LFT
Guardrail, Reset ......................................................................... LFT
Guardrail, Terminal System, W-Beam Curved, _____.............. EACH
320 type
Guardrail, Thrie-Beam .............................................................. LFT
Guardrail, Thrie-Beam, Double Faced ...................................... LFT
Guardrail, W-Beam, ____ ft ____ in. Spacing .......................... LFT
Guardrail, W-Beam, Cable Terminal Anchor ............................ EACH
Guardrail, W-Beam, Double Faced,
_____ ft _____ in. Spacing ................................................ LFT
Guardrail, W-Beam, Nested ...................................................... EACH
Guardrail, W-Beam, Shop Curved,
_____ ft _____ in. Spacing ................................................ LFT
330 Guardrail, WR-Beam ................................................................. LFT
Impact Attenuator, ________, ________ .................................. EACH
type-width test level
Impact Attenuator, Reset, ________, ________ ....................... EACH
type-width test level
Modified Posts, Nested Guardrail ............................................. EACH

For W-beam guardrail, the substitution of 6 ft posts for 7 ft posts where conditions
will not allow the use of the longer post will be at the same contract unit price of the
longer post.
340
The substitution of W 6 x 8.5 for W 6 x 9 steel posts, in MGS W-beam guardrail,
will be at the same contract unit price for heavier post.

The cost of resetting guardrail shall include the removal, necessary storage,
resetting and replacement of damaged or missing parts and new posts as required.

The cost of reflectorization of impact attenuators and guardrail end treatments

shall be included in the respective pay items.

350 The cost of all grading required for the guardrail buried end treatment shall be
included in the cost of guardrail end treatment, type II.

The cost of earthwork, grading, and transition panel if required, and PCC pad shall
be included in the cost of impact attenuator.

The cost of excavation, concrete footings, reinforcement, and structural steel

tubing required for modified posts, nested guardrail, shall be included in the cost of
the pay item.

454
 602.03

360 The cost of all materials, including replacing damaged or missing parts, labor, and
necessary incidentals required to reset impact attenuators, will be included in the cost
of impact attenuator, reset.

Where guardrail transition type TGB is used with bridge railing type TR, the cost
of eliminating the thrie-beam terminal connector and driving the posts to the height
above ground shown on the plans shall be included in the cost of the guardrail
transition.

SECTION 602 – CONCRETE BARRIER

602.01 Description
This work shall consist of the construction of concrete barriers and concrete glare
screens in accordance with these specifications, and as shown on the plans.

MATERIALS

602.02 Materials
10 Materials shall be in accordance with the following:

Barrier Delineators ...................................................... 926.02(c)

Cast-in-Place Barriers .................................................. 702
Cast-in-Place Concrete Glare Screens ......................... 702
Concrete Sealers .......................................................... 709
Construction Warning Lights ...................................... 923.03
Precast Barriers............................................................ 707
Precast Concrete Glare Screen .................................... 707
Reinforcing Bars.......................................................... 910.01
20
CONSTRUCTION REQUIREMENTS

602.03 Concrete Barrier and Concrete Glare Screen

Concrete barrier and concrete glare screen may be precast or cast-in-place. The
option selected shall be used continuously throughout the project. Irregular sections
shall be cast-in-place regardless of the option selected.

Concrete glare screen may only be precast when constructed in combination with
new precast barrier. Concrete glare screen shall be cast-in-place when constructed in
30 combination with cast-in-place barrier, and also when constructed on top of existing
concrete barrier.

Excavation and compaction shall be in accordance with 605.03(a). Backfilling

shall be in accordance with applicable requirements of 605.03(d).

455
 602.03

(a) Precast Concrete Barrier and Concrete Glare Screen

Precast concrete barrier and concrete glare screen shall be constructed in
accordance with applicable requirements of 707, except the minimum 28-day
compressive strength shall be 3,000 psi. The precast units shall not be shipped or used
40 until this strength is attained. The surfaces of individual precast units shall vary no
more than 1/4 in. in 10 ft from the specified cross section, as measured from a
longitudinal straightedge. The maximum variation in the vertical and horizontal
alignment of adjacent units shall be 1/4 in. across the joint, as measured from a 10 ft
longitudinal straightedge. Approved bedding may be used to obtain proper alignment
of the concrete barrier sections.

(b) Cast-in-Place Concrete Barrier and Concrete Glare Screen

Cast-in-place concrete barrier and concrete glare screen shall be constructed in
accordance with applicable requirements of 706.03 or by the use of an approved
50 slip-form machine. The surfaces of the concrete shall vary no more than 1/4 in. in
10 ft from the specified cross section, as measured from a longitudinal straightedge.
Where concrete pavement or concrete shoulder abuts the concrete barrier, 1/2 in.
preformed joint filler shall be placed as shown on the plans.

Where the concrete barrier is to be placed on PCCP, epoxy coated reinforcing bars
shall be placed as shown on the plans. The epoxy coated reinforcing bars shall be
installed in the PCCP by drilling and grouting.

The barrier wall shall be constructed in single pours without subsequent vertical
60 extensions.

When shown on the plans, cast-in-place modified concrete barrier sections shall
be in accordance with the above requirements and the concrete shall be class A in
accordance with 702.02.

(c) Finishing
Concrete barrier and concrete glare screen shall be finished in accordance with
702.21. If slip-form construction is used, an approved brush finish will be allowed.
Curing material in accordance with 912.01(e) shall be applied as a bond breaker to all
70 areas which result in concrete to concrete contact. It shall be applied at a minimum
rate of 1 gal./75 sq ft. If material is applied at a rate less than the minimum rate, a
second application shall be applied.

(d) Sealing
Regardless of the method of construction, all exposed surfaces of the concrete
barrier and concrete glare screen shall be sealed in accordance with the applicable
requirements of 709.

(e) Joints
80 The type, size and location of joints and preformed joint filler shall be as shown
on the plans.

456
 602.06

(f) Reflectorization
All concrete barrier shall be reflectorized with barrier delineators spaced a
minimum of 40 ft apart and centered 2 ft above the surface of adjacent pavement or
shoulder. The reflectorization shall be on both sides of the wall if traffic is on both
sides. All delineators damaged during installation or placement of the concrete barrier
shall be replaced with no additional payment. The color of the reflectors shall match
the color of the adjacent pavement traffic markings.
90
602.04 Blank

602.05 Method of Measurement

Concrete barrier will be measured by the linear foot along the centerline of the
barrier, including irregular barrier sections around median obstructions such as bridge
piers. Barrier delineators will be measured per each provided there is a pay item shown
in the Schedule of Pay Items. Concrete glare screen will be measured by the linear foot
along the centerline of the glare screen. Class A concrete for cast-in-place modified
concrete barriers will be measured by the cubic yard for the modified barrier section.
100 No deductions will be made for reinforcing bars or joints. Reinforcing bars for cast-
in-place modified concrete barriers will be measured in accordance with 703.07.

602.06 Basis of Payment

Concrete barrier will be paid for at the contract unit price per linear foot, complete
in place. Class A concrete for cast-in-place modified concrete barriers will be paid for
at the contract unit price per cubic yard. Reinforcing bars for cast-in-place modified
concrete barriers will be paid for in accordance with 703.08. Barrier delineators used
on concrete barrier will be paid for at the contract unit price per each, complete in
place.
110
Concrete glare screen will be paid for at the contract unit price per linear foot,
complete in place.

Payment will be made under:

Pay Item Pay Unit Symbol

Barrier Delineator ...................................................................... EACH

Concrete Barrier Glare Screen ................................................... LFT
120 Concrete Barrier ........................................................................ LFT
Concrete Barrier, Modified Section........................................... CYS

The cost of polyethylene film, surface seal or curing-sealing material for concrete
barrier and curing material shall be included in the cost of concrete barrier.

457
 603.01

SECTION 603 – FENCES

603.01 Description
This work shall consist of the construction of fence and gates in accordance with
105.03.

603.02 Materials
Materials shall be in accordance with the following:

10 Barbed Wire ................................................................ 910.18(b)4

Chain Link Fabric ........................................................ 910.18(b)
Concrete, Class B ........................................................ 702
Concrete, Packaged Dry .............................................. 901.08
Farm Field/Woven Wire .............................................. 910.18(a)
Fence Posts .................................................................. 910.13
Gates ............................................................................ 910.18(d)
Tension Wire ............................................................... 910.18(b)1

CONSTRUCTION REQUIREMENTS
20
603.03 General Requirements
Clearing and grubbing shall be in accordance with 201.03.

At locations where breaks in a run of fencing are required, or at intersections with

existing fences, appropriate adjustment in post spacing shall be made in accordance
with the requirements for the type of closure indicated.

When the plans require that posts, braces, or anchors be imbedded in concrete,
temporary guys or braces shall be installed, if required to hold the posts in proper
30 position. Unless otherwise specified, no materials shall be installed on posts or strain
placed on guys and bracing set in concrete until 96 h have elapsed from the time of
placing of the concrete.

The tops of all posts shall be set to the required grade and alignment. Cutting of
the posts will only be allowed with the approval of the Engineer. Post caps shall be
installed at the time the fence fabric is placed on the posts.

Wire or fencing of the size and type required shall be firmly attached to the posts
and braces in the manner indicated. All wires shall be stretched taut and installed to
40 the required elevations.

At each location where an electric transmission, distribution, or secondary line

crosses any of the types of fences covered by these specifications, a ground,
conforming to applicable requirements of the National Electric Safety Code, shall be
furnished and installed.

458
 603.05

603.04 Setting Posts

Posts, including the concrete foundation for posts, braces and anchors shall be set
so that the entire fence is inside the right-of-way and the fence can be placed on the
50 side of the post facing the roadway. If an object, such as a tree, is located on the right-
of-way and is to remain in place, the fence may be adjusted to miss the obstruction.
There shall be a gradual offset for at least three posts in each direction of the
obstruction.

Line posts for farm field type fence shall be set on 16 ft centers, and for chain link
fence on 10 ft centers. In either case, a tolerance of ±2 ft in spacing will be allowed at
special locations as approved. Spacing of these posts shall be as uniform as practicable
under the existing conditions. However, additional posts shall be set to maintain the
bottom clearance dimensions as required.
60
Pull posts shall be set at 500 ft maximum intervals in straight runs and at each
vertical angle point of 10° or more.

Corner posts shall be set at each horizontal angle point of 10° or more.

End, corner, and pull posts for both types of fence, line posts for chain link fence
and diagonal braces for farm field type fence shall be set in concrete as shown on the
plans.

70 Except where rock is encountered, intermediate or line posts shall be driven and
furnished with an approved anchor plate or other satisfactory device to hold the post
in proper alignment and plumb. The plate or anchor shall be welded or riveted to the
post with no less than two rivets.

Gate posts shall be set in concrete as shown on the plans.

Extra length posts shall be required at stream crossings as shown on the plans or
as directed and also at ground depressions where it is not practicable for the fencing
to follow closely the contour of the ground. These posts shall be set in concrete as
80 shown on the plans.

At small stream crossings and ground depressions, the space below the fence
fabric shall be closed with barbed or ground tension wire, either on horizontal lines or
fanned, as shown on the plans or as directed. The wires shall be stretched taut between
and fastened to the posts to prevent vertical movement of the wires. Barbed or tension
wire shall not be placed where its installation would cause collecting drifts in the
channel.

603.05 Placing Barbed and Tension Wire and Fabric

90 The bottom of the fabric shall be placed above the ground line as shown on the
plans. Over irregular ground, a minimum of 1 in. and a maximum of 4 in. clearance

459
 603.06

will be allowed. All necessary excavation and backfilling required shall be in

accordance with 201.03.

The tension required to stretch the fabric and wire shall be applied by mechanical
fence stretchers and with single wire stretchers designed and manufactured for the
purpose, and in accordance with the fence manufacturer’s recommendations.

All splices in the fabric and wire shall be securely made in accordance with the
100 best practice and the manufacturer’s recommendations, and by the use of tools
designed for that purpose.

Farm field fence shall be placed by fastening one end and then applying sufficient
tension to remove all slack before making permanent attachments elsewhere. The line
wires shall be fastened to end, corner, and pull posts by wrapping the wires around the
posts and tying the wire back on itself with no less than 1 1/2 tightly wrapped twists.
Tying shall be with tools designed for the purpose in accordance with the fence
manufacturer’s recommendations. This same method shall be used in placing barbed
or tension wire. Fence fabric shall be fastened to intermediate or line posts with at least
110 five wire ties. Barbed or tension wire shall be fastened in the same manner with one
fastening device for each post.

The top and bottom tension wires of chain link fence shall be placed, stretched
taut, and secured at the ends and to all posts before the fabric is placed. The ends of
the fabric shall be secured by the use of stretcher-bars threaded through the loops of
the fabric and secured to the posts by means of clamps with bolts and nuts. The number
of clamps shall be as indicated on the plans. The fabric shall be placed by securing one
end and then applying tension to remove all slack before making attachments
elsewhere. The fabric shall be fastened to the line posts and to the top and bottom
120 tension wires with tie wires spaced as shown on the plans.

603.06 Resetting Fence

Resetting fence shall consist of the removal of existing fence within the specified
limits and, if necessary, storing and then resetting it in accordance with the plans, or
as directed. Resetting fence shall be in accordance with 603.03, 603.04, and 603.05.
Damaged or missing parts, including posts shall be replaced.

603.07 Method of Measurement

Fence and resetting fence will be measured by the linear foot for the type
130 specified. Measurement will be made along the top of the fence from outside to outside
of end posts for each continuous run of fence.

Gates will be measured as complete units of the size and type specified.

603.08 Basis of Payment

The accepted quantities of fence and resetting fence will be paid for at the contract
unit price per linear foot for the type specified, complete in place. Gates will be paid

460
 604.02

for at the contract unit price per each for fence gate, of the type and size specified,
complete in place.
140
Payment will be made under:

Pay Item Pay Unit Symbol

Fence Gate, _____, ______ in. x _____ ft ................................. EACH

type height length
Fence, _____, ______ in. .......................................................... LFT
type height
Fence, _____, Reset................................................................... LFT
150 type
Fence, Farm Field, Barbed Wire, _____ in. .............................. LFT
Fence, Farm Field, Tension Wire, _____ in. ............................. LFT

The cost of adding grounding in accordance with the National Electric Safety
Code including all materials, and labor shall be included in the cost of the fence.

The cost of fence, and corner, end, line, and pull posts shall be included in the cost
of the fence.

160 The cost of fence, post and miscellaneous hardware shall be in the cost of the gate.

The cost of all miscellaneous hardware related to the type of fence including brace
connections, caps, clips, clamps, hinges, rivets, ties, truss rods, diagonal braces and
stretcher bars shall be included in the cost of the fence.

The cost of concrete for posts, braces or anchors shall be included in the cost of
the fence and gates.

The cost of removal, storage, re-installation, and the replacement of damaged or

170 missing parts shall be included in the cost of the resetting fence.

SECTION 604 – SIDEWALKS, CURB RAMPS, STEPS, AND HANDRAILS

604.01 Description
This work shall consist of constructing HMA or PCC sidewalks, curb ramps,
concrete steps, or the reconstruction of PCC sidewalks in accordance with 105.03.

MATERIALS

604.02 Materials
10 Materials shall be in accordance with the following:

Coarse Aggregate, Class D or Higher, Size No. 53 ..... 904

461
 604.03

Concrete, Class A ........................................................ 702

Detectable Warning Surfaces ...................................... 905.05
Fine Aggregate, Size No. 23, No. 24, or No. 15 .......... 904
Joint Filler ................................................................... 906.01
Joint Sealing Materials ................................................ 906.02
Reinforcing Bars.......................................................... 910.01
Silica Sand ................................................................... ASTM C 778
20
Hand railing shall be aluminum pipe in accordance with ASTM B 221, alloy 6063,
temper T52 or galvanized steel pipe in accordance with ASTM A 53, grade B, all as
specified.

The detectable warning surface in concrete curb ramps shall be selected from the
Department’s list of approved Detectable Warning Surfaces in accordance with
905.05.

The mortar bed material shall be high-strength mortar in accordance with ASTM
30 C 387. Part of the mix water shall be replaced with a Type II polymer modifier meeting
the requirements of ASTM C 1438. The proportioning of water and polymer modifier
shall be as recommended by the manufacturer of the polymer modifier.

A type C certification in accordance with 916 shall be furnished for the masonry
mortar and polymer modifier prior to use of the material.

A type C certification in accordance with 916 for the silica sand shall be furnished
prior to use of the material.

40 CONSTRUCTION REQUIREMENTS

604.03 Portland Cement Concrete Sidewalks and Curb Ramps

(a) General Requirements

The location of curb ramps shall take precedence over the location of drainage
structures and signal, utility, or light poles. Drainage structures and poles shall not be
located within the limits of the curb ramp, exclusive of flared sides. Poles located
within a sidewalk shall not reduce the clear width to less than 4.0 ft. Crosswalk
markings shall be located such that the curb ramps and curb ramp clear spaces are
50 contained within the markings unless otherwise specified. The flared sides need not
fall within the crosswalk lines. The normal gutter flow line shall be maintained
throughout the curb ramp area, and appropriate drainage structures shall be used, as
needed, to intercept the flow prior to the curb ramp area. Positive drainage shall also
be provided to carry water away from the intersection of the curb ramp and the gutter
line.

The bottom edge of curb ramps and the top of curb shall be flush with the edge of
the adjacent pavement or the gutter line. Vertical surface discontinuities shall be a

462
 604.03

maximum of 1/2 in. Vertical surface discontinuities greater than 1/4 in. up to 1/2 in.
60 shall be beveled at a slope no steeper than 1V:2H.

The curb ramp running slope shall not exceed 8.33%. Curb ramp and sidewalk
cross slope shall not exceed 2.00%. The slope of the turning space shall not exceed
2.00% in any direction. A running slope or cross slope that exceeds the maximum shall
be as shown on the plans.

Construction tolerance shall not apply to running slope and cross slope
percentages.

70 (b) Excavation
Excavation shall be made to the required depth and to a width that will enable the
installation and bracing of the forms. The foundation shall be shaped and compacted
to a firm even surface in accordance with the section shown on the plans. All soft and
yielding material shall be removed and replaced with acceptable material.

(c) Forms
Forms shall be of wood, metal, or other approved material and shall extend for
the full depth of the concrete. Forms shall be straight, free from warp, and of sufficient
strength to resist the pressure of the concrete without springing. Bracing and staking
80 of forms shall be such that the forms remain in both horizontal and vertical alignment
until their removal.

(d) Placing Concrete

The foundation shall be thoroughly moistened immediately prior to the placing of
the concrete. The proportioning, mixing, and placing of the concrete shall be in
accordance with 702. The thickness of the concrete in the curb ramp, including flared
sides, shall be as shown on the plans.

(e) Finishing
90 Immediately after striking off, the grade, running slopes and cross slopes shall be
checked with a 2 ft level and a long handled straightedge of light construction that can
completely span the surface. The level and straightedge shall be laid parallel and
perpendicular to the grade or running slope at intervals of no more than 2 ft on curb
ramps and 10 ft along sidewalks. All high spots shall be removed and depressions
filled with fresh concrete and then leveled. Checking and leveling shall continue until
the surface has the required grade, running slope and cross slope and is free of voids.

The surface shall be finished with a wooden float. No plastering of the surface
will be allowed. The final surface shall be free from porous spots caused by the
100 disturbance of coarse aggregate particles. Curb ramp surfaces shall be coarse broomed
transverse to the running slope as shown on the plans.

All exposed edges shall be finished with a 1/4 in. radius.

463
 604.03

(f) Joints
The type and location of joints and the size of preformed joint filler shall be as
shown on the plans.

All concrete joints shall be finished with a 1/4 in. radius.

110
Preformed 1/2 in. joint filler shall be placed around all appurtenances, such as
manholes and utility poles which extend into and through the sidewalk, and between
the sidewalk and any fixed structure, such as a building or bridge. The preformed joint
filler shall extend for the full depth of the sidewalk or curb ramp, and shall be flush
with the surface of the adjacent concrete.

(g) Detectable Warning Surfaces

Detectable warning surfaces shall be placed the full width of the curb ramp. Where
forming is required for installation of the detectable warning surfaces, the border width
120 shall not exceed 2 in. within the ramp width, as shown on the plans.

Detectable warning surfaces shall contrast visually from the adjacent surfaces.
The surface shall consist of truncated domes aligned in a square or radial grid pattern
as shown on the plans.

Surfaces shall be installed to be level across joints or seams and shall be flush
with the edges of adjoining concrete. Surfaces from various manufacturers shall not
be mixed in any individual curb ramp.

130 1. Brick Surfaces

Brick surfaces shall be placed in a mortar setting bed within the hardened concrete
block out. The concrete base of the block out shall have a rough textured finish, such
as would be produced by a screed or wood float. The depth of the block out shall be
such that a mortar bed thickness of 3/8 to 3/4 in. is achieved for the nominal depth of
the brick. The hardened concrete base shall be free of all material which might prevent
the mortar setting bed from adhering. The concrete base shall be dampened with water,
but be surface dry immediately prior to the placing the mortar setting bed. The mortar
setting bed shall be placed at the desired thickness, and no more than 2 ft ahead of
laying the bricks. The bricks shall be buttered with mortar on the bottom before
140 placement into the setting bed.

Brick surfaces shall be installed in a running or stacked bond pattern with a 1/16
in average joint width. The joint width shall not exceed 1/8 in. Whole bricks should
be laid first, followed by bricks cut to size, keeping the number of joints to a minimum.
A masonry saw shall be used to produce a clean, accurate, straight cut. The joint
between bricks shall be completely filled with a dry fine aggregate. The fine aggregate
may be obtained from a non-Certified Aggregate Producer, but it shall be natural sand
having a gradation where at least 95% of the material passes the No. 4 sieve. Excess
fine aggregate shall be removed from the surface of the bricks.
150

464
 604.06

2. Cast Surfaces
Cast iron surfaces shall be installed in accordance with the manufacturer’s
recommendations. When required, cutting of the cast iron shall be in accordance with
the manufacturer’s recommendations. Cut edges shall be ground to a smooth shape
consistent with the manufactured edges.

(h) Curing
Concrete shall be cured for at least 72 h. Curing shall be in accordance with 504.04
except curing compound shall not be used in the area where detectable warning
160 surfaces are to be installed.

604.04 PCC Steps

PCC steps shall be in accordance with the applicable provisions of 604.03.

604.05 Reconstructed PCC Sidewalk and Curb Ramp

Where existing concrete sidewalk is to be reconstructed, all disintegrated
concrete, brick, stone, or other material shall be completely removed and replaced with
new concrete sidewalk in accordance with 604.03.

170 Such sidewalk shall be constructed to a minimum depth of 4 in. unless another
depth is designated, and to the width of the adjoining walk, or to a width of no less
than 48 in. from the back face of curb, or to such other width as directed.

The removal of concrete sidewalk shall be to uniform lines as directed. The

sidewalk to be removed shall be cut in a straight line with an approved power driven
concrete saw. The sawing shall be such that the portion of sidewalk to remain in place
shall not be damaged. All portions which are damaged or removed back of the
established line shall be replaced.

180 Unless otherwise directed, sidewalk which must be removed shall be removed
between tool marks or joints. At locations where the sidewalk and curb are adjacent
and the curb is deteriorated, the curb shall also be replaced as directed.

The new sidewalk shall have a joint pattern similar to the surrounding sidewalk.
Sidewalk placed at drives shall be 6 in. thick, or the same depth of the existing drive,
whichever is greater.

Where existing curb ramp is to be reconstructed for placement of detectable

warning surfaces, all concrete, brick, stone, or other material shall be completely
190 removed and replaced in accordance with 604.03.

604.06 Re-Laid Sidewalk

This work consists of the removal and re-laying of concrete, stone-slab, or brick
sidewalk at the locations shown on the plans or as directed. In the operations of
removing and re-laying, care shall be taken not to damage any of the sidewalk. Before
re-laying, a cushion of fine aggregate shall be spread on the prepared subgrade to a

465
 604.07

depth of no less than 2 in. Cracked or damaged sections shall not be re-laid but shall
be disposed of as directed. The cross slope of the re-laid sidewalk shall be checked
with a 2 ft level in accordance with 604.03(e).
200
604.07 HMA Sidewalk

(a) Excavation and Forms

Excavation and forms, when required, shall be in accordance with 604.03(b) and
604.03(c).

(b) Bed Course

Bed course material shall be coarse aggregate No. 53 and shall be placed in lifts
not exceeding 4 in. in depth. Each lift shall be thoroughly compacted.
210
(c) Placing HMA Sidewalk
HMA sidewalk material shall be placed on a compacted bed course in one or more
courses. The mixture shall consist of HMA base, intermediate, or surface, type B in
accordance with 402, except the 9.5 mm surface gradation can go above or below the
PCS control point in accordance with 401.05. A MAF in accordance with 402.05 will
not apply. Aggregate requirements of 904.03(d) do not apply. Compaction shall be
accomplished by means of a hand operated or power roller of an acceptable type and
weight in accordance with 402.15. In areas inaccessible to the roller, hand tamping
will be allowed. In any case, the HMA sidewalk material shall be uniformly
220 compacted. The grade and cross slope shall be checked with a 2 ft level in accordance
with 604.03(e).

If the finished compacted surface is too open or remains sticky, the surface shall
be given a coating of fine aggregate, well broomed over the surface, leaving no excess.

604.08 Backfilling and Finishing Shoulders and Slopes

After forms have been removed, the space on each side of the sidewalks shall be
filled to the required elevation with suitable material which shall be firmly compacted
and neatly graded. Adjacent shoulders and slopes shall be finished to the required
230 grade and cross section.

604.09 Hand Rails

This railing shall be erected in a workmanlike manner, straight and true to grade.
Posts shall be vertical and railings shall be parallel to the walk surface or the plane of
the steps and spaced as shown on the plans. Fastenings shall be as indicated on the
plans. Railing posts on masonry shall be held in place in a manner that develops the
full strength of the railing post in bending.

Fabrication and placement of railings shall be completed in accordance with the

240 applicable requirements of 711. Ends of tube sections shall be milled or sawed. Cut
ends shall be true, smooth, and free from burrs and ragged edges. Welds shall be
ground smooth. The rail system shall be continuous except as shown on the plans.

466
 604.11

Joints shall be spliced as detailed on the plans. Welding of steel shall be in accordance
with 711.32 and welding of aluminum shall be in accordance with the applicable
requirements of 803. Radiographic, magnetic particle, and dye penetrant inspection
will not be required.

All aluminum surfaces in contact with concrete shall be coated with an aluminum
impregnated caulking compound prior to installation. After installation and alignment,
250 openings between metal surfaces and concrete shall be sealed in a watertight manner
with the caulking compound.

Steel pipe railing not designated to be painted shall be galvanized after fabrication
and prior to installation. Railing designated to be painted shall receive one shop coat
of paint after fabrication and two field coats after installation. The type and color of
paint shall be as specified on the plans. Cleaning and painting shall be in accordance
with 619.

604.10 Method of Measurement

260 Concrete sidewalk, reconstructed concrete sidewalk, and re-laid concrete
sidewalk will be measured by the square yard of finished surface. HMA for sidewalk
will be measured by the ton of mixture placed. Bed course material will be measured
by the ton.

Concrete curb ramps will be measured by the square yard and will include the
ramp, turning space, flared side, and setback. Turning spaces shared by more than one
curb ramp will be measured only once. Detectable warning surfaces and retrofitted
detectable warning surfaces will be measured by the square yard.

270 Concrete steps will be measured by the cubic yard based on the neat lines shown
on the plans.

Hand rails will be measured by the linear foot in accordance with the dimensions
shown on the plans or as directed. Measurements will be made from end to end of the
railing along the centerline.

Curb and curb and gutter will be measured in accordance with 605.09.
Reinforcing bars, if used, will be measured in accordance with 703.07.

280 Joint material will not be measured.

604.11 Basis of Payment

The accepted quantities of concrete sidewalk will be paid for at the contract unit
price per square yard for sidewalk, concrete. HMA for sidewalk will be paid for at the
contract unit price per ton, complete in place. Bed course material will be paid for at
the contract unit price per ton. Concrete steps will be paid for at the contract unit price
per cubic yard for steps, concrete. Reconstructed sidewalk and re-laid sidewalk will
be paid for at the contract unit price per square yard for sidewalk, reconstruct, or

467
 604.11

sidewalk, re-lay. Detectable warning surfaces and retrofitted detectable warning

290 surfaces will be paid for at the contract unit price per square yard.

The accepted quantities of curb ramps will be paid for at the contract unit price
per square yard for curb ramp, concrete, complete in place.

Hand rails will be paid for at the contract unit price per linear foot.

Curb and curb and gutter will be paid for in accordance with 605.10.

Reinforcing bars, if used, will be paid for in accordance with 703.08. Curb, if
300 directed to be replaced, will be paid for in accordance with 605.10.

Payment will be made under:

Pay Item Pay Unit Symbol

Bed Course Material .................................................................. TON

Curb Ramp, Concrete ................................................................ SYS
Detectable Warning Surfaces .................................................... SYS
Detectable Warning Surfaces, Retrofit ...................................... SYS
310 Hand Rail, _____ ....................................................................... LFT
type
HMA for Sidewalk .................................................................... TON
Sidewalk, Concrete .................................................................... SYS
Sidewalk, Concrete, Reconstruct ............................................... SYS
Sidewalk, Concrete, Re-Lay ...................................................... SYS
Steps, Concrete .......................................................................... CYS

The cost of the ramp, including border, turning space, flared side, return curb, and
setback shall be included in the cost of the curb ramp.
320
The cost of excavation, backfill, joint material, and necessary incidentals shall be
included in the cost of the pay items in this section.

The removal and disposal of concrete sidewalk which is unsuitable for re-laying
and which has not been damaged due to negligence will be paid for in accordance with
202.14. Concrete sidewalk which is specified to be re-laid or to remain in place and
which is damaged shall be removed and disposed of and replaced with no additional
payment.

330 If directed, concrete sidewalk shall be constructed to a depth greater than that
shown on the plans. Such additional thickness will be converted into the equivalent
square yards quantity of concrete sidewalk of the thickness shown on the plans and
will be paid for as such.

468
 605.03

The cost of furnishing and applying sand to finished compacted surfaces shall be
included in the cost of HMA for sidewalk.

The cost of the detectable warning surfaces, thin set mortar, and fine aggregate
for filling joints shall be included in the cost of the detectable warning surfaces.
340
The cost of removal, disposal, and replacement of portions of the concrete curb
ramp, concrete base, including border, detectable warning surfaces, thin set mortar,
and fine aggregate for filling joints shall be included in the cost of the detectable
warning surfaces, retrofit.

The cost of aluminum impregnated caulking compound and the painting of steel
hand railing shall be included in the cost of the hand rail.

SECTION 605 – CURBING

605.01 Description
This work shall consist of the construction of curb or curb turnouts; combination
curb and gutter, combined curb and gutter turnouts; or resetting curb in accordance
with 105.03.

MATERIALS

10 605.02 Materials
Materials shall be in accordance with the following:

Coarse Aggregate, Class D or Higher, Size No. 53 ..... 904

Concrete ...................................................................... 502
Joint Materials ............................................................. 906
Joint Mortar ................................................................. 907.12
Precast Concrete Curbing ............................................ 905.04
Reinforcing Bars.......................................................... 910.01

20 605.03 Precast Cement Concrete Curbing

(a) Excavation
Excavation shall be made to the required depth and the base upon which the curb
is to be set shall be compacted to a firm even surface. All soft and unsuitable material
shall be removed and replaced with suitable material which shall be thoroughly
compacted.

(b) Installation
The curb shall be set in accordance with the line and grade required. The face and
30 top of the curb shall be checked with a 10 ft straightedge. Portions showing
irregularities of 1/4 in. or more shall be removed and replaced with no additional

469
 605.04

payment. All spaces under the curbing shall be filled with bed course material. The
bed course material shall be coarse aggregate No. 53 and shall be thoroughly tamped.

(c) Joints
Curbing shall be laid with joints as indicated on the plans. These joints shall be
filled with mortar as specified. Where a portland cement concrete pavement is to be
constructed contiguous to a curbing, joints shall be constructed in the curbing directly
in line with pavement expansion joints. The joint in the curbing shall be the same width
40 as the pavement joint and shall be filled with an expansion joint filler of the nominal
thickness as the pavement joint. Any voids between the joint filler and the curb shall
be filled with mortar.

(d) Backfilling
After the curb has set, any remaining excavated areas shall be filled with approved
material. This material shall be placed and thoroughly tamped in layers not exceeding
6 in. in depth.

605.04 Cast in Place Cement Concrete Curbing

50
(a) Excavation
Excavation and bedding shall be in accordance with 605.03(a).

(b) Forms
Forms shall be of wood or metal, straight, free from warp, and of such
construction that there will be no interference to the inspection of grade or alignment.
All forms shall extend for the entire depth of the curb and shall be braced and secured
sufficiently so that no deflection from alignment or grade shall occur during the
placing of the concrete.
60
(c) Proportioning and Placing
Concrete shall be proportioned, mixed, and placed in accordance with 502, except
utilization of the Department provided spreadsheet is not required for the CMDS.
Where integral curb and gutter is specified, that portion of the curb below the upper
surface elevation of the adjoining pavement shall be constructed by extending the
pavement to the outer vertical plane of the curb at the time the pavement is placed.
The concrete used in this extension shall be the same composition as that of the
pavement.

70 As an option, an integral curb and gutter may be placed at the same time as the
PCCP pavement by the slip form method. The slip form machine must have an
attachment to place, consolidate and shape the concrete to the required shape and
dimensions. The reinforcing tie bars or stirrups between the pavement and the curb
shall be omitted.

470
 605.04

After the concrete for the upper portion is placed in the forms, it shall be tamped
and spaded or vibrated until mortar entirely covers the surface. The top shall be floated
smooth and the outer upper corner rounded to a 1/4 in. radius.

80 The face and top of the curb, integral curb, and gutter shall be checked with a 10 ft
straightedge. Portions showing irregularities of 1/4 in. or more shall be removed and
replaced.

Consolidation of concrete placed in the forms shall be by vibration or other

acceptable methods. Forms shall be left in place for 24 h or until the concrete has set
sufficiently so that they can be removed without injury to the curbing. Upon removal
of the forms, the exposed curbing face shall be rubbed immediately to a uniform
surface. Rubbing shall be accomplished by the use of water and a carborundum brick.
For the purpose of matching adjacent concrete finishes or for other reasons, other
90 methods of finishing may be allowed. No plastering will be allowed.

(d) Curb Turnouts and Combined Concrete Curb and Gutter Turnouts
Turnouts will be required with specified inlets or with concrete gutter and paved
side ditch in accordance with 607 and as shown on the plans. Concrete gutter and
paved side ditch shall be constructed monolithically with the curb turnout.

(e) Joints
Joints in integral curbs shall be located at joints in adjoining PCCP. The joints
shall be saw cut or formed with 1/4 in. thick preformed joint material. Joint sealant is
100 not required for joints in integral curbs.

Curbing not constructed integral with adjacent pavement shall be constructed with
intermediate joints located at 10 ft intervals. These joints may be sawed or formed with
metal separator plates, and the depth and width shall be in accordance with the plans.

Preformed expansion joints, 1/4 in. thick, shall be placed at the beginning and end
of all curb returns and also at castings.

(f) Curing
110 Immediately upon completion of the rubbing, the curbing shall be moistened and
kept moist for three days, or cured by the use of membrane forming material. The
method and details of curing shall be subject to approval.

(g) Backfilling
After the concrete has set sufficiently, the spaces in front and back of the curb
shall be refilled with suitable material to the required elevations in layers of not more
than 6 in. and be tamped thoroughly.

(h) Curb Machine

120 Curb machines may be used to construct curb provided the curb can be
constructed to the requirements of the specifications.

471
 605.05

605.05 Reflecting Cement Concrete Curbing

Construction methods for this item shall be in accordance with 605.03 and the
following requirements.

The reflecting surface of the curbing shall be a mortar mix consisting of 1 part
white portland cement to 1 3/4 parts of light colored, washed, mortar sand. This mortar
mix shall have a thickness of approximately 1 in. Alternately, the entire curbing may
130 be constructed of concrete made with white portland cement.

Washed mortar sand shall meet all the requirements for mortar sand and shall be
of a light satisfactory color. The reflecting surface mortar shall be placed immediately
after the placing of the base concrete. No more than 20 minutes shall elapse between
the placing of the base concrete and the placing of the reflecting surface.

Scoring or surface deformation and finish of the reflecting surface shall be in

accordance with the details shown on the plans.

140 605.06 Concrete Center Curbing

The subgrade shall be prepared the same as for the adjoining pavement. If subbase
is provided for the adjoining pavement, it shall be carried through for the full width of
the curb and at the same thickness as that for the pavement.

The temperature limitations of 502.11 shall apply to placing the concrete. The
surface shall be troweled smooth with a metal trowel. Curing shall be in accordance
with 504.04.

Forms shall be removed within 24 h after the concrete has been placed. Plane
150 surfaces and exposed sides of the curb shall be checked with a 10 ft straightedge.
Portions showing irregularities of 1/4 in. or more shall be removed and replaced in
compliance with these specifications.

Joints in center curbs adjacent to PCCP shall be aligned with joints in adjoining
PCCP. Joints in center curbs adjacent to asphalt shall be spaced at 18 ft maximum.
The joints shall be saw cut or formed with 1/4 in. thick preformed joint material. Joint
sealant is not required for joints in center curbs.

Where an expansion joint is constructed in PCCP adjacent to concrete center curb,

160 the expansion joint shall be carried through the center curb in accordance with
applicable requirements of 503.03(f).

605.07 HMA Curbing

(a) Excavation
Excavation shall be in accordance with 605.03(a).

472
 605.07

(b) Preparation of Bed

When curbing is to be constructed on a fresh laid HMA surface, the curb may be
170 laid only after the surface has been cleaned.

When curbing is to be constructed on a cured or aged portland cement concrete

base, asphalt pavement, or asphalt treated base, the bed shall be thoroughly swept and
cleaned with compressed air. The surface shall be thoroughly dried and, immediately
prior to placing of the HMA mixture, shall receive a tack coat in accordance with 406.
During application, the spread of this tack coat to areas outside of the area to be
occupied by the curb shall be prevented.

(c) Mixture
180 The mixture shall be in accordance with 402.07(d).

Acceptance of HMA curbing mixtures will be a type D Certification in accordance

with 916. The test results shown on the certification shall be the quality control tests
representing the material supplied and include gradation and binder content. The
gradation tolerances shall be ±2.5% on the No. 200 (75 µm) sieve, ±4.0% on the No.
4 (4.75 mm) sieve, and binder content tolerance shall be ±0.5% from DMF.

(d) Placing
HMA curbing shall be constructed by use of a self-propelled automatic curber,
190 curb machine or paver with curbing attachments. The curbing shall be in accordance
with the section shown on the plans. The automatic curber or machine shall meet the
following requirements and shall be approved prior to use.

1. The weight of the machine shall be such that required

compaction is obtained without the machine riding above
the bed on which curbing is being constructed.

2. The machine shall form curbing that is uniform in texture,

shape, and density.
200
The construction of curbing by means other than the automatic curber or machine
may be allowed when short sections or sections with short radii are required, or for
such other reasons as may seem warranted. The resulting curbing shall conform in all
respects to the curbing produced by the use of the machine. The face and top of the
HMA curb shall be checked with a 10 ft straightedge. Portions showing irregularities
of 1/4 in. or more shall be removed and replaced.

Weather limitations shall be in accordance with 402.12.

210 (e) Painting and Sealing

When sealing or painting is required, it shall be performed only on a curbing
which is clean and dry and which has reached the ambient temperature.

473
 605.08

605.08 Resetting Curbing

(a) Salvage of Curbing

Curbing specified for resetting shall be cleaned, removed, and stored. Any
existing curbing that is to be reset which is lost, damaged, or destroyed as a result of
operations or because of failure to store and protect it in a manner that would eliminate
220 its loss or damage, shall be replaced.

(b) Curb Removal

Curbing, which is unsuitable for resetting and which has not been damaged due
to negligence, shall be removed and disposed of as directed.

(c) Excavation
Excavation and bedding shall be in accordance with 605.03(a).

(d) Resetting
230 The curb shall be set on a firm bed in accordance with the required line and grade.
All sections of curbing shall be set so that the maximum opening between adjacent
sections is 3/4 in. wide for the entire exposed top and face. Any dressing of the ends
of the curbing necessary to meet this requirement shall be done as needed. Cutting or
fitting may be necessary in order to install the curbing at the locations as directed.

After the curb has been set, the joints shall be completely filled with mortar as
specified.

(e) Backfilling
240 The spaces in front and back of the curb shall be refilled to the required elevation
with suitable material. This material shall be tamped thoroughly in layers of not over
6 in. in depth.

605.09 Method of Measurement

Curbing, both new and reset, and curb removal will be measured by the linear foot
along the front face of the section at the finished grade elevation. Combined curb and
gutter will be measured along the face of the curb. Curb turnout will be measured
longitudinally by the linear foot as curb of the type specified, from the ends of the radii
which touch the front face of the longitudinal curb portion. Combined curb and gutter
250 turnout will be measured longitudinally by the linear foot as curb and gutter of the type
specified, from the ends of the radii which touch the front face of the longitudinal curb
portion. No deduction in length will be made for drainage structures installed in the
curbing such as catch basins or drop inlets. Concrete center curb will be measured by
the linear foot, unless it is of variable width, in which case measurement will be by the
square yard.

Bed course material will be measured by the ton.

474
 606.01

605.10 Basis of Payment

260 The accepted quantities of curb work will be paid for at the contract unit price per
linear foot for curb; curb and gutter; curb, reset; or center curb, of the type specified.
Variable width center curb will be paid for at the contract unit price per square yard
for center curb, of the width specified. Bed course material will be paid for at the
contract unit price per ton, complete in place.

Curb turnout will be paid for at the contract unit price per linear foot of the type
of curb specified. Combined curb and gutter will be paid for at the contract unit price
per linear foot for curb and gutter of the type specified.

270 Payment will be made under:

Pay Item Pay Unit Symbol

Bed Course Material .................................................................. TON

Center Curb, _____ ................................................................... SYS
type LFT
Curb and Gutter, _____ ............................................................. LFT
type
Curb, _____ ............................................................................... LFT
280 type
Curb, Remove ............................................................................ LFT
Curb, Reset, _____ .................................................................... LFT
type

The cost of tack coat, reinforcing bars or welded wire reinforcement for curb, curb
and gutter, or center curb shall be included in the cost of the pay items. The cost of
replacement curb portions for those which show irregularities or 1/4 in. or more shall
be included in the cost of curb.

SECTION 606 – PAVEMENT CORRUGATIONS

606.01 Description
This work shall consist of placing corrugations in the pavement in accordance
with 105.03. Corrugations shall not be constructed within the limits of reinforced
concrete bridge approaches or on bridge decks.

The operation shall be coordinated such that milled materials do not encroach on
pavement lanes carrying traffic and all milled materials are disposed of in accordance
10 with 104.07. When corrugations are installed, milled materials shall be swept and
vacuumed following the milling operation.

The corrugations shall be constructed by cutting smooth strips in existing or newly

constructed pavement. The operation shall be conducted by means of a cutting

475
 606.02

machine that provides a series of smooth cuts without tearing or snagging. The
equipment shall include guides to maintain uniformity and consistency in the
alignment of the strips.

Longitudinal rumble stripes are the combination of either the center line pavement
20 marking placed in the center line corrugation or the edge line pavement marking
placed in the edge line corrugation. They shall be installed as shown on the plans and
as specified herein.

Longitudinal rumble strips are corrugations placed in the shoulder near the travel
lane. They shall be installed as shown on the plans and as specified herein.

When corrugations are installed, control points are required as a guide for milling
corrugations and shall be spotted with paint for the full length of the road to be milled.
Control points along tangent sections shall be spaced at a maximum interval of 100 ft.
30 Control points along curve sections shall be spaced to ensure the accurate location of
the milled corrugations. The location of control points shall be as approved prior to
the milling operations.

If snowplowable raised pavement markers exist where center line corrugations

are being placed into the existing surface, the prismatic reflectors in these markers
shall be temporarily covered and corrugations gapped a maximum of 5 ft and not
within 6 in. of the markers.

Milled HMA corrugations shall be the type designated in the contract documents,
40 Conventional or Sinusoidal. Milled PCCP corrugations shall be Conventional.

MATERIALS

606.02 Materials
Materials shall be in accordance with the following:

Pavement Markings ..................................................... 808

Liquid Asphalt Sealant ................................................ 902.01

50 CONSTRUCTION REQUIREMENTS

606.03 General Requirements

In the presence of D-1 pavement joints or castings which conflict with the location
of the corrugations, the corrugations shall be gapped a maximum of 5 ft and not within
6 in. of the joint or casting.

Corrugations installed on HMA shall be sealed using liquid asphalt sealant in

accordance with 401.15.

476
 606.05

60 Corrugations shall not be installed on PCCP until the PCCP has cured for a
minimum of 14 days. The milling operations for installing corrugations on PCCP shall
not exceed 12 mph.

(a) Installation Tolerances

Lateral deviation of milled corrugations shall not exceed 1 in. in 100 ft. The
alignment of all pavement markings placed within rumble stripes shall be ±1/2 in. of
its specified location.

(b) Maintenance of Traffic

70 The rumble stripe traffic control procedures shall be submitted to the Engineer
and shall be in accordance with 808.08. Vehicles used in performing the milling,
sweeping, vacuuming, or sealing operations shall have a rear escort vehicle that
follows at a distance of 100 to 500 ft.

606.04 Method of Measurement

HMA and PCC pavement corrugations will be measured by the linear foot,
measured parallel to the center line of the roadway. Gaps longer than 20 ft will not be
included in the measurement for milled corrugations.

80 606.05 Basis of Payment

HMA and PCC pavement corrugations will be paid for at the contact unit price
per linear foot, for the type specified.

Payment will be made under:

Pay Item Pay Unit Symbol

Milled HMA Corrugations, _______ ........................................ LFT

type
90 Milled PCCP Corrugations, Conventional ................................ LFT

The cost of temporarily covering existing prismatic reflectors in rumble strip

retrofit sections shall be included in the cost of the pay items.

Milling, sweeping, vacuum cleaning, operation protection and maintenance of

traffic associated with these pay items, and all necessary incidentals shall be included
in the cost of the pay items.

Where corrugations are placed in an existing HMA surface, liquid asphalt sealant
100 shall be included in the cost of the pay items.

477
 607.01

SECTION 607 – PAVED SIDE DITCH OR CONCRETE GUTTER

607.01 Description
This work shall consist of placing a portland cement concrete lining, gutter, or
reinforced concrete gutter turnout for side ditches in accordance with 105.03.

MATERIALS

607.02 Materials
10 Materials shall be in accordance with the following:

Concrete, Class A ........................................................ 702

Reinforcing Bars.......................................................... 910.01

CONSTRUCTION REQUIREMENTS

607.03 General Requirements

The excavation shall be to the required depth and shape of the bottom of the type
and size of the side ditch being constructed, the details of which are shown on the
20 plans. All soft, yielding, or unsuitable materials encountered at the required excavation
elevation shall be removed and replaced with approved materials which shall be
compacted and finished to a firm, smooth surface.

The applicable requirements of 605.04(b) shall apply to forms.

Placing, finishing, and curing shall be in accordance with 605.04 except the curing
period shall be no less than 72 h. The finished surface need not be brushed.

Reinforcement will be required for all paved side ditch, cut-off-walls, and lugs as
30 shown on the plans.

Paved side ditch transitions will be required at intersections with earth ditches and
pipe culverts.

Transitions of 10 ft or less will be required between two different types of paved

side ditches.

Cut-off wall and lug details shall be as shown on the plans. A cut-off wall shall
be constructed at the beginning and end of any paved side ditch. Lugs shall be poured
40 monolithic with paved side ditch on steep grades. Their locations shall be as shown on
the plans or as otherwise directed. Backfilling shall be in accordance with 605.04(g).

607.04 Cement Concrete Gutter and Turnout

Concrete gutter and concrete gutter turnout shall be constructed as shown on the
plans or where directed. Construction shall be in accordance with all applicable
requirements set out herein for paved side ditch.

478
 608.02

607.05 Method of Measurement

Paved side ditch or cement concrete gutter will be measured by the linear foot
50 along the centerline of the ditch per each type specified. Each cutoff wall or lug will
be measured as 8 lft of paved side ditch or cement concrete gutter. Paved side ditch
transitions at earth ditches and pipe culverts will be measured as equivalent lengths in
linear feet of the paved side ditch specified at each location. Transitions at the
intersection of two different types of paved side ditch will be converted to equivalent
lengths in linear feet of the larger type of paved side ditch specified at each site.

Reinforced concrete gutter turnout will be measured as 50 lft of concrete gutter.

Additional length, if required, will be measured by the linear foot of concrete gutter.

60 607.06 Basis of Payment

The accepted quantities of paved side ditch or cement concrete gutter of the type
specified, including cutoff walls and lugs measured in accordance with 607.05, will
be paid for at the contract unit price per linear foot complete in place. Concrete gutter
turnout will be paid for at the contract unit price per linear foot for gutter, concrete, of
the type specified.

Payment will be made under:

Pay Item Pay Unit Symbol

70
Gutter, Concrete, _____ ............................................................ LFT
type
Paved Side Ditch, _____ ........................................................... LFT
type

The cost of reinforcing bars or welded wire reinforcement, excavation, joints, and
necessary incidentals shall be included in the cost of the pay items.

SECTION 608 – SHOULDER DRAINS

608.01 Description
This work shall consist of constructing shoulder drains in accordance with these
specifications and in accordance with 105.03.

MATERIALS

608.02 Materials
10 Materials shall be in accordance with the following:

Coarse Aggregates, Class D or Higher, Size No. 8 ..... 904

479
 608.03

CONSTRUCTION REQUIREMENTS

608.03 General Requirements

Unless otherwise designated, shoulder drains shall be installed on both sides of
the pavement by trenching from the edges of the pavement through the shoulders and
backfilling with aggregate at low points in the grade and at other locations when so
20 directed. This work shall precede the finishing of the shoulders.

The width of the trench shall be approximately 12 in. unless otherwise directed.
Other dimensions shall be as shown on the plans.

After the trench has been prepared, it shall be backfilled to the required elevation
with aggregate, and then be well compacted. After this, any remaining unfilled trench
area shall be filled with material approved for shoulders and compacted by rolling or
tamping or both. The finished shoulder elevation shall conform with that required at
that point.
30
608.04 Method of Measurement
Shoulder drains will be measured by the ton of aggregate placed.

608.05 Basis of Payment

The accepted quantities of aggregate for shoulder drains will be paid for at the
contract unit price per ton for aggregate for shoulder drains complete in place.

Payment will be made under:

40 Pay Item Pay Unit Symbol

Aggregate for Shoulder Drains .................................................. TON

Excavation, trenching, backfilling, and other related miscellaneous items will not
be paid for separately, but the cost thereof shall be included in the cost of the pay item.

SECTION 609 – REINFORCED CONCRETE BRIDGE APPROACHES

609.01 Description
This work shall consist of constructing reinforced concrete bridge approaches,
RCBA, and extensions required for bridge railing transitions in accordance with
105.03.

MATERIALS

10 609.02 Materials
Materials shall be in accordance with the following:

480
 609.07

Coarse Aggregate, Class D or Higher, Size No. 53 ..... 904

Concrete, Class C* ...................................................... 702
Curing Materials .......................................................... 912.01
Joint Materials ............................................................. 906.02(a)1
Reinforcing Bars, Epoxy Coated ................................. 910.01
Support Devices .......................................................... 910.01(b)9
Surface Seal ................................................................. 709.02
20 Threaded Tie Bar Assembly ........................................ 910.01(b)2
* Coarse Aggregate shall be Class AP, Size No. 8

CONSTRUCTION REQUIREMENTS

609.03 General Requirements

Subgrade shall be prepared in accordance with 207. Subbase shall be prepared in
accordance with 302.

The RCBA extension shall be placed only where a concrete bridge-railing

30 transition shall be located on the RCBA. If the transition shall be placed on the bridge,
the RCBA shall be placed as shown on the plans.

609.04 Forms
Forms shall be either steel or wood and shall be in accordance with 508.04(c)1 or
508.04(c)2.

609.05 Joints
Longitudinal construction joints will only be allowed as shown on the plans. The
type I-A joint shall be constructed as shown on the plans.
40
Type I-A joints shall be created by sawing slots using sawing equipment in
accordance with 508.07. The joint shall be cut in two operations. The initial saw cut
shall commence as soon as the concrete has hardened sufficiently to enable sawing
without raveling, usually 2 to 12 h after placement.

The second saw cut shall be made after the concrete has sufficiently cured, but
before opening the RCBA to all traffic. Slurry or saw residue remaining in the slot
shall be immediately flushed. Construction traffic shall not be on the RCBA after the
second saw cut until the joint is sealed.
50
The sawed slot shall be cleaned to remove all foreign matter from the entire depth
of cut. Joint sealing shall be in accordance with 503.05.

609.06 Reinforcing Bars

Furnishing and placement of reinforcing bars shall be in accordance with 703.

609.07 Thickness
The depth of the RCBA will be checked by the Engineer prior to pouring, by
making stringline measurements every 3 ft across the width of the approach. Any
481
 609.08

60 location deficient in depth by 1/2 in. or more shall be corrected prior to placing the
concrete.

609.08 Concrete Placement

The subbase shall be uniformly moist at the time of concrete placement. Delivery
and placement of concrete shall be in accordance with 702.

609.09 Finishing
The RCBA shall be finished with equipment in accordance with 508.04(c)3 and
508.04(c)4. The operations shall be controlled so that an excess of mortar and water is
70 not worked to the top. Long handled floats may be used to smooth and fill in open
textured areas. The edges of formed RCBA shall be tooled or chamfered.

The finished RCBA surface shall be textured with a double thickness burlap drag
or a minimum 4 ft wide turf drag. Immediately after the finishing operation is complete
and before the surface film has formed, the surface of the RCBA shall be textured by
transverse grooving in accordance with 504.03. The grooves may be formed by
mechanized equipment using a vibrating beam roller, a series of discs or other
approved device. Manual tools such as fluted floats, spring steel tined rakes, or finned
floats with a single row of fins may be used. The grooves shall be relatively uniform
80 and smooth and shall be formed without tearing the surface or bringing coarse
aggregate to the top.

All areas of hardened RCBA which do not conform to the requirements due to
either a deficiency in the grooving or a rough open textured surface shall be corrected.
Corrections shall be made by cutting transverse grooves in the hardened surface with
an approved cutting machine and retexturing to a satisfactory finish as directed.

609.10 Curing
RCBA shall be wet cured in accordance with 702 or shall have liquid membrane
90 forming curing compound applied to exposed surfaces within 30 minutes after the
finishing operations have been completed. The edges of the RCBA shall be cured
immediately upon removal of the forms. The edge shall be covered with curing
materials equal to the material used on the surface or banked with soil 12 in. wide or
greater.

When conditions arise which prevent timely application of curing materials the
surfaces shall be kept wet with a fine spray of water. The fine spray of water shall
continue until application of curing materials is resumed.

100 Liquid membrane forming curing compound shall be applied in a continuous

uniform film at a rate not less than 1 gal./150 sq ft. Additional applications, if needed,
shall follow the previous application within 30 minutes. The curing compound may be
warmed in a water bath during cold weather at a temperature not exceeding 100°F.
Thinning with solvents will not be allowed. Non-uniform film rates will result in the
discontinuance of that application method.

482
 609.14

A new coat of curing compound shall be applied to areas damaged by rain or other
means during the curing period. The recoating shall be applied as soon as possible and
at a rate equal to that specified for the original coat.
110
609.11 Smoothness
The smoothness of the surface of the RCBA will be measured by means of a 10 ft
long straightedge as soon as practical following curing or completion of adjoining
roadway or structure sections. All surface variations shall be corrected to 1/8 in. or
less.

Smoothness variations outside specified tolerances shall be corrected in

accordance with 502.20.

120 609.12 Opening to Traffic

RCBA may be opened to traffic after 14 days. The RCBA may be opened earlier
if test beams indicate a modulus of rupture of 550 psi or greater.

The Contractor and Engineer will conduct an inspection of the new RCBA for any
damage. The inspection and all necessary repairs shall be completed prior to opening
to traffic.

609.13 Method of Measurement

Reinforced concrete bridge approaches, including extensions required for bridge
130 railing transitions, will be measured by the square yard. Dense graded subbase will be
measured in accordance with 302.08. Reinforcing bars will be measured in accordance
with 703.07. Threaded tie bar assemblies will be measured in accordance with 703.07.
Surface seal will be measured in accordance with 709.07.

Subgrade preparation will not be measured for payment. Finishing and curing of
the RCBA will not be measured for payment. Construction joints or type I-A joints
will not be measured.

609.14 Basis of Payment

140 Reinforced concrete bridge approaches, including extensions required for bridge
railing transitions, will be paid for at the contract unit price per square yard. Dense
graded subbase will be paid for in accordance with 302.09. Reinforcing bars will be
paid for in accordance with 703.08. Threaded tie bar assemblies will be paid for in
accordance with 703.08. Surface seal will be paid for in accordance with 709.08.

Payment will be made under:

Pay Item Pay Unit Symbol

150 Reinforced Concrete Bridge Approach, ________ in. .............. SYS

thickness

483
 610.01

The cost of all materials, water, equipment, and all labor for the compaction of
the subgrade, shall be included in the cost of the RCBA.

The cost of finishing, furnishing and placing curing materials shall be included in
the cost of the RCBA.

The cost of corrections for smoothness or re-texturing shall be included in the cost
160 of the RCBA.

The cost of all labor and materials for the placement of construction joints and
type I-A joints shall be included in the cost of the RCBA.

SECTION 610 – APPROACHES AND CROSSOVERS

610.01 Description
This work shall consist of constructing or resurfacing public road intersections;
turn lanes, passing lanes, acceleration lanes, deceleration lanes, or recovery lanes
where the total longitudinal dimension is less than 100 ft, excluding tapers; mailbox
approaches; private and commercial driveways; and crossovers; in accordance with
105.03.

10 MATERIALS

610.02 Materials
Materials shall be in accordance with the following:

Aggregate Base............................................................ 301.02

HMA............................................................................ 402.03
PCCP ........................................................................... 502.02
Prime Coat ................................................................... 405.02
Seal Coat ..................................................................... 404
20 Subbase........................................................................ 302.02
Tack Coat .................................................................... 406.02

CONSTRUCTION REQUIREMENTS

610.03 General Requirements

Subgrade for approaches shall be prepared in accordance with 207. Aggregate
base shall be constructed in accordance with 301. HMA for approaches shall be
constructed in accordance with 402. HMA mixture for approaches shall be HMA
surface or intermediate, type B, C, or D in accordance with 402.04. A MAF in
30 accordance with 402.05 will not apply.

484
 610.06

Dense graded subbase shall be constructed in accordance with 302. PCCP for
approaches shall be constructed in accordance with 502. The CMDS shall be submitted
to the Engineer for approval. Utilization of the Department provided spreadsheet is
not required.

610.04 Existing Approaches and Crossovers

If an existing surface is to be left in place as an approach pavement or crossover,
the surface shall be patched in accordance with 304.04 or 305.04, or as directed.
40 Existing approaches or crossovers that have been rubblized shall be primed in
accordance with 405 prior to being paved.

610.05 Method of Measurement

Compacted aggregate base will be measured in accordance with 301.09. HMA
mixture for approaches will be measured by the ton of the type specified, in accordance
with 109.01(b). Dense graded subbase will be measured in accordance with 302.08.
PCCP for approaches will be measured by the square yard of the thickness specified.
Subgrade treatment will be measured in accordance with 207.05.

50 HMA patching in accordance with 610.04, will be measured by the ton in

accordance with 304.06. PCCP patching in accordance with 610.04, will be measured
by the square yard in accordance with 305.06.

Prime coat will be measured in accordance with 405.09. Tack coat will be
measured in accordance with 406.06. Seal coat will be measured in accordance with
404.13.

610.06 Basis of Payment

The accepted quantities of HMA mixture for approaches will be paid for at the
60 contract unit price per ton of the type specified, complete in place. Compacted
aggregate base will be paid for in accordance with 301.10. PCCP for approaches will
be paid for at the contract unit price per square yard of the thickness specified,
complete in place. Dense graded subbase will be paid for in accordance with 302.09.
Subgrade treatment will be paid for in accordance with 207.06.

HMA patching will be paid for in accordance with 304.07. PCCP patching will
be paid for in accordance with 305.07.

Prime coat will be paid for in accordance with 405.10. Tack coat will be paid for
70 in accordance with 406.07. Seal coat will be paid for in accordance with 404.14.

The quantities of materials placed on the 3 ft wedge on approaches, when placed

with the mainline pavement shall be included in the mainline HMA items and paid for
in accordance with 401.22 or 402.20. The quantities, when placed separately from the
mainline pavement, shall be included in the quantities for HMA for approaches and
paid for in accordance with 610.06.

485
 611.01

The quantities of materials for the paving or resurfacing of turn lanes, passing
lanes, acceleration lanes, deceleration lanes, and recovery lanes greater than 100 lft,
80 excluding tapers, shall be included in the mainline quantities and paid for in
accordance with 401.22, 402.20, 501.31, or 502.23 whichever is applicable.

The accepted quantities of HMA material for mailbox approaches will be included
with quantities required to construct the shoulder section when the shoulder is to be
paved. If the shoulder is not to be paved, the HMA material for mailbox approaches
will be paid for as HMA mixture for approaches of the type specified.

Payment will be made under:

90 Pay Item Pay Unit Symbol

HMA for Approaches, Type * ........................................... TON

PCCP for Approaches, _____ .................................................... SYS
thickness
* Mixture type in accordance with 402.04.

The cost of excavation, shaping, leveling, forming, compaction, placing, and all
necessary incidentals shall be included in the cost of the pay items in this section.

100 The cost for curbing placed monolithically with the PCCP on approaches shall be
included in the cost of PCCP for approaches.

SECTION 611 – MAILBOX INSTALLATIONS

611.01 Description
This work shall consist of the construction of mailbox installations, or the removal
and resetting of existing mailboxes and assemblies, in accordance with 105.03.

MATERIALS

611.02 Materials
10 Materials shall be in accordance with the following:

Mailbox Support Galvanized Hardware ...................... ASTM A 153

Nominal Standard Galvanized Pipe ............................. ASTM A 53
Treated Wood Posts..................................................... 911.02(e)

CONSTRUCTION REQUIREMENTS

611.03 Mailbox Assembly

Existing mailboxes and assemblies shall be removed without damage from the
20 highway right-of-way. Mailboxes, which must remain in service between removal and
erection of the new assembly, shall be securely mounted to an empty 55 gal. metal
486
 611.05

drum. The temporary assembly shall be located where it is accessible for mail delivery
but placed as far as possible from the traveled roadway. The apparent owner of the
existing mailbox shall be contacted and allowed to take possession of the existing
mailbox and assembly. If the owner refuses to take possession, the existing mailbox
and assemblies shall be removed.

Mailbox assemblies shall be furnished and installed as shown on the plans.

Alternate mailbox assemblies which have been crash tested and approved in
30 accordance with NCHRP 350 requirements may be considered upon receipt of a
written request. Alternate mailbox assemblies approved for use shall be furnished and
installed in conformance with the manufacturer’s recommendations.

Mailboxes complying with the requirements of the United States Postal Service,
including markings and sizes, shall be furnished and installed with the mailbox
assembly. The mailbox shall be of comparable size to the existing mailbox previously
removed from the highway right-of-way. The markings shall include “approved by
U.S. Postmaster” stamped on the mailbox by the manufacturer and the address
number, box number, or house number, in 2 in. or larger reflective material placed on
40 the side of the mailbox in view of motorists in the nearest travel lane.

Existing mailboxes and assemblies that are to be reset shall be removed and
reinstalled without damage. If the existing mailboxes and assemblies are damaged
during removing and resetting, they shall be replaced in kind at no additional cost.

611.04 Method of Measurement

Mailbox assemblies will be measured by the number of units of the type installed.
Resetting of mailbox assemblies will be measured by the number of units of the type
reinstalled.
50
611.05 Basis of Payment
Mailbox assemblies will be paid for at the contract unit price per each per type,
complete in place. Resetting of mailbox assemblies will be paid for at the contract unit
price per each per type, complete in place.

Payment will be made under:

Pay Item Pay Unit Symbol

60 Mailbox Assembly, Double ....................................................... EACH

Mailbox Assembly, Single ........................................................ EACH
Mailbox Assembly, Reset, Double ............................................ EACH
Mailbox Assembly, Reset, Single.............................................. EACH

The cost of wood or pipe posts, support hardware, mailbox, and removal of
existing mailbox and its assembly shall be included in the cost of the mailbox
assembly.

487
 612.01

The cost of all materials, labor, equipment and incidentals required to remove and
70 reset the existing mailboxes shall be included in the cost of mailbox assembly, reset.

SECTION 612 – UNDERSEALING

612.01 Description
This work shall consist of drilling holes and furnishing and pumping an asphalt
material under cement concrete pavement in accordance with 105.03.

MATERIALS

612.02 Materials
10 Asphalt material shall be in accordance with the following:

Utility asphalt, UA-III ................................................. 902.01(d)

CONSTRUCTION REQUIREMENTS

612.03 Weather Limitations

Undersealing shall not be performed when pavement surface temperatures are
below 40°F, or when the subgrade or subbase is frozen. If proper undersealing cannot
be achieved due to excessive temperatures or direct sunlight, work shall be performed
20 at night.

612.04 Shoulders
All holes, low areas, or displaced areas in the shoulders immediately adjacent to
the pavement edge shall be filled with loam, clay, or other approved material and
compacted to the elevation of the pavement. Such areas, including all other shoulder
areas immediately adjacent to the pavement edge, shall be compacted with a roller or
another approved method.

612.05 Drilled Holes

30 Where the existing pavement has transverse joints, holes not to exceed 1 1/2 in.
in diameter shall be drilled on the centerlines of the pavement lane to be treated. Such
holes, unless otherwise directed, shall be located longitudinally between transverse
joints or cracks at approximately 30 to 36 in. from the joints or cracks. Intermediate
holes, if necessary, shall be spaced as directed.

If the existing pavement does not have transverse joints, holes not to exceed
1 1/2 in. in diameter shall, unless otherwise specified, be located on the centerline of
the pavement lane to be treated and be spaced as directed.

40 An approved method shall be used to prevent the drill from entering the subgrade
after penetrating the pavement. Automatic stops on mechanical equipment and marked

488
 612.06

drill bits on hand operated jackhammers may be approved subject to satisfactory

operation.

Just prior to pumping operations, the surface of the pavement around each hole
for an area of at least 1/2 the width of the lane being treated shall be thoroughly
sprinkled with water to prevent the undersealing material from adhering to the
pavement surface.

50 612.06 Pumping
All storage tanks, pipes, retorts, booster tanks, and distributors used for storing or
handling the materials shall be kept clean and in good operating condition at all times
so there is no contamination of the materials.

Where undersealing operations are being performed under traffic, necessary signs,
barricades, watchers, and flaggers shall be used to maintain one lane of traffic in the
immediate vicinity of pumping operations. Traffic may be allowed to use the pumped
areas upon removal of the original plugs and after the hardwood plugs are driven.

60 When directed, certain portions may be required to be undersealed a second time.

The number of holes involved in this second undersealing shall not exceed 5% of the
number of holes indicated in the Schedule of Pay Items.

(a) Asphalt Material

The asphalt shall be pumped through the drilled holes and under the pavement
with an approved type of self-propelled pressure distributor, the pressure to be as
directed. A metallic hose shall connect the asphalt tank through an asphalt pump to a
1 in. nozzle and a return metallic hose shall connect the nozzle to the asphalt distributor
tank.
70
The nozzle shall be equipped with a 3-way valve that allows the asphalt to
circulate back to the distributor tank when pumping operations are not in progress. The
nozzle shall be inserted in the hole, driven to a snug fit, and pumping of the asphalt
continued until the undersealing is complete, or to such other amount as directed. In
case of an existing asphalt resurface on concrete, holes shall be drilled through the
resurface and the underlying concrete and the nozzle shall be of sufficient length that
it can be driven to a snug fit into the concrete without the upper part of the nozzle
being below the elevation of the existing asphalt resurface.

80 The asphalt shall not be heated above 500°F at any time and, when pumped under
the pavement, the temperature shall be no less than 350°F. All material heated beyond
500°F shall be rejected.

(b) Wood Plugs

Upon completion of the pumping operation, the nozzle shall be removed and a
wood plug driven into the hole. After the pumped material has hardened, the original
plug shall be removed and a 4 in. or longer hardwood plug a minimum of 1/16 in.

489
 612.07

larger than the diameter of the drilled hole shall be driven flush with the surface of the
pavement. All material extruded during the pumping operations shall be immediately
90 cleaned from the pavement surface and removed from the limits of the contract within
a period of 24 h.

The hardwood plugs shall be inspected after any milling operation in the case
where a resurface exists on the concrete. Damaged or missing plugs shall be replaced
prior to overlaying with a new surface.

612.07 Method of Measurement

Asphalt material will be measured by the ton. Drilled holes for underseal will be
measured per each hole drilled.
100
612.08 Basis of Payment
This work will be paid for at the contract unit price per ton for material for
underseal. Drilled holes for underseal will be paid for at the contract unit price per
each, complete in place.

Additional holes and materials required for a second undersealing operation will
be paid for at the contract unit prices for the quantities involved.

Payment will be made under:

110
Pay Item Pay Unit Symbol

Drilled Hole for Underseal ........................................................ EACH

Material for Underseal ............................................................... TON

The cost of shoulder material, wood and hardwood plugs, and necessary
incidentals shall be included in the cost of the pay items.

SECTION 613 – SALVAGED ROAD MATERIALS

613.01 Description
This work shall consist of removing approved material from an existing road
within the limits of the contract, including intersecting approaches, and using it in
reconstruction of the road in accordance with these specifications or as directed.

613.02 Materials
Approved materials may be asphalt treated or untreated gravel, stone, slag, or all
10 combinations of these or other materials which are suitable for salvaging.

613.03 Construction Requirements

Before any filling or further work is done at locations where material is to be
salvaged, such material shall be removed and stored in stockpiles outside the

490
 613.05

construction limits and adjacent thereto, or it may be incorporated directly into the
work without stockpiling if conditions allow.

The quantities removed, if available, shall be sufficient to complete the item of

work or certain portions thereof for which it is intended. The depth of excavation shall
20 be as directed.

The incorporation of the salvaged material into the work shall be in accordance
with applicable provisions of the specifications for which the material is to be used or
in accordance with the special provisions, depending on the nature of the material and
the use to which it is put.

613.04 Method of Measurement

Salvaged road material will be measured by the cubic yard in stockpiles after
removal from its original position or, if the Contractor prefers, it will be measured by
30 the cubic yard in its original position. All measurements will be made by means of
cross sections. The volumes will be computed by the average end area method.

If salvaged road material is used as subbase, the combined pay quantities of

subbase and salvaged road material for subbase shall equal but shall not exceed the
total theoretical volume as calculated to the neat lines shown on the plans for subbase.
If the volume of salvaged road material used as subbase determined by the cross
section method does exceed the total theoretical volume of subbase, the final pay
quantity for salvaged road material for subbase shall be the total theoretical volume.

40 The final pay quantity of subbase will be determined by deducting the final pay
quantity of salvaged road material for subbase from the total theoretical volume of
subbase.

If salvaged road material is obtained from within the pay limits of the new
construction, such cubic yardage of salvaged material will be deducted from the
excavation quantities to be measured for payment.

613.05 Basis of Payment

The accepted quantities of salvaged road material for the use shown on the
50 Schedule of Pay Items will be paid for at the contract unit price per cubic yard,
complete in place.

Payment will be made under:

Pay Item Pay Unit Symbol

Salvaged Road Material for ______ .......................................... CYS

The cost of removal of the material, storage, incorporating it into the work, and
60 necessary incidentals shall be included in the cost of the pay item.

491
 614.01

SECTION 614 – CONCRETE HEADER

614.01 Description
This work shall consist of the construction or reconstruction of PCC headers
adjacent to railroad tracks, bridges, and similar locations in accordance with 105.03.

MATERIALS

614.02 Materials
10 Materials shall be in accordance with the following:

Concrete ...................................................................... 702

Reinforcing Bars.......................................................... 910.01

If the header is adjacent to cement concrete base or pavement, the header concrete
shall be the same composition as that of the base or pavement header constructed
monolithic with the base or pavement. If the adjacent base or pavement is thickened,
that portion forming the thickening shall be considered as part of the header.

20 If the header is adjacent to asphalt pavement, the concrete shall be class A in

accordance with 702 using class AP coarse aggregate.

CONSTRUCTION REQUIREMENTS

614.03 PCC Header

Construction shall be in accordance with the applicable provisions of 702 and with
these requirements.

Welding shall be in accordance with 711.32.

30
Headers at railroad crossings shall be as shown on the plans.

614.04 Reconstructed Cement Concrete Header

This work shall be in accordance with the plans. Round plug welds or rectangular
shaped plug welds may be used to weld the steel angle to the existing steel edge
protection. Round plug welds shall be a minimum of 1 in. diameter.

Welding shall be in accordance with 711.32.

40 614.05 Method of Measurement

Cement concrete header and reconstructed cement concrete header will be
measured by the linear foot.

492
 615.03

614.06 Basis of Payment

The accepted quantities of this work will be paid for at the contract unit price per
linear foot for header, cement concrete, of the type specified, or header, cement
concrete, reconstruct, complete in place.

Payment will be made under:

50
Pay Item Pay Unit Symbol

Header, Cement Concrete, _____ .............................................. LFT

type
Header, Cement Concrete, Reconstruct ..................................... LFT

The cost of edge protection, metal chairs, excavation, and necessary incidentals
shall be included in the cost of the pay items.

SECTION 615 – MONUMENTS, MARKERS, AND PARKING BARRIERS

615.01 Description
This work shall consist of furnishing and setting, setting only, or resetting
right-of-way markers, monuments for marking section or other lines, bench mark posts
and tablets, and parking barriers in accordance with 105.03.

MATERIALS

10 615.02 Materials
Materials shall be in accordance with the following:

Coarse Aggregate, Class A or Higher,

Size No. 8 or 91 .................................................... 904
Fine Aggregate, Size No. 23........................................ 904
Portland Cement .......................................................... 901.01(b)
Post .............................................................................. 911.02(f)
Reinforcing Bars.......................................................... 910.01

20 615.03 Reinforced Cement Concrete Right-of-Way Markers

These markers shall conform with the dimensions and lettering shown on the
plans. The reinforcement shall be securely held in place by at least four spacers of an
approved design. The concrete ingredients shall be graded and proportioned to produce
a strong dense concrete.

When tested as hereinafter described, a specimen shall support a total load of at

least 2,400 lb before the first crack appears. The specimen will be tested as a simple
beam. The distance between supports shall be exactly 24 in. with the load applied at

493
 615.04

the rate of approximately 1,200 lb per minute in the center of the span. Loading will
30 continue until the first crack appears.

The cement concrete shall absorb no more than 8% water. Specimens for
absorption may be taken from the markers tested for strength. The absorption test shall
be as described in accordance with AASHTO T 280 except the specimen tested shall
be the full cross section marker.

The markers shall have a smooth workmanlike finish free from cracks, patches,
honeycomb, exposed reinforcement, and excessive bubble holes. Each marker shall be
plainly marked near the bottom with the trademark or initials of the manufacturer and
40 the date of manufacture. These letters and figures shall be no less than 1 in. in height
and shall be indented 1/8 in.

Right-of-way markers furnished under this specification shall be covered by a

type C certification in accordance with 916.

615.04 Monuments
Monuments shall be of the type specified in the Proposal book, the details of
which are shown on the plans. Any portion extending above the ground shall be
finished in accordance with 702.21.
50
Where concrete is required, it shall be class A in accordance with 702. When
placed in the forms it shall be tamped in layers until mortar covers the outer surface.
The tops of the monument shall be floated smooth. Monuments may be cast in place
or cast outside and then set.

The pin shall be set perpendicular to and flush with the top of the monument while
the concrete is plastic and left undisturbed until the concrete has set. The pin shall be
steel and shall be 1 in. in diameter and 5 in. long. If for type D monuments, the hole
shall be drilled in the center with a 1/8 in. drill for a depth of 1 1/2 in. The hole shall
60 be filled with lead flush with the end of the pin. Castings for protected monuments
shall be in accordance with 910.05(b).

615.05 Bench Mark Posts

Bench mark posts shall be of the dimensions shown on the plans and cast in
accordance with applicable provisions of 615.03, except the strength shall be
determined by concrete cores taken from the finished product. At least two concrete
cores will be taken from each unit and the average strength of the unit shall be at least
4,000 psi with no individual core strength less than 3,600 psi. Tablets will be furnished
by the Department and shall be set in the posts as indicated on the plans.
70
615.06 Parking Barriers
Parking barriers shall be of the dimensions shown on the plans.

494
 615.09

Placement of parking barriers shall be at the locations and in accordance with the
details shown on the plans, or as otherwise directed.

Existing parking barriers to be removed and reset shall be removed without

damage, stored and reinstalled as shown on the plans.

80 (a) Concrete
The concrete barriers shall be cast and tested in accordance with the applicable
requirements of 615.03, except the strength shall be determined by concrete cores
taken from the finished product. At least two concrete cores will be taken from each
unit and the average strength of the unit shall be at least 4,000 psi with no individual
core strength less than 3,600 psi.

(b) Timber Post

Vertical timber posts as parking barriers shall be round, roofed on top, and be
dimensioned as shown on the plans. The posts shall be in accordance with the
90 applicable requirements of 911.02(f).

CONSTRUCTION REQUIREMENTS

615.07 Setting Right-of-Way Markers

The back face of these markers shall be set on the right-of-way lines
approximately 1,000 ft apart as hereinafter provided. They shall be set at all corners
of irregular right-of-way lines, opposite each P.C. and P.T. of curves, and not to exceed
500 ft apart on the inside and outside of curves. Care shall be used in locating markers
on tangents so that a marker is plainly visible from each of those adjacent.
100
Markers shall be set plumb, to the depth required on the plans, and with the letters
facing the pavement. Portions of the holes not occupied by markers shall be backfilled
and compacted in layers with suitable material up to the level of the original ground.
The markers shall not be displaced during backfilling.

615.08 Resetting Right-of-Way Markers

When the proposal provides that existing right-of-way markers be reset, the
existing markers shall be removed and reset at designated locations in accordance with
615.07.
110
615.09 Setting Monuments
If the location of a monument falls within the limits of a cement concrete
pavement, a steel pin, the details of which are shown on the plans, shall be set
perpendicular to and flush with the top of the finished pavement. It shall be placed just
before the concrete takes initial set and then left undisturbed until the concrete has set.
Other monuments shall be of the type shown on the plans, depending on the type or
surface of the pavement in which they are to be placed or if they are to be placed
outside of pavement. Necessary excavation shall be to the required depth. The bottom
of the excavation shall be firm and true to line and grades given. After a monument is

495
 615.10

120 in place, the remaining excavated areas shall be backfilled with suitable material
firmly tamped in layers. The monument shall not be disturbed.

Existing monuments which are not required to be disturbed or re-established, but

which are disturbed during construction operations, shall be re-established.

615.10 Re-Established Monuments

It may be necessary to re-establish existing monuments in pavements or bases
which are disturbed unavoidably or covered by operations embraced in the contract.

130 If the existing monument is, or contains a brass, copper, or steel pin, the pin shall
be extended to the surface of the new pavement by attaching a pin of the same metal
with at least a 1 in. diameter and of the length required. Such extensions shall be
attached by tapping the original pin and providing a necessary screw attachment such
that the extension can be fastened securely to the original pin. The tapped hole shall
be at least 1/4 in. in diameter and no less than 1 in. deep. The screw attachment shall
have the same diameter as for the hole in the original pin and shall be no less than 1
in. in length.

Where an existing monument of the type specified above has not been
140 re-established on a previous contract, the monument shall be re-established in the same
manner as set out above.

Where existing monuments are protected and encased in cast iron, such castings
shall be adjusted to meet the elevation of the proposed surface by means of an asphalt
coated, cast iron, adjustment casting. The size shall be the same as the original casting
and of the depth necessary to meet the elevation of the proposed new surface.

615.11 Setting Bench Mark Posts and Tablets

Bench mark posts shall be set at locations marked on the plans or as directed.
150 Excavation shall be to the depth indicated and to dimensions sufficient to provide for
the concrete backfilling. This concrete shall be class A and shall extend for 6 in. around
and below the post. The bottom shall be monolithic with the sides. The remainder of
the excavation up to the original ground line shall be backfilled with suitable material
well tamped in layers. Care shall be taken not to disturb the post. When specified on
the plans, or directed, bench mark tablets furnished by the Department shall be placed
in newly constructed or existing drainage structures located within the limits of the
contracts.

615.12 Reset Bench Mark Posts

160 When the Proposal book provides that existing bench mark posts be reset, the
existing bench mark posts shall be removed and reset at designated locations in
accordance with 615.11.

496
 616.01

615.13 Method of Measurement

Right-of-way markers, reset right-of-way markers, monuments, re-established
monuments, castings adjusted to grade monuments, bench mark posts, reset bench
mark posts, parking barriers, and reset parking barriers will be measured by the
number of units installed.

170 615.14 Basis of Payment

The acceptable quantities of right-of-way markers, reset right-of-way markers,
monuments, re-established monuments, castings adjusted to grade monuments, bench
mark posts, and reset bench mark posts, parking barriers, and reset parking barriers
will be paid for at the contract unit price per each, complete in place.

Payment will be made under:

Pay Item Pay Unit Symbol

180 Bench Mark Post ....................................................................... EACH

Bench Mark Post, Reset ............................................................ EACH
Casting Adjusted to Grade, Monument ..................................... EACH
Monument, _____ ..................................................................... EACH
type
Monument, Re-Establish ........................................................... EACH
Parking Barrier, Concrete .......................................................... EACH
Parking Barrier, Reset ............................................................... EACH
Parking Barrier, Timber Post ..................................................... EACH
Right-of-Way Marker ................................................................ EACH
190 Right-of-Way Marker, Reset ..................................................... EACH

The cost of setting tablets in structures or bench mark posts, extensions for
monuments, adjustment castings, backfill, disposal of surplus materials, re-
establishing disturbed existing monuments, and all other necessary incidentals shall
be included in the cost of the pay items in this section.

The cost of existing parking barrier removal, storage, resetting, and all other
necessary incidentals needed for resetting shall be included in the cost of parking
barrier, reset. Existing barriers that are damaged by the Contractor shall be replaced
200 with no additional payment.

SECTION 616 – RIPRAP AND SLOPEWALL

616.01 Description
This work shall consist of placing broken stone or concrete which may or may not
be grouted, precast slabs, or slopewall in accordance with these specifications and in
accordance with 105.03.

497
 616.02

MATERIALS

10 616.02 Materials
Materials shall be in accordance with the following:

Asphalt Joint Filler ...................................................... 906.01

Clay ............................................................................. 903.01
Concrete, Class A ........................................................ 702
Fine Aggregate, Size No. 23........................................ 904
Geotextile for Riprap ................................................... 918.02
Portland Cement .......................................................... 901.01(b)
Precast Concrete Riprap .............................................. 904.04(e)
20 Riprap .......................................................................... 904.04
WWR, Smooth ............................................................ 910.01(b)5
Water ........................................................................... 913.01

CONSTRUCTION REQUIREMENTS

616.03 Placing Dumped Riprap

Dumped riprap shall be placed to produce a surface of approximate regularity but
need not necessarily be hand placed. The finished surface shall vary no more than 9
in. from a true plane. The thickness perpendicular to its surface shall be no more than
30 2 ft nor less than 1 ft unless otherwise directed.

616.04 Placing Grouted Riprap

The aggregate, preparation of the slope, and the depth of riprap aggregate for
grouted riprap shall be in accordance with 616.05. After the aggregate has been placed
and accepted, all openings shall be filled with cement grout. The finished surface shall
be approximately smooth, solid, and true to line, grade, and section.

Grout shall be composed of 1 part portland cement and 4 parts fine aggregate. The
portland cement and fine aggregate shall be dry-mixed to a uniform mixture. Water
40 shall be added as the mixing continues until the grout attains a consistency that will
enable it to flow into the openings.

616.05 Placing Revetment, Class 1, and Class 2 Riprap

Revetment, class 1 and class 2 riprap may be placed by dumping and shall be
placed to the required thickness. The finished surface shall be free from clusters of
small stones or of large ones. The finished surface shall vary from a true plane no more
than 9 in. for revetment riprap or 18 in. for class 1 or class 2 riprap but shall not be
less than the minimum depth specified.

50 616.06 Placing Uniform Riprap

Uniform riprap shall be placed to produce a surface of approximate regularity with
edges having projections no more than 3 in. above the required cross section. The
material shall be hand laid or placed by other approved means.

498
 616.10

616.07 Blank

616.08 Placing Precast Cement Concrete Riprap

The slope on which the riprap is to be placed shall be in accordance with that
shown on the plans unless otherwise designated. Laying shall begin in a trench below
60 the toe of the slope and progress upward. Each piece shall be laid by hand
perpendicular to the slope. It shall be firmly embedded against the slope in such a
manner that the vertical joint space between individual units does not exceed 3/8 in.,
unless otherwise specified. Half blocks, odd shaped blocks, or class A concrete shall
be used to fill the voids at the ends of sections to be placed or on curved shaped
sections. The top course shall conform, as nearly as practicable, with the prescribed
berm or shoulder elevation. Any adjustment necessary to achieve this shall be obtained
by constructing a wedge course near the top of the slope as directed. This wedge
course, when required, shall consist of class A concrete. If the thickness of the course
does not allow class A concrete, it shall be constructed of a 1:2 mortar proportioned
70 by volume. Toewalls, when required, shall consist of class A concrete.

616.09 Slopewall
The slope on which slopewall is to be placed shall be in accordance with that
shown on the plans unless a different slope is designated.

The concrete mixture shall be class A. Where paved slopewall abuts or surrounds
columns, piers, or other structures, 5/8 in. of asphalt joint filler shall be used between
the slopewall and such structure. Welded steel wire reinforcement shall be placed
within the middle 1/3 of the slopewall thickness unless otherwise directed. The fabric
80 shall extend through all construction joints. The surface of the slopewall shall be cured
for 48 h in accordance with 501.20. Construction joints may be either butt or keyway
type.

Inspection holes shall be provided at the locations shown on the plans or as

directed. The holes shall be approximately 3 ft by 3 ft in size.

Precast concrete riprap, type B, as shown on the plans, may be used in lieu of
slopewall of 4 in. thickness.

90 616.10 Undermined Paved Side Ditch

Treatment of undermined existing paved side ditch and placement of revetment
riprap shall be as shown on the plans or as otherwise directed.

Undermined paved side ditch shall be broken up and left in place. If it is

determined that erosion is excessive, the eroded area shall be backfilled with a
cohesive material, compacted, regraded, and lined with revetment or uniform riprap.

499
 616.11

616.11 Installation of Geotextile Under Riprap

Storage and handling of geotextiles shall be in accordance with the manufacturer’s
100 recommendations, except that the geotextile shall not be exposed to direct sunlight,
ultraviolet rays, water, temperature greater than 140°F, mud, dirt, dust, and debris, to
the extent that its strength, toughness, or permeability requirements are diminished.
Each geotextile roll shall be labeled or tagged to provide product identification
sufficient for inventory and quality control purposes. Exposure of geotextiles to the
elements between lay down and cover shall be a maximum of 14 days. At the time of
installation, the geotextile shall be rejected and replaced with no additional payment
if defects, rips, flaws, deterioration or damage incurred during manufacture,
transportation, storage, or construction is evident.

110 The surface to receive the geotextile shall be prepared to a relatively smooth
condition free of obstructions, depressions, and debris within the limits indicated on
the plans.

Geotextiles used along channels shall be placed with the machine direction of the
geotextile parallel to the channel. Successive geotextile sheets shall be overlapped in
such a manner that the upstream sheet is placed over the downstream sheet and the
upslope sheet over the downslope sheet.

Geotextiles used for 2:1 slopes or greater shall be placed with the machine
120 direction of the geotextile sheets perpendicular to the toe of slope. The geotextile
sheets shall be overlapped in the direction of the anticipated movement of water.

Adjacent pieces of geotextile may be joined by sewing if approved, or by

overlapping and pinning. The minimum overlap shall be 18 in. except when placed
under water. When placed under water, the overlap shall be a minimum of 3 ft.
Securing pins shall be steel, 3/16 in. in diameter, 18 in. long, pointed at one end and
fabricated with a head to retain a steel washer having an outside diameter of no less
than 1 1/2 in. Securing pins with washers shall be inserted through both strips of
overlapped geotextile at spacing intervals in Table 1 along a line through the midpoint
130 of the overlap. The geotextile strip shall be placed so that the lower strip will be
overlapped by the next higher strip. Pins shall be driven until the washer bears against
the geotextile and secures it firmly to the ground.

Whether the fabric is joined by sewing or pinning, additional pins shall be

installed as necessary to prevent any slippage of the fabric regardless of location.

Slope Pin Spacing

steeper than 3:1 2 ft
3:1 to 4:1 3 ft
4:1 or flatter 5 ft
Table 1

500
 616.13

The geotextile shall be placed in such a manner that placement of the overlying
140 materials will not excessively stretch or tear the geotextile and will not pull the
required overlap or seam apart. Construction equipment shall not be on the exposed
geotextile. Placement of riprap or stone shall start from the base of the slope, moving
upslope and from the center outward. Riprap shall not roll downslope and the height
of drop for riprap shall be kept to less than 2 ft.

616.12 Method of Measurement

Dumped, revetment, class 1 and class 2 riprap obtained from outside the
right-of-way will be measured by the ton. If obtained from inside the right-of-way, no
measurement will be made if placed as shown on the plans unless direct payment is
150 specified. If placed at locations not shown on the plans, measurement will be made by
the square yard.

Grouted riprap and precast concrete riprap, including the area occupied by the
wedge course, will be measured by the square yard, parallel to the slope. Slopewall
will be measured by the square yard. Holes for inspecting slopewalls will be measured
per each. Geotextiles used under riprap will be measured by the square yard by the
type specified, complete in place. Uniform riprap will be measured by the ton.

Treatment of undermined paved side ditch will be measured by the linear foot of
160 paved side ditch, broken and left in place.

616.13 Basis of Payment

The accepted quantities of dumped, revetment, class 1, and class 2 riprap obtained
from outside the right-of-way will be paid for at the contract unit price per ton.
Dumped, revetment, class 1, and class 2 riprap obtained from within the project limits
will be paid for at the contract unit price per square yard. Uniform riprap will be paid
for at the contract unit price per ton. Grouted riprap will be paid for at the contact unit
price per square yard of the specified depth. Precast concrete riprap, and concrete
slopewall will be paid for at the contract unit price per square yard, all complete in
170 place. If slag is used as dumped riprap and payment will be made per ton, the pay
quantity will be adjusted in accordance with 904.01.

The accepted quantities of geotextiles used under riprap will be paid for at the
contract unit price per square yard, complete in place.

Inspection holes will be paid for at the contract unit price per each.

The treatment of undermined paved side ditch will be paid for at the contact unit
price per linear foot for paved side ditch, break. Backfill required for treatment of
180 paved side ditch will be paid for at the contract unit price per cubic yard for borrow,
cohesive.

Payment will be made under:

501
 619.01

Pay Item Pay Unit Symbol

Borrow, Cohesive ...................................................................... CYS

Geotextiles for Riprap, _____ ................................................... SYS
type
190 Inspection Hole.......................................................................... EACH
Paved Side Ditch, Break ............................................................ LFT
Riprap, Class _____................................................................... TON
........................................................................ SYS
Riprap, Dumped ........................................................................ TON
SYS
Riprap, Grouted, _____ in. ........................................................ SYS
depth
Riprap, Precast Concrete ........................................................... SYS
Riprap, Revetment ..................................................................... TON
200 SYS
Riprap, Uniform ........................................................................ TON
Slopewall ................................................................................... SYS
Slopewall, Concrete, _____ in. .................................................. SYS
depth

If the contract includes a pay item for removing materials from within the project
limits which are used as grouted riprap, the cost of such removal shall be included in
the cost of the pay item for the removal work. The cost of placing such material shall
be included in the cost of the riprap pay item.
210
The cost of paved side ditch required at the top of riprap and along the edge of
riprap will be paid for in accordance with 607.06. The cost of welded steel wire
reinforcement shall be included in the cost of the slopewall.

The cost of excavation below the finished riprap or slopewall shall be included in
the cost of the riprap and slopewall pay items. The cost of excavation, grading, sewing,
pinning, and necessary incidentals shall be included in the cost of geotextiles.

SECTION 617 – BLANK

SECTION 618 – BLANK

SECTION 619 – PAINTING BRIDGE STEEL

619.01 Description
This work shall consist of preparing surfaces, disposing of waste residue, and
applying paint to steel bridges in accordance with 105.03.

502
 619.03

MATERIALS

619.02 Materials
10 Materials shall be in accordance with the following:

Epoxy Intermediate Paint ............................................ 909.02(b)

Finish Coat for Weathering Steel ................................ 909.02(e)
Multi-Component Inorganic Zinc Silicate Primer ....... 909.02(a)1
Organic Zinc Primer .................................................... 909.02(a)2
Polyurethane Finish Coat ............................................ 909.02(c)
Structural Steel Coating Systems ................................ 909.03
Waterborne Finish Paint .............................................. 909.02(d)

20 Material safety data sheets shall be provided in the QCP for all materials to be
delivered to the project site.

Caulk used to form the drip bead on weathering steel shall be a clear, 100%
silicone caulk.

Caulk used on joints of lapping members shall be compatible with either the
structural steel paint system or the partial paint system, and in accordance with the
paint manufacturer’s recommendations.

30 CONSTRUCTION REQUIREMENTS

619.03 Quality Control and Quality Assurance

The Contractor shall be responsible for the quality of work on the contract and
shall ensure that all work has been performed by accepted quality control methods. A
QCP shall be prepared and submitted by the Contractor in accordance with ITM 803.
No work may begin until written notice has been received that the QCP was accepted
by the Engineer. The QC manager shall furnish the current referenced SSPC Standards
at the project site.

40 Cleaning and painting shall be done by a Contractor certified as SSPC-QP 2 for

cleaning and painting existing bridge steel on steel bridges constructed before 1995,
regardless of whether the existing coating is advertised as non-hazardous based or
hazardous based. Cleaning and painting shall be done by a Contractor that at a
minimum is certified as SSPC-QP 1 for cleaning and painting new bridge steel or for
cleaning and painting existing bridge steel on steel bridges constructed after 1994.

The Department will accept work performed on the project through quality
assurance inspections and testing. Acceptance testing will be performed and will be
the basis for which acceptance will be made.
50

503
 619.03

(a) Test Methods and Procedures

The current version of the following test methods and procedures shall be
performed as a minimum for quality control by the Contractor. These and other tests
may be performed for acceptance testing by the Engineer. The results of the following
tests and procedures shall be compiled and submitted to the Engineer on a daily basis.

Test/Procedure Method and Procedure

Clean Compressed Air ASTM D 4285
Cleaning of Steel SSPC-Vis 1, Vis 3
Cleanliness of Recycled Ferrous
SSPC-AB 2
Metallic Abrasives
Dry Film Thickness SSPC-PA 2
Relative Humidity ASTM E 337
State of Cure of Inorganic Zinc
ASTM D 4752
Primers
Surface Profile ASTM D 4417, Method B or C

Relative humidity, dew point, and surface temperature shall be recorded before
the application of any coating and at least once per hour during the application of any
60 coating.

Air compressor output and blasting abrasives shall be inspected at least once every
four hours for contamination.

Visual inspections for cleaning shall be performed after each phase of the
applicable cleaning operations for compliance with the specified requirements for each
lot. The surface shall be wiped with a white glove or white rag to ensure the surface is
free of dust and other contaminants.

70 The blast cleaned surface shall be inspected for surface profile, oil contamination,
dust, and blasting residue, and accepted prior to the application of the primer.

The required number of surface profile measurements and dry film thickness
measurements shall be in accordance with SSPC-PA 2.

If a lot is non-conforming, corrective action shall be taken to make the lot

acceptable. Corrective action shall be submitted in writing and performed as approved.
A phase shall not be covered until the whole lot has been accepted.

80 (b) Acceptance Testing

Acceptance testing of painting steel bridge work will be in accordance with ITM
803. The results of the acceptance testing will be compared to the specific
requirements for that phase of work. The Contractor shall not proceed to the next phase
of work until written approval has been received from the Engineer that the current
phase is accepted.

504
 619.07

619.04 Prosecution of Work

Prosecution of work shall be in accordance with the applicable requirements of
108.03. Once the cleaning and painting operations have begun, it shall be performed
90 on all work days without stoppage until all work has been completed. If the contract
contains more than one bridge, a schedule shall be included in the QCP which provides
the sequence of work on the bridges. Once work has begun on a bridge, it shall be
performed until complete, including all cleanup.

Permission shall be obtained in writing to start or continue work at the hold points
as follows:

(a) prior to the acceptance of the QCP and start of work;

(b) immediately following each phase of surface preparation;
100 (c) immediately before the application of the first coat;
(d) prior to the application of each succeeding coat; and
(e) after the final coat has cured.

A minimum of one day’s notice shall be given in advance of each of the hold
points.

619.05 Inspection Access to Bridges

Safe and reasonable access to all points of the bridge shall be provided for the
Engineer’s inspections immediately upon request.
110
619.06 Maintaining Traffic
The traffic lanes may be restricted when surface preparation or painting phases
are being performed on a portion of the bridge over the traveled roadway, or as
directed, when the need exists.

Construction signs in accordance with 801.04 shall be furnished and placement at

each project site shall be as shown in the QCP. However, a “Bridge Painting Ahead”
sign may be used in place of the “Road Construction Ahead” sign.

120 The traffic maintenance plan shall include a type of barrier system which shall
protect against blasting of vehicles or pedestrians, eliminate abrasive materials and
debris from falling onto the traveled portion of the pavement, and prevent the
spreading of abrasive materials and debris in the area which may create a traffic
hazard. If the intended purpose of the protective devices has not been accomplished,
work shall stop until adequate corrections have been made. All abrasive material or
debris shall be removed by the end of each day’s work in accordance with 619.07.

619.07 Environmental and Safety Requirements

Pollution control and waste disposal of existing paint residue and debris shall be
130 in accordance with the following requirements.

505
 619.07

Workers shall be protected in accordance with IOSHA requirements. All

personnel on the project site shall wear personal protective equipment to the level as
determined by the sampling and monitoring requirements. The protective equipment
shall be furnished by the Contractor, including to Department personnel. Training shall
be given to all personnel provided with the protective equipment. Protective equipment
shall include, but not be limited to, clean air supplied respirators, air purifying
respirators, conventional hood as applicable, eye protection, and protective clothing.
Two rooms for changing and washing shall be provided on bridges containing
140 hazardous-based coatings.

(a) Pollution Control

1. Containment for Advertised Non-Hazardous Sites

Blasting materials, scrapings, wire brushings, and paint particles shall be
contained in accordance with SSPC-Guide 6, Class 2A with method A, level 2
emissions, specifically for non-hazardous primed bridges.

2. Containment for Advertised Hazardous Sites

150 Blasting materials, scrapings, wire brushings, and paint particles shall be
contained in accordance with SSPC-Guide 6, Class 2A or better with method A, level
0 emissions, for hazardous primed bridges.

Regardless of the level of containment as listed above, if a spill, as defined in

IDEM Regulation 327 IAC 2-6.1 does occur, all work shall stop and immediate action
shall be taken to clean up the site. Spills of material, that enter or threaten to enter the
water, shall be handled in accordance with IDEM Regulation 327 IAC 2-6.1. The
IDEM Emergency Response Branch, the local health department, and all water intake
users within 500 ft of the bridge shall be immediately contacted and advised of the
160 spill. Written documentation of all such contacts and actions shall be kept. All
applicable Federal, State, and local rules and regulations described in 619.07(b)1 shall
be observed.

3. Waste Stream Sampling

Each bridge shall generate a separate waste stream and shall not be commingled
with other materials. The sample of waste residue from the bridge shall be obtained at
the conclusion of the first day of the removal operation for that bridge. The sample
will be shipped to be tested within 24 h in a manner agreed to by the Department and
as described in the QCP. The Engineer will witness the extraction of the waste residue
170 sample. The Department will maintain custody of the waste residue sample until it is
shipped. The waste residue sample shall be taken by random method as described in
the QCP which reflects representation of the entire bridge. The samples shall be
analyzed for all contaminants listed in ITM 803 by the TCLP. All remaining waste
residue shall be placed in an approved container. Such containers shall be labeled and
maintained to comply with 40 CFR 264.

506
 619.07

No waste shall remain on the booms or on any water surface overnight. All
blasting debris shall be cleaned up after each day’s work. All waste material shall be
properly stored at the project site to prevent loss or pollution.
180
If hazardous materials are found in the waste residue sample of an advertised,
non-hazardous site, the Contractor shall immediately stop all cleaning and painting
operations on that bridge. The Contractor shall notify the Engineer that hazardous
materials have been found and, if not addressed in the QCP, the Contractor shall
submit revisions to the QCP that detail the necessary changes due to the presence of
hazardous materials. The Contractor shall not return to work until the revised QCP is
approved in writing.

(b) Waste Disposal

190 Regardless of the waste characterization obtained from the waste sample, disposal
of existing paint and debris shall be in accordance with SSPC-Guide 7 and the
following requirements.

1. Laws to be Observed
Federal and State laws and regulations regulate the disposal of bridge painting
debris. Bridge paint debris shall be manifested or certified and shall be disposed of at
an appropriate disposal facility.

The Contractor shall have direct knowledge regarding compliance with laws
200 pertaining to pollution control and waste management such as the following.

a. subtitle C of the RCRA, 40 CFR 261, 262, 263, 265,

and 268;

b. the Solid Waste Rule, 329 IAC 10;

c. the Hazardous Waste Rule, 329 IAC 3.1;

d. the Air Pollution Rule 329 IAC 6-4;

210
e. the Water Pollution Rule, 327 IAC 2-6.1;

f. the United States Department of Transportation

regulations 49 CFR 172.300; and

g. OSHA worker safety regulations 29 CFR 1926.

2. Time Limitations
The maximum time limit from the date the generated waste is placed in a container
220 and the date the material is transported to a permitted treatment, storage, and disposal
facility shall be 90 calendar days.

507
 619.07

3. Marking of Spent Material Containers

Spent material containers shall be marked with the date that waste residue is first
placed in the container. Until laboratory results are received concerning the category
of the waste residue, the containers shall be labeled “LEAD PAINT WASTE
DEBRIS” or “ZINC PAINT WASTE DEBRIS”, as appropriate. The labeling shall
include the contract number, bridge number, sample number, and sample date.
Labeling of containers as hazardous waste will not be required until the appropriate
230 laboratory analysis determines the waste residue to be hazardous in accordance with
the current RCRA hazardous waste definitions. Immediately upon notice that the waste
residue is hazardous, the containers shall be marked in accordance with 49 CFR 172,
Subpart D.

4. Instruction for Disposal of Paint Waste Residue

Sampling and analysis of the paint waste residue shall be performed to determine
if the wastes are hazardous. If the waste residue is not found to be hazardous in
accordance with current RCRA hazardous waste definitions, the waste residue
material shall be disposed of at an appropriate disposal facility. If the waste residue is
240 found to be hazardous, IDEM will be notified and an EPA identification number will
be obtained. This number will be provided to the Contractor within 30 days of the start
of waste generation for bridges having hazardous waste paint debris. The waste residue
from different bridges shall not be commingled. The Contractor shall have the
following responsibilities:

a. determining the location for disposal, treatment, or

recycling of the waste residue, obtaining the Engineer’s
approval of the site, and arranging with the approved
site for acceptance of the materials;
250
b. preparing a hazardous waste manifest, as required by
Federal and State requirements, for signature;

c. scheduling the shipment of waste residue to the

permitted disposal site;

d. ensuring that the hazardous waste manifest is carried in

the transportation vehicle;

260 e. ensuring that all required hazardous materials placards

are properly displayed on the vehicle;

f. ensuring prompt movement of the vehicle to the

disposal site; and

g. returning one copy of signed manifest documents to the

Engineer. A copy of the chemical and physical analysis
of the waste, all deposit receipts, manifests, and

508
 619.08

required paperwork for disposal shall be given to the

270 Engineer and all waste residues disposed of before the
contract will be accepted.

5. Instructions for Disposal of Other Project Generated Waste

The other wastes that may be generated on the project include, but are not limited
to, spent solvents from cleaning of equipment and empty or partially empty containers
of paint, paint thinners, spent abrasives, and solvents. The Contractor shall recycle or
dispose of all project generated waste materials.

If the waste is defined as a hazardous waste in accordance with the current RCRA
280 definitions, the waste shall be recycled or disposed of in accordance with 619.07(b)4.
All project generated waste and the method of recycling or disposal shall be identified
in the QCP.

619.08 Surface Preparation

Cleaning of steel surfaces shall be performed by an SSPC certified contractor.
This requirement will not apply to the following:

(a) shop cleaning;

290 (b) sections of beams or other structural members less than 180 sq
ft of total area to be painted for the contract where heat-
straightening or similar repairs have taken place.

Surfaces to be painted shall be cleaned in accordance with the SSPC classification,

unless otherwise specified. Compressed air shall pass through an oil and water
extractor before entering another apparatus.

Pressure washing in accordance with 619.08(a) and solvent cleaning in

accordance with 619.08(b) shall be performed to remove all oils, soluble salts, visible
300 grease, and any other surface contaminants before all other cleaning methods are
started.

Field cleaned steel surfaces shall be primed the same day as cleaned. If rust forms
after cleaning, the surface shall be cleaned again before painting. Work shall be
stopped when there is disagreement about whether a surface has been adequately
cleaned. Written notification shall be provided specifically identifying the problem.

Cleaning shall be scheduled so that dust or other contaminates do not fall on wet,
newly painted surfaces.
310
A dust collector suitable for the containment type and size shall be used during all
blast cleaning operations in preparation for all structural steel paint systems and as
directed for a partial paint system.

509
 619.08

On existing bridges when abrasive blast cleaning is used, clean dry media in
accordance with SSPC-AB 1 or SSPC-AB 3 shall be used. The media shall produce a
profile that is free of oil, soluble salts, greases, and other similar substances which can
contaminate the blasted surface. If ferrous metallic media is chosen and the Contractor
elects to recycle the media by running the media through recycling equipment, the
320 recycling equipment shall be capable of separating the blasting media from the paint
debris and the cleanliness of the recycled ferrous metallic media shall be in accordance
with SSPC-AB 2.

The surface profile of cleaned new steel surfaces and cleaned existing steel
surfaces shall not be less than 1 mil and not greater than 3 mil.

(a) Pressure Washing

All surfaces to be painted and the tops of pier and abutment caps shall be washed.
The washing shall be accomplished by means of a low pressure power water washer
330 with potable water. The pressure shall be between 800 and 1,500 psi. If detergents or
other additives are added to the water, the surface shall be rinsed with potable water
before the detergents dry. All washed surfaces shall be completely free of all oils and
soluble salts. The Contractor shall obtain the hold point release for pressure washing
prior to beginning other surface preparation activities.

(b) Solvent Cleaning

After the hold point for pressure washing cleaning has been released, solvent
cleaning shall be performed in accordance with SSPC-SP1.

340 (c) Hand Tool Cleaning

Hand tool cleaning shall be in accordance with SSPC-SP2.

(d) Brush-Off Blast Cleaning

Brush-off blast cleaning shall be in accordance with SSPC-SP7/NACE No. 4.

(e) Commercial Blast Cleaning

Commercial blast cleaning shall be in accordance with SSPC-SP 6/NACE No. 3.

(f) Near-White Blast Cleaning

350 Near-white blast cleaning shall be in accordance with SSPC-SP 10/NACE No. 2.

(g) White Metal Blast Cleaning

White metal blast cleaning shall be in accordance with SSPC-SP 5/NACE No. 1.

(h) Power Tool Cleaning

Power tool cleaning shall be in accordance with SSPC-SP 3.

(i) Commercial Grade Power Tool Cleaning

Commercial grade power tool cleaning shall be in accordance with SSPC-SP 15.
360

510
 619.10

(j) Power Tool Cleaning to Bare Metal

Power tool cleaning to bare metal shall be in accordance with SSPC-SP 11.

Upon completion of cleaning operations, the Contractor shall vacuum or blow off
under full containment any residual dust remaining from the cleaning operation.

The Engineer will check the prepared surface for dust prior to the Contractor
beginning painting operations.

370 619.09 Paint Systems

Paint systems shall be applied in accordance with the manufacturer’s
recommendations. The dry film thickness of a paint coating will be measured with a
calibrated film thickness gauge in accordance with SSPC PA 2. All paint coatings shall
have a dry film thickness not less than 80% of the required dry film thickness.

(a) Structural Steel Paint System

The coating system shall consist of an inorganic zinc primer with a dry film
thickness of 3 mil, an epoxy intermediate coat with a dry film thickness of 4 mil, and
a polyurethane finish coat with a dry film thickness of 3 mil for the painting of steel
380 bridges and other structural steel.

(b) Partial Paint System

The coating system shall consist of organic zinc primer with a dry film thickness
of 3 mil and a waterborne finish coat with a dry film thickness of 3 mil for partial
painting of steel bridges and other structural steel.

619.10 Painting
Painting shall be performed by a SSPC certified contractor, except as noted in
619.08.
390
Concrete at all junction points of concrete and steel shall be adequately shielded
or otherwise protected so the application of paint on steel is full and complete, and that
spraying onto the concrete is minimized.

If a blasted or painted surface is unsatisfactory, removal of the paint, thorough

cleaning of the surface, and repainting or other correction will be required as directed.
Where defects or damages occur in a film of any coating, all defective areas shall be
removed to soundly bonded paint or bare steel and painted to the specified thickness.

400 No lettering shall be painted on bare or painted steel surfaces, except marks
required for erection and project information stenciled in accordance with 619.10(g).

Joints of all lapping members shall be caulked after either the application of the
epoxy intermediate coat of the structural steel paint system or the application of the
organic zinc primer of the partial paint system. The intermediate or primer coat shall
be cured to the manufacturer’s recommended coating cure time prior to caulking.

511
 619.10

1. All vertical and diagonal lapping members shall be caulked

along the top and sides. The bottom shall remain open for
410 drainage.

2. All horizontal lapping members shall be caulked along the

leading edge and sides of steel members facing toward
oncoming traffic or facing toward the prevailing wind
direction.

3. All horizontal members shall remain uncaulked along the

side of steel members facing away from oncoming traffic
or prevailing wind direction.
420
(a) Weather Limitations
Field painting will not be allowed between November 15 and the following April
1 unless different date ranges are requested in the QCP and approved in writing.
Painting shall begin only when the 24 h ambient temperature is to remain above 50°F
after paint application, and the steel surface temperature is between 50°F and 100°F
unless different temperature ranges are requested in the QCP and approved in writing.
Coating, painting, and curing shall be done only when the relative humidity is to
remain between 30% and 80%. The pot life and induction time shall be in accordance
with the manufacturer’s recommendations for the existing temperature and humidity.
430
Paint shall not be applied when the air is misty, or when conditions are otherwise
unsuitable. The surface temperature of the steel to be painted shall not be within 5°F
of the dew point. When painting in a protected area to eliminate the above conditions,
the steel shall remain under cover until the paint is dry. All wet paint which has been
exposed to excessive humidity, rain, snow, or condensation shall be allowed to dry.
Damaged paint shall then be removed. The surface shall be re-cleaned and repainted
as directed. The Engineer will be the sole authority to decide when work may begin or
shall stop due to weather conditions.

440 (b) Storage

Paint shall be stored in accordance with the manufacturer’s recommendations. If
paint is allowed to remain in storage, the containers shall be turned end for end at least
once per week. The paint shall be used within the manufacturer’s recommended shelf
life.

(c) Mixing
Paint shall be thoroughly mixed so that the pigment is completely in suspension
and the consistency is uniform. Mechanical mixers shall be used in accordance with
the manufacturer’s instructions. The paint shall remain in this condition during
450 application to the steel surface. After initial mixing and before application, zinc primer
shall be strained through a metal screen not coarser than the No. 30 (600 µm) sieve.

512
 619.10

Partially empty containers of paint shall not be used. Partial mixing of containers
will not be allowed. All paint containers shall remain closed until needed for mixing.

(d) Thinning
When required for proper application, the thinning of field paint will be allowed.
Only thinners recommended by the manufacturer and as approved shall be used.
Thinners shall be added to paint in accordance with the manufacturer’s
460 recommendations. The maximum quantity added shall not exceed the manufacturer’s
recommendations. The thinned paint shall not exceed IDEM regulations for volatile
organic compounds.

The Contractor shall contact IDEM and the local air pollution control board for
information about any volatile organic compound regulations or restrictions.

(e) Application of Paint

All paint coatings shall be of colors to produce a distinct contrast with adjacent
coatings, including the color of a clean steel surface.
470
Paint shall be applied by either an airless or conventional spray method which has
been recommended by the paint manufacturer. The compressed air used for painting
shall pass through an oil and water extractor before entering the paint pot. However,
areas to be painted which are inaccessible to spray application or areas requiring
touchup may be painted with brush or daubers. Epoxy intermediate and polyurethane
finish paints may be applied by brushes or rollers provided the coating cures to a
smooth and uniform finish. Spray shall be adjusted to produce a uniform coating.

1. Stripe Coat
480 If using the structural steel paint system in accordance with 619.09(a), a stripe
coat in accordance with SSPC-PA Guide 11 shall be applied. All sharp edges, welds,
outside corners, bolt heads, nuts, threads, crevices, plate seams, back-to-back angle
seams, pitted steel, rivet heads, and other sharp discontinuities shall be striped on the
second and third coats, and then repainted with the remaining steel surfaces. Striping
shall extend at least 1 in. from edges. If specified, the stripe coat shall be allowed to
dry to the manufacturer’s recommended recoat dry time prior to painting the second
and third coats on the remaining steel surfaces.

If using the partial paint system in accordance with 619.09(b), a stripe coat in
490 accordance with SSPC-PA Guide 11 shall be applied. All sharp edges, welds, outside
corners, bolt heads, nuts, threads, crevices, plate seams, back-to-back angle seams,
pitted steel, rivet heads, and other sharp discontinuities shall be striped on each of the
coats, and then repainted with the remaining steel surfaces. Striping shall extend at
least 1 in. from edges. If specified, the stripe coat shall be allowed to dry to the
manufacturer’s recommended recoat dry time prior to painting the remaining steel
surfaces. Painting techniques shall minimize dry overspray. Dry overspray shall be
removed prior to application of other coatings and after application of the finish coat.

513
 619.11

For both paint systems, the stripe coat may be applied with either a brush or a
500 sprayer. If the Contractor-chosen method of applying the stripe coat is not producing
results acceptable to the Engineer, the Engineer will require the stripe coat application
method to be changed.

(f) Curing Time

The minimum curing time between coatings shall be 24 h for inorganic zinc
primers and 8 h for the epoxy intermediate coat. The curing time will vary depending
on the temperature and humidity. The inorganic zinc primer shall be cured to a
minimum solvent resistance rating of 4 in accordance with ASTM D 4752 prior to the
application of the epoxy intermediate coat. It shall be demonstrated that the inorganic
510 zinc primer is in accordance with this requirement. The epoxy intermediate coat shall
be cured in accordance with the manufacturer’s recommendations prior to the
application of the polyurethane finish coat. The polyurethane finish coat shall be
applied within 12 calendar days of application of the epoxy intermediate coat.

The curing time of all other paint systems or coatings shall be in accordance with
the manufacturer’s recommendations.

(g) Stencil Identification

After the hold point for the finish coat has been released, project identification
520 information shall be painted with a stencil in 2 in. black capital letters onto the outside
of both fascia beams, at the right end of the beam and near the end bent, which reads
as follows:
_____________________
bridge number

______________________
contract number

PAINTED _____________
530 date
619.11 Shop Prime Coating
The shop performing the cleaning and the application of the prime coat for
structural steel shall have a valid AISC-420-10/SSPC-QP 3 certification. Abrasive
used for cleaning steel in the shop shall be an abrasive that produces a surface profile
in accordance with 619.08. The inorganic zinc primer coat shall be applied to all
structural steel in the shop. The remaining two coats shall be applied in the field after
final erection. A structural steel paint system in accordance with 619.09(a) shall be
used. When shear connectors have been specified, the top of the top flange shall not
be primed. Erection marks may be painted on zinc painted surfaces. Machine finished
540 surfaces for sliding contact shall be coated with heavy grease as soon as practicable
after being accepted, but before removal from the shop.

Shop primed beams shall not be loaded for shipment until the primer has been
allowed to cure for a minimum of 48 h.

514
 619.13

(a) Non-Weathering Steel

All structural steel shall be cleaned in accordance with 619.08(f).

All structural steel shall receive an inorganic zinc primer, including faying
550 surfaces of high strength bolted connections and areas in contact with concrete.
Surfaces, other than the contact surfaces described above, which are inaccessible after
erection shall be painted in the shop with the full paint system required on the
completed bridge.

(b) Weathering Steel

All structural steel shall be left unpainted, except as shown on the plans. All
diaphragms, stiffeners, and other appurtenances located within the limits shown on the
plans shall be included in the painting area. Surfaces to be painted shall be cleaned in
accordance with 619.08(f). Surfaces shall be painted in accordance with 619.09(a),
560 except the finish coat shall be in accordance with 909.02(e).

619.12 Field Painting New Steel Bridge

All structural steel surfaces which are accessible after final erection shall be
painted with the remaining coatings specified for structural steel paint system in
accordance with 619.09(a) in the field after final erection.

If application of inorganic zinc primer on a steel surface is not performed in the

shop before erection of the bridge, the surfaces which are exposed shall be cleaned in
accordance with 619.08(a), 619.08(b), and 619.08(f). These surfaces shall then be
570 painted with the structural steel paint system after final erection.

Surface areas where the inorganic zinc primer was damaged during shipping,
handling, and erection shall be cleaned in accordance with 619.08(a), 619.08(b), and
either 619.08(e) or 619.08(j). Likewise, all bolt and field connections shall be cleaned
in the same manner. All the damaged areas, and bolt and field connections shall then
be painted with the inorganic zinc primer applied in the shop. This requirement will
not apply to temporary steel bridges.

Where steel surfaces have been painted with the full paint system and the paint
580 coatings have been damaged, the affected steel surface areas shall be cleaned in
accordance with 619.08(j). Structural steel paint system shall then be re-applied.

For weathering steel girders, caulk shall be applied to act as a drip bead as shown
in the plans.

619.13 Painting Existing Steel Bridges

The surfaces to be cleaned and painted shall include the surfaces of all steel
members of the superstructure, substructure, floor beams, stringers, plates, castings,
bearing assemblies, ornamental handrails, lattice work, and other steel appurtenances.
590 When shear connectors have been specified, the top of the top flange shall not be

515
 619.14

painted.

If the contract specifies clean steel bridge, the bridge steel shall be cleaned in
accordance with 619.08(a), 619.08(b), and either 619.08(e) or 619.08(j). The structural
steel paint system in accordance with 619.09(a) shall be used for painting.

If the contract specifies clean steel bridge, partial, the bridge steel shall be cleaned
in accordance with 619.08(a), 619.08(b), and either 619.08(e), or 619.08(h), or
619.08(j). The partial paint system in accordance with 619.09(b) shall be then used for
600 painting.

619.14 Drain Castings Treatment

Roadway drain castings located in a bridge deck shall be satisfactorily cleaned in
accordance with 619.08(d) or 619.08(h). The castings shall not be shot-blasted.

The roadway drain castings shall be painted with a black finish coat in accordance
with 909.02(c).

If a roadway drain casting extension pipe is damaged or missing, it shall be

610 replaced. The extension pipe shall be in accordance with 715.

619.15 Responsibility for Damage

Unless otherwise specified by the Engineer in writing, full containment shall be
provided when performing the surface preparation operation and when applying all
coats of paint, except primer coats, with spray equipment. All persons and property
shall be protected from damage or injury from the surface preparation operations and
painting operations by providing containment as described in the QCP. Persons and
property shall include, but not be limited to, pedestrians, vehicles, and other traffic
upon or underneath a bridge, all portions of the bridge superstructure and substructure,
620 and all adjacent property. The Contractor shall be responsible for damages in
accordance with 107.17.

619.16 Blank

619.17 Method of Measurement

Cleaning and painting will not be measured for payment. Disposal of the waste
stream generated by the cleaning operation will not be measured for payment.

Cleaning roadway drain castings, caulking joints of lapping members, and

630 caulking on weathering steel will not be measured for payment.

If a bridge is advertised as having existing hazardous materials, no measurement

will be made of the area covered by mill scale. For bridges advertised as having
existing non-hazardous materials, the area of structural steel covered by mill scale will
be measured for payment after a proper cleaning of the entire containment area or an
agreed large portion thereof and removing all other existing materials, including all
paint and rust. The percentage of the area of structural steel covered by existing mill
516
 619.18

scale will be representative of this entire area. The pre-established remedies for this
changed condition apply in accordance with 104.02(d) and 619.18.
640
Roadway drain casting extension pipe will be measured in accordance with
715.13.

The estimated weight, length, number of steel spans, surface area of steel, and
type of primer shown on the plans or in the Proposal book is incidental information.
Such information is approximate only. The Department will not guarantee its
accuracy.

619.18 Basis of Payment

650 Existing steel bridges to be cleaned, or partially cleaned, whichever is specified,
will be paid for at the contract lump sum price for clean steel bridge or clean steel
bridge, partial, at the bridge number specified. Existing steel bridges to be painted, or
partially painted, whichever is specified, will be paid for at the contract lump sum
price for paint steel bridge or paint steel bridge, partial, at the bridge number specified.

(a) Pre-Established Remedies for Changed Conditions

1. Discovery of Hazardous Materials but No Mill Scale on a Site

Advertised as Non-Hazardous
660 The payment will be an additional 25% of the clean steel bridge item as computed
in 619.18(b)1 in accordance with 109.05 as payment for all additional costs incurred.

2. Discovery of Mill Scale but No Hazardous Materials on a Site

Advertised as Non-Hazardous
If, on a bridge advertised as having existing non-hazardous materials and the
presence of hazardous materials has not been confirmed by laboratory analysis, the
area of structural steel covered by mill scale comprises greater than 15% of the area of
structural steel in accordance with 619.17, additional compensation for the removal of
the mill scale will be made as an adjustment to the clean steel bridge item in
670 accordance with the following:

a. For areas of structural steel greater than 15% and up to

and including 25% of the area covered by mill scale, an
additional payment of 15% of the clean steel bridge
item as computed in accordance with 619.18(b)1 will
be made.

b. For areas of structural steel greater than 25% and up to

and including 50% of the area covered by mill scale, an
680 additional payment of 30% of the clean steel bridge
item as computed in accordance with 619.18(a)1 will
be made.

517
 619.18

c. For areas of structural steel greater than 50% and up to

and including 75% of the area covered by mill scale, an
additional payment of 45% of the clean steel bridge
item as computed in accordance with 619.18(b)1 will
be made.

690 d. For areas of structural steel greater than 75% of the area
covered by mill scale, an additional payment of 60% of
the clean steel bridge item as computed in accordance
with 619.18(b)1 will be made.

3. Discovery of Hazardous Materials and Mill Scale on a Site

Advertised as Non-Hazardous
If the laboratory analysis of a waste residue sample on a bridge advertised as
having non-hazardous materials yields results indicating the presence of hazardous
materials, the entire bridge shall be considered as having mill scale and the following
700 pre-established remedy for this changed condition in accordance with 104.02(d) shall
apply. If agreed to in writing between the Contractor and the Department, the work
shall proceed with the Contractor assuming all risks for removal of mill scale. An
additional 55% of the clean steel bridge item as computed in 619.18(b)1 in accordance
with 109.05 will be paid as additional compensation for the removal and disposal of
the hazardous materials, the removal of the mill scale, the additional containment
required, and all other incidental items associated with the removal of the hazardous
materials and mill scale.

(b) Prices used in Pre-Established Remedies to Changed Conditions

710 The following prices will be computed and used as the price for the pay item
identified below in all pre-established remedies to changed conditions referenced in
this section.

The price for the clean steel bridge item, per bridge, used in all pre-established
remedies to changed conditions referenced in this section will be limited to the lesser
of the following:

1. 70% of the sum of the clean steel bridge item and paint
steel bridge item for that bridge; or
720
2. the actual amount for the clean steel bridge item for that
bridge shown in the Schedule of Pay Items.

Roadway drain casting extension pipe will be paid for in accordance with 715.14.

The cost of transportation and disposal of waste materials, waste residues, waste
residue containers, and all other debris generated from environmental control and
cleaning that is disposed of will be paid for at the contract lump sum price for disposal
of cleaning waste, hazardous or non-hazardous, at the bridge number specified.

518
 619.18

730
Payment will be made under:

Pay Item Pay Unit Symbol

Clean Steel Bridge, Partial, QP- ____, Br. No. ____ ................ LS
Clean Steel Bridge, QP- ____, Br. No. ___ ............................... LS
Disposal of Cleaning Waste, ______, Br. No.____ ................... LS
waste type
Paint Steel Bridge, Br. No.____ ................................................ LS
740 Paint Steel Bridge, Partial, Br. No.____ .................................... LS

The cost to prepare a QCP shall be included in the cost of the pay items of this
section. The cost of providing the Department with access to the bridge and seasonal
or weather limitations shall be included in the cost of the pay items of this section.

If a bridge is advertised as having existing hazardous materials, no additional

payment will be made for the removal of mill scale. The cost of the removal of mill
scale shall be included in the cost of clean steel bridge or clean steel bridge, partial.

750 If a bridge is advertised as having existing non-hazardous materials and the

percentage of the area covered by mill scale is less than or equal to 15% of the total
structural steel surface area of a bridge measured in accordance with 619.17 no
additional payment will be made for the removal of mill scale. The cost of the removal
of mill scale shall be included in the cost of clean steel bridge or clean steel bridge,
partial.

The cost of furnishing all materials, equipment, and labor required for washing,
solvent cleaning, scraping, steel brushing, or other acceptable methods for removing
paint in the locations directed shall be included in the cost of clean steel bridge or clean
760 steel bridge, partial. The cost of cleaning roadway drain castings shall be included in
the cost of clean steel bridge or clean steel bridge, partial.

The cost of providing containment in accordance with 619.15 and personal

protective equipment shall be included in the cost of the pay items of this section.

The cost of furnishing all materials, equipment, and labor required to perform the
quality control tasks outlined in 619.03 shall be included in the cost of clean steel
bridge or clean steel bridge, partial.

770 The cost of furnishing all materials including caulk, equipment, and labor to
perform caulking and painting, including the stripe coats, with the structural steel paint
system or the partial paint system shall be included in the cost of paint steel bridge or
paint steel bridge, partial. The cost of switching stripe coat application methods shall
be included in the cost of paint steel bridge or paint steel bridge, partial. The cost of

519
 621.01

furnishing all materials, equipment, and labor to perform painting of the roadway drain
castings shall be included in the cost of paint steel bridge or paint steel bridge, partial.

The cost of all equipment, material, labor, testing, use of special cleaning
methods, and shipping of waste residue samples shall be included in the cost of the
780 clean steel bridge or clean steel bridge, partial pay item.

SECTION 620 – BLANK

SECTION 621 – SEEDING AND SODDING

621.01 Description
This work shall consist of either or both plain and mulched seeding or placing
approved sod. It includes furnishing and placing seed, fertilizer, inoculants, top soil,
and mulch, if required, in a prepared seed bed or furnishing and placing sod at locations
in accordance with 105.03.

MATERIALS
10
621.02 Materials
Materials shall be in accordance with the following:

Fertilizer ...................................................................... 914.03

Grass Seed ................................................................... 914.04
Grass Seed, Temporary ............................................... 914.02
Leguminous Inoculants ............................................... 914.06
Mulch .......................................................................... 914.05(a)
Plastic Net ................................................................... 914.09(g)
20 Sod, including Nursery Sod ......................................... 914.07
Top Soil ....................................................................... 914.01
Water ........................................................................... 914.09(a)
Staples ......................................................................... 914.09(f)

CONSTRUCTION REQUIREMENTS

621.03 Preparation of Ground Before Seeding

The area to be seeded shall be made smooth and uniform and shall be in
accordance with the finished grade and cross section shown on the plans or as
30 otherwise designated and shall be trimmed in accordance with 210.

The seed bed, if not loose, shall be loosened to a minimum depth of 3 in. before
fertilizer or seed is applied. In areas of excessive vehicular traffic, such as parking of
construction equipment near a bridge repair, the soil shall be loosened to a minimum
depth of 6 in. Areas to be covered with topsoil shall be milled or disked slightly before

520
 621.05

the topsoil is placed. A disk, spike-toothed harrow, or other similar device may be used
for this purpose. Such loosening will be required to ensure bond of the topsoil with the
surface on which it is put and to form a uniform surface. The topsoil shall then be
spread to a sufficient depth to produce the thickness specified after it has been
40 compacted lightly with an approved roller, tamping device, or other method.

621.04 Preparation of Ground Before Applying Erosion Control Blankets

Prior to placing the blankets, the area to be covered shall be relatively free of all
rocks or clods over 1 1/2 in. in diameter, and all sticks or other foreign material, which
prevent the close contact of the blanket with the seed bed. If as a result of a rain,
prepared seed bed becomes crusted or eroded, or if eroded places, ruts, or depressions
exist, the soil shall be reworked until it is smooth. Such areas which are reworked shall
be re-seeded.

50 621.05 Applying Fertilizer, Seed, and Mulch

(a) Fertilizer
Fertilizer as specified shall be spread uniformly over the area to be seeded.
Fertilizer shall be spread at the rate of 800 lb/ac unless otherwise specified.

(b) Seed
Seed may be drilled in or mixed with water. The mixture shall be sprayed over
the area to be seeded. An approved mechanical method which shall place the seed in
direct contact with the soil may be used. In places inaccessible to mechanical
60 equipment, or where the area to be seeded is small, a hand operated cyclone seeder or
other approved equipment may be used. Seed of warm season grasses, forbs, or aquatic
species shall not be covered more than 1/8 in. All other seed shall not be covered more
than 1/2 in.

Leguminous seeds, unless otherwise specified, shall be inoculated with a culture

in accordance with 914.06. The culture shall be mixed with sufficient water to
distribute it thoroughly. The seed shall be wetted thoroughly with the solution and
allowed to dry sufficiently to be in condition for sowing. Inoculated seed shall be sown
within 30 h after treatment. Where seeding is to be done by hydraulic methods, the
70 inoculate may be added to the water in the spray tank.

(c) Mulch
Mulching material, when specified, shall be applied uniformly in a continuous
blanket at the rate of 2 t/ac. Mulch shall be placed within 24 h after seeding. The
percent of moisture in the mulch shall be determined in accordance with 621.14(c).

Mulching material shall be punched into the soil so that it is partially covered. The
punching operation shall be performed longitudinally with the mulch tiller. The tools
used for punching purposes shall be disks that are notched and have a minimum
80 diameter of 16 in. The disks shall be flat or uncupped such as notched coulters

521
 621.05

commonly used on moldboard plows. Disks shall be placed a minimum of 8 in. apart
along the axle or shaft. Shaft or axle sections of disks shall not exceed 8 ft in length.

The mulch tiller for punching shall be constructed so that weight may be added or
hydraulic force from the tractor may push the puncher into the ground. If heavy
weights are not used, several trips over the area may be necessary to work part of the
mulch into the soil. Care shall be exercised to obtain a reasonably even distribution of
mulch incorporated into the soil.

90 After procedures for holding the mulch in place have been completed, mulch,
other than when applied by hydroseeder, shall be watered thoroughly. The seed or soil
beneath it shall not be displaced. The mulching material shall be maintained in place
satisfactorily until final completion and acceptance of the contract except as provided
in 107.18. When seeding is performed between June 1 and August 15, a second
thorough watering shall be applied approximately 21 days after seeding.

On slopes steeper than 3:1, or when specified, the following methods will be
allowed.

100 1. Method A
The mulch may be held in place by means of a commercially produced mulch
binder which is in accordance with all applicable State and Federal regulations. Such
product shall be applied in accordance with the manufacturer’s written instructions. A
copy of the written instructions shall be supplied to the Engineer prior to the seeding
work. The product shall contain a coverage indicator to facilitate visual inspection for
evenness of application. If the mulch fails to stay in place, the Contractor shall repair
all damaged areas. A change in the mulch binder may be requested by the Engineer.

2. Method B
110 The mulch may be held in place by spraying it with a satisfactory liquid asphalt
or asphalt emulsion. The bituminous material may be applied immediately after the
mulch is in place or it may be injected into the mulch as it leaves a power driven mulch
spreader. If applied to the surface, the amount shall be approximately 0.06 gal./sq yd.
If applied as the mulch comes from the spreader, the amount shall be approximately
60 gal./t of mulch material. The exact amount shall be as directed.

3. Method C
The mulch may be held in place with binder twine fastened down with wooden
pegs not less than 6 in. long spaced 4 ft apart. The twine shall be placed parallel to and
120 also at 60° with the pavement edge in both directions. The distance between the
intersections of the diagonal strands measured along the strands shall be 12 ft. The
strand parallel to the pavement shall cross the diagonal strands at their intersections to
form equilateral triangles 12 ft on a side.

522
 621.05

4. Method D
The mulch may be held in place with a polymeric plastic net. The plastic net shall
be unrolled such that it lays out flat, evenly, and smoothly, without stretching the
material. The plastic net shall be held in place by means of staples. The wire staples
shall be driven at a 90° angle to the plane of the soil slope. Staples shall be spaced not
130 more than 4 ft apart with rows alternately spaced. The plastic net shall be secured along
the top and bottom of the soil slope with staples spaced not more than 1 ft on center.
The ends and edges of the plastic net shall be overlapped approximately 4 in. and
stapled. Overlaps running parallel to the slope shall be stapled 1 ft on center and
overlaps running perpendicular to the slope shall be stapled at least 3 ft on center. The
plastic net shall be placed with the length running from top of slope to toe of slope, or
the plastic net shall be placed with the length running horizontally or parallel to the
contour.

5. Method E
140 The area may be covered with erosion control blankets. The Contractor will be
allowed to use excelsior blanket, paper mat, or straw mat.

(d) Excelsior Blankets

Excelsior blankets may be used where mulched seeding is specified or where
erosion control blanket is specified. Excelsior blankets shall be placed within 24 h
after seeding operations have been completed. The ground shall be prepared in
accordance with 621.04. After the area has been properly shaped, fertilized, and
seeded, the blanket shall be laid out flat, evenly, and smoothly, without stretching the
material. Excelsior blankets shall be held in place by means of staples. The staples
150 shall be driven at a 90° angle to the plane of the soil slope. Staples shall be spaced not
more than 5 ft apart in three rows for each strip, with a row along each edge and one
row alternately spaced in the middle. The upslope edge shall be fastened by staples
spaced 12 in. apart. The ends and edges of the blankets shall be tightly butted together,
but not lapped. When excelsior blanket is used, the blanket shall be placed with the
length running from top of slope to toe of slope, or the blanket shall be placed with the
length running horizontally or parallel to the contour. The staples used for stapling
shall be in accordance with 914.09(f).

(e) Paper Mat

160 Paper mat may be used for mulch for seeding where mulched seeding is specified
or where erosion control blanket is specified. Paper mat shall be placed within 24 h
after seeding operations have been completed. The ground shall be prepared in
accordance with 621.04.

After the area has been properly shaped, fertilized, and seeded, two anchor
trenches shall be dug, one along the foot of the slope and the other 1 ft back from the
crown of the slope. These anchor trenches shall be 4 in. deep and at least 6 in. wide.
One edge of the paper mat shall be placed into the top trench and stapled 9 in. on
center. The trench shall then be filled with soil. The paper mat shall then be unrolled
170 such that it lays out flat, evenly, and smoothly, without stretching the material. Paper

523
 621.05

mat shall be held in place by means of staples. The staples shall be driven at a 90°
angle to the plane of the soil slope. Staples shall be placed not more than 3 ft apart
with rows alternately spaced. The paper mat shall be secured in the bottom anchor
trench in the same manner as it was secured in the upper anchor trench. The ends and
edges of the mat shall be overlapped at least 4 in. and stapled.

Overlaps running parallel to the slope shall be stapled 18 in. on center and
overlaps running perpendicular to the slope shall be stapled at least 9 in. on center.
When paper mat is used, the mat shall be placed with the length running from top of
180 slope to toe of slope, or the mat shall be placed with the length running horizontally or
parallel to the contour.

(f) Straw Mat

Straw mat may be used for mulch for seeding on projects where mulched seeding
is specified or where erosion control blanket is specified. Straw mat shall be placed
within 24 h after seeding. The ground shall be prepared in accordance with 621.04.
After the area has been properly shaped, fertilized, and seeded, the straw mat shall be
unrolled over the designated area so that the plastic mesh is on top and the straw fibers
are snugly and uniformly in contact with the soil surface without stretching the
190 material. The rolls shall be butted snugly together and stapled in place. The staples
shall be driven through the blanket at a 90° angle to the plane of the ground surface.
Each staple shall anchor the plastic mesh. The staples shall be spaced at approximately
3 ft increments, both longitudinally and transversely.

For placement on slopes, the straw mat shall be placed with the length running
from the top of slope to the toe of slope and shall extend a minimum of 3 ft over the
crown of the slope. On slope applications, six staples shall be installed across the uphill
end of the roll. The downhill ends of the lowermost rolls across the slope shall also be
anchored with six staples, placed on uniform spacing.
200
For placement in ditch lines, the straw mat shall be unrolled parallel to the
centerline of the ditch. The mat shall be placed so that there are no longitudinal seams
within 24 in. of the bottom centerline of the ditch. In ditch lines, six staples shall be
placed at uniform spacing across the upstream end of each roll.

(g) Wood Cellulose Fiber Mulch

Wood cellulose fiber may be used where mulched seeding is specified. Wood
cellulose fiber mulch shall be placed at the rate of 1 ton/ac within 24 h after seeding
operations have been completed. Application shall be by hydraulic mulching and
210 consist of mixing wood cellulose fiber mulch and grass seed with water. It shall be
mixed in standard hydraulic mulching equipment to form a homogeneous slurry. The
slurry shall be sprayed, under pressure, uniformly over the soil surface. The hydraulic
mulching equipment shall contain a continuous agitation system that keeps all
materials in uniform suspension throughout the mixing and distribution cycles.
Fertilizer shall be applied in accordance with 621.05(a).

524
 621.06

621.06 Seed Mixtures

Seed mixtures are classified as follows. Mixes including warm season grasses,
forbs, or aquatic species will be specified in the plans.
220
(a) Seed Mixture R
This seed mixture shall be applied at the rate of 205 lb/ac consisting of 100 lb/ac
of low endophyte Tall Fescue, 50 lb/ac of turf type Perennial Ryegrass, 50 lb/ac of
Creeping Red Fescue, and 5 lb/ac of White Dutch Clover. Seed used in this mixture
shall be drought tolerant. Fertilizer and mulching material, where specified or directed,
shall be applied in accordance with 621.05.

(b) Seed Mixture U

This seed mixture shall be applied at the rate of 200 lb/ac consisting of 100 lb/ac
230 of a 4-way blend of turf type Tall Fescue, 50 lb/ac Creeping Red Fescue, 45 lb/ac
Perennial Ryegrass and 5 lb/ac White Dutch Clover. Fertilizer and mulching material,
where specified or directed, shall be applied in accordance with 621.05.

(c) Seed Mixture P

This seed mixture shall be applied at the rate of 130 lb/ac consisting of 35 lb/ac
of Weeping Alkaligrass, 35 lb/ac of Creeping Red Fescue, 35 lb/ac of Slender
Creeping Red Fescue, and 25 lb/ac of Perennial Ryegrass. Seed used for this mixture
shall be salt tolerant. Fertilizer shall be applied at the rate of 400 lb/ac. Fertilizer and
mulching material, where specified or directed, shall be applied in accordance with
240 621.05.

(d) Blank

(e) Seed Mixture D

This seed mixture is intended for ditch situations which experience seasonal to
chronic saturated soils. This seed mixture shall be used on maintenance contracts or
where otherwise specified. This mixture shall be applied at the rate of 16 lb/ac. It shall
consist of the materials and be applied at the rates shown below.

Common Name Botanical Name Application Rates

Alkaligrass Puccinellia distans 3 oz/ac
Bearded Strangletop Leptochloa fascicularis 3 oz/ac
Creeping Bentgrass Agrostis stolonifera 2 lb/ac
Fowl Manna Grass Glyceria striata 2 oz/ac
Perennial Ryegrass Lolium perenne 5 lb/ac
Red Fescue Festuca rubra 2 lb/ac
Redtop Agrostis gigantea 1 lb/ac
Rice Cut Grass Leersia oryzoides 2 oz/ac
Virginia Wild Rye Elymus virginicus 5 lb/ac
Wetland Carex Species Carex spp. 3 oz/ac
Wetland Rush Species Juncus spp. 3 oz/ac
250

525
 621.06

Seed used in this mixture shall be wet tolerant. If certain species in this mix are
unavailable, substitutions may be submitted for approval. The mix shall be applied as
specified per acre. The method of planting shall be by means of hydroseeding or by
means of a hand method with a minimal amount of mulch applied in a separate
operation. Fertilizer shall not be added to this seed mixture.

(f) Blank

(g) Seed Mixture Grass

260 This seed mixture shall be placed when specified as shown below.

1. Type 1
This seed mixture shall be placed at the rate of 235 lb/ac consisting of 15 lb/ac of
Smooth Brome Grass, 10 lb/ac of Orchard Grass, and the mixture specified in
621.06(a).

2. Type 2
This seed mixture shall be placed at the rate of 125 lb/ac consisting of 20 lb/ac of
Smooth Brome Grass, 10 lb/ac of Orchard Grass, 40 lb/ac of Kentucky Bluegrass,
270 35 lb/ac of Creeping Red Fescue, and 20 lb/ac of Perennial Rye Grass.

(h) Seed Mixture Legume

This seed mixture shall be placed when specified as shown below. Mulched
seeding, when specified, shall be in accordance with 621.07. Legume mixtures shall
only be used from February 1 to May 31.

1. Type 1
This seed mixture shall be placed at the rate of 230 lb/ac consisting of 7 lb/ac of
Korean Lespedeza, 6 lb/ac of Red Clover or Alsike Clover, 7 lb/ac of Partridge Pea
280 and the mixture specified in 621.06(a).

2. Type 2
This seed mixture shall be placed at the rate of 150 lb/ac consisting of 7.5 lb/ac of
Korean Lespedeza, 7.5 lb/ac of Red Clover or Alsike Clover, 7.5 lb/ac of Birdsfoot
Trefoil, 7.5 lb/ac of Partridge Pea, 50 lb/ac of Kentucky Bluegrass, 45 lb/ac of
Creeping Red Fescue, and 25 lb/ac of Perennial Rye Grass.

“Do Not Spray” signs shall be placed near the beginning and end of this work, at
200 ft intervals, or as otherwise directed. The sign shall be 16 gauge aluminum. The
290 size and message arrangement shall be as shown on the plans. The sign background
shall be white. The sign lettering shall be black. The sign shall not be reflectorized.
Paint and primer shall be in accordance with 909.04. The sign post shall be placed as
shown on the plans. The post shall otherwise be in accordance with 910.15.

526
 621.09

621.07 Mulched Seeding

Mulched seeding, when specified, shall consist of applying the seed mixtures in
accordance with 621.06(a), 621.06(b), and 621.06(c) as specified. This mixture shall
include fertilizer and mulching material in the amounts set out herein. If erosion
control blanket is specified, the Contractor will be allowed to use excelsior blanket,
300 paper mat, or straw mat in accordance with 621.05(d), 621.05(e), or 621.05(f),
respectively.

621.08 Preparation of Ground Before Sodding

The area to be sodded shall be smooth, uniform, and shall be in accordance with
the required cross section. Surfaces prepared for sod shall be of sufficient depth below
unseated areas that newly laid sod shall be in accordance with the surrounding surface.

For those areas which shall be covered with topsoil, the procedure for the
application of topsoil shall be in accordance with 621.03.
310
After the area has been prepared for sod, fertilizer shall be applied at the rate of
400 lb/ac. The surface shall be loosened to a depth of 1 to 2 in. and then raked before
the sod is placed. All clods, lumps, boulders, or waste material shall be removed
satisfactorily.

In areas where the above method of preparation is impracticable, a different

method may be approved.

621.09 Laying Sod

320 Sod strips shall be laid in the designated direction. The sod shall be fitted to the
surrounding grade and fixed objects. The sod strips shall be butted together closely to
avoid open joints. Overlapping of sod will not be allowed. After laying and initial
watering, the sod shall be tamped or rolled as directed to ensure contact with the soil
underneath and shall be in accordance with the surrounding surface. After compaction,
the sod shall present a smooth even surface free from lumps and depressions. On slopes
of 3:1 or flatter, the use of broken sod strips will be allowed. Where broken pieces are
laid, no overlaps will be allowed.

Sod placed in ditches with grades steeper than 1% and on slopes 3:1 and steeper
330 shall be pegged. The pegs shall be spaced not over 2 ft apart in each strip measured
lengthwise of the strip. Pegs shall be driven down until no more than 1 in. protrudes
above the surface of the sod. Grades and slopes flatter than specified herein shall be
pegged as directed.

Pegs shall be wood at least 1/2 in. by 3/4 in. by 12 in. In lieu of pegs, T-shaped
wire pins may be used. The pins shall be machine bent from eight gage low carbon
steel with a minimum of an 8 in. leg, a 4 in. head, and a 1 in. secondary drive. Pins
shall be driven flush with the top of the sod.

527
 621.10

340 621.10 Watering Sod

Sod shall be watered immediately after laying. The amount of watering shall be
sufficient to saturate the sod and the upper few inches of the underlying soil. The sod
shall be watered once every day of the first week, once every second day of the second
week, once every third day of the third week, and once a week thereafter. Sod shall be
maintained for a minimum of four weeks from the time it is laid before being accepted.
During periods of ample rainfall, watering may be modified to simulate the above
schedule. The requirements of 107.19 shall apply.

621.11 Seeding or Sodding Disturbed Areas Outside Construction Limits

350 Areas outside shown construction limits which are disturbed by the Contractor
shall be repaired to their original condition or better. The areas shall be seeded with a
seed mixture grass type 2 in accordance with 621.06(g)2 or seed mixture legume type
2 in accordance with 621.06(h)2 as directed. If the contract contains seed mixtures
other than the two listed here, the Contractor may seed the disturbed area with the
mixture contained in the contract provided the area is less than 1 ac in size. If the area
disturbed is well maintained and part of a residential or commercial lot, it shall be
sodded unless the Engineer determines otherwise.

621.12 Seasonal Limitations

360 The Contractor shall post a warranty bond for all permanent seeding done from
October 16 through January 31. Only completed seeding with seed mixtures R, U, or
P shall satisfy the requirements of the warranty bond. Seeding without mulch shall not
be done between May 1 and August 15.

Sod placed during the months of June, July, and August shall be subject to the
following conditions.

(a) sod shall be in good, live, growing condition; and

370 (b) sod shall be placed within 36 h after cutting and protected from
damage during that period.

Winter sodding will be allowed when the temperature is above 35°F. No frozen
sod shall be laid and no sod shall be laid on frozen soil. Sod shall be properly protected
from drying out and shall be laid within 48 h after cutting.

621.13 Method of Measurement

Fertilizer and mulching material will be measured by the ton. Seed mixtures will
be measured by the pound. Topsoil will be measured by the cubic yard in accordance
380 with 211.09. Mulched seeding and sodding will be measured by the square yard. Water
will be measured by the 1,000 gal. Mobilization and demobilization for seeding will
be measured per each trip, when directed, to the project site. “Do Not Spray” signs
will be measured by the number of signs installed.

528
 621.14

621.14 Basis of Payment

The accepted quantities of fertilizer and mulching material, furnished and
delivered complete in place, will be paid for at the contract unit price per ton, except
as set out below for sodding. Seed mixtures will be paid for at the contract unit price
per pound for the class and type specified. Mulched seeding will be paid for at the
390 contract unit price per square yard for the class and type specified, complete in place.
Topsoil will be paid for at the contract unit price per cubic yard. Sodding and nursery
sodding will be paid for at the contract unit price per square yard, complete in place.
“Do Not Spray” signs will be paid for at the contract unit price per each.

Payment for mobilization and demobilization for seeding will be made for the
initial movement to the project site so that permanent or mulching work, as specified,
is performed. When one or more operations are completed within the same
mobilization, payment will be made for one mobilization. Payment will be for all work
necessary to move personnel and equipment to and from the project site. Payment will
400 also be made for additional mobilization, when directed.

Payment will be made under:

Pay Item Pay Unit Symbol

Erosion Control Blanket ............................................................ SYS

Fertilizer .................................................................................... TON
Mobilization and Demobilization for Seeding .......................... EACH
Mulched Seeding _____, _____ ................................................ SYS
410 class type
Mulching Material ..................................................................... TON
Seed Mixture _____, _____ ...................................................... LBS
class type
Sign, “Do Not Spray” ................................................................ EACH
Sodding...................................................................................... SYS
Sodding, Nursery ....................................................................... SYS
Topsoil ....................................................................................... CYS
Water ......................................................................................... kGAL.

420 The cost of leguminous inoculants, preparing seed beds, sowing, raking, and all
other necessary incidentals shall be included in the cost of seed mixtures. The cost of
furnishing and placing fertilizer, seed mixtures, and mulching material, in addition to
the incidentals listed above for seed mixtures shall be included in the cost of mulched
seeding.

The cost of furnishing, hauling, and placing the material, including material used
as tie-down, repair of areas for which mulch fails to stay in place, all labor, equipment,
and necessary incidentals shall be included in the cost of mulching material.

529
 621.14

430 Repair of areas outside the construction limits which must be disturbed to
construct the work required by the contract will be paid for in accordance with
201.07(e).

Water will be paid for only when ordered after the 30 day period, in accordance
with 621.10.

Payment will not be made for topsoil which is obtained from within the
right-of-way.

440 The cost of fertilizer, water, excavation of earth bed, disposal of surplus material,
and all necessary incidentals shall be included in the cost of sodding or nursery
sodding.

(a) Warranty Bond

Permanent seeding that requires a warranty bond to meet the requirements of
621.12 shall be warranted against failure resulting from lack of germination or method
of application. The seeding shall be warranted to germinate and shall be free of obvious
erosion occurrences. The intent of the warranty bond shall be to enable the final
acceptance of the contract and payment of the retainage. All seeding which has
450 significantly failed to attain approximately 70% germination shall be replaced with no
additional payment. A properly executed maintenance bond with a surety shall be
provided prior to the completion of the work. A warranty shall be made, with no
additional payment, to replace all seeding in areas which has not effectively performed
useful service as specified, as well as for the repair of designated erosion areas caused
by seeding failure. Such warranty shall be in writing with proper execution of the
maintenance bond with a proper surety. The warranty shall be equivalent to 1 1/2 times
the cost of the seeding work completed after October 15 with a minimum bond amount
of $25,000. All requirements for seeding work will still apply during the warranty
period unless otherwise directed.
460
For the terms of the warranty, a reseeding unit shall be defined as an area equal to
or larger than 2,000 sq ft in size. An erosion unit may be of an area of significance as
determined.

The warranty shall cover work completed from October 16 through January 31.
The Department will determine if the Contractor shall be released from the warranty.
This determination will be made within 10 calendar days after documented request for
inspection is made by the Contractor. Such determination will not be made prior to
April 1. All replacement work shall be finished prior to June 15 with no additional
470 payment. The requirements of 107.17 will apply to the warranty area only. The
Engineer will certify in writing as to the completion of the work and will make proper
notification for the releasing of the bond.

If the Contractor does not complete the necessary repairs before June 15, and there
are no justifiable reasons for the Department to grant an extension, the Contractor shall

530
 621.14

forfeit the bond for the seeding work only. If a bond is forfeited, the Contractor will
be required to explain to the Department why the Contractor’s experience reduction
factors do not warrant an increase.

480 (b) Changed Fertilizer

A fertilizer may be required with a higher nitrogen content than that specified, or
the fertilizer specified may be required to be enriched by adding chemicals in order to
be in accordance with such requirements. All additional cost incurred due to such
procedure will be paid at the prices shown by certified vouchers. Such payment will
include and will be full compensation for furnishing the required chemicals, or
furnishing and processing the additional materials required.

(c) Mulching
The percent of moisture shall be determined at the time the mulching material is
490 weighed. Facilities shall be provided for weighing in accordance with 109.01(b).
Arrangements shall be made in advance so that the percent of moisture will be
determined at the time of weighing and that the weight of the material will be checked.
Moisture content of the mulch will be determined on the basis of air dry weight as
follows:

Wet Weight of sample – Air Dry Weight of sample

Moisture Content % = ---------------------------------------------------------------- x 100
Air Dry Weight of Sample

500 The gross, or wet, weight of mulching material furnished and placed will be paid
for if the moisture content does not exceed 10%. If the moisture content exceeds 10%,
the weight to be paid for will be the gross, or wet, weight minus the weight of excess
moisture computed as follows:

110
Weight to be paid for = G x ------------
(100 + M)

G = Gross, or wet, weight of mulching material

510 M = Moisture content, %, in the mulching material to the nearest 0.5%.

Mulching material which contains more than 50% moisture will be rejected.
Wood cellulose fiber mulch containing more than 15% moisture will be rejected.

531
 622.01

SECTION 622 – PLANTING TREES, SHRUBS, AND VINES

622.01 Description
This work shall consist of furnishing, delivering, and planting trees, shrubs, and
vines, and also seedlings for wildlife habitat. This work shall also consist of the
performance of incidental planting procedures and plant establishment work to provide
a complete operation in accordance with 105.03.

MATERIALS
10
622.02 Materials
Materials shall be in accordance with the following:

Backfill Material.......................................................... 914.01

Fertilizer ...................................................................... 914.03
Mulch .......................................................................... 914.05(b)
Pipe .............................................................................. 914.09(e)
Plants ........................................................................... 914.08
Porous Material ........................................................... 914.09(d)
20 Tree Wound Dressing .................................................. 914.09(c)
Water ........................................................................... 914.09(a)

Soil conditioners such as peat moss or calcine clay may be added with written
permission.

Guy wire shall be minimum No. 14 gage galvanized wire.

CONSTRUCTION REQUIREMENTS

30 622.03 Care and Handling of Plants

(a) Bare Rooted Plants

If the outside air temperature exceeds 35°F when the plants are delivered, the
plants shall be planted immediately or placed in inside or outside storage. If they are
stored outside, the roots shall first be puddled in a paste solution of backfill and water.
The plants shall then be separated and their root systems heeled-in by completely
covering with moist soil. If they are stored inside, the roots shall be puddled in a paste
solution of backfill and water. Straw, peat moss, or corncobs shall be worked in and
around the root system and kept moist. Plants which are delivered in boxes, wrapped
40 bundles, or other forms of closed containers, including trucks, and which are stored
inside may remain in the container for 48 h from time of delivery, provided the
containers are opened immediately and the plants are watered if necessary.

If the outside temperature is 35°F or less when plants are delivered, the plants
shall be placed in inside storage immediately. Inside storage procedures shall be in
accordance with the above requirements. Plants may be transferred to outside storage

532
 622.05

when the outside temperature exceeds 35°F provided they are puddled again and then
heeled-in.

50 Temperature inside the storage building shall be maintained between 35°F and
55°F. Plants shall not remain in storage, either inside or outside, for more than seven
days, unless otherwise specified because of unfavorable planting conditions.

Plants may be rejected on failure to comply with these specifications.

(b) Balled and Burlapped Plants and Container Grown Plants

Plants shall be planted or placed in storage before being exposed for 10
consecutive hours at temperatures less than 35°F. Storage of plants shall be in a moist
storage building or they shall be placed outside in a compact group with balls or
60 containers completely covered with corncobs and kept moist. Plants shall not remain
in storage for more than 10 days, unless otherwise specified because of unfavorable
planting conditions.

Plants may be rejected on failure to comply with these specifications.

622.04 Collected Plants

At least 24 h before starting to dig collected plants, notification shall be given of
the time and place of digging so inspection of the work and of the plants can be made,
if so desired.
70
Collected plants shall be dug carefully in a satisfactory manner. All operations of
digging, transporting, and replanting collected plants shall be in accordance with all
applicable laws and regulations of the State.

622.05 Excavation for Plant Holes

Stakes will be set to locate plant holes for each tree, shrub, or vine. The outline of
each seeding bed will be staked and the planting on the required centers shall be as
directed. Stakes for the staking operation shall be furnished. The location stakes shall
be removed as directed. Excavation shall be such that the plant holes are cylindrical in
80 shape with the sides approximately vertical. Material excavated from the holes may
be used for backfill providing it is in accordance with 914.01. Otherwise, it shall be
distributed uniformly within the construction area as directed. The excavated material
shall not be stockpiled on turf or in ditches. Material unsuitable for the growth of
vegetation, including rocks and boulders, shall be disposed of outside the right-of-way
as directed and in accordance with 203.01 and 203.10. Plant holes shall be in
accordance with the details and tables shown on the plans. If plants have not been
planted within 10 days after excavation of the hole, the hole shall be refilled and re-
excavated at the time of planting. No additional payment will be made for this
operation.
90
If, after staking or excavation of the plant holes at the locations shown on the
plans, it becomes apparent that the location is unsuitable for planting due to

533
 622.06

accumulation of ground water, possible flooding because of terrain conditions, or

unsuitable soil conditions, plant holes shall be relocated as directed. Such relocation
shall be done with no additional payment.

622.06 Planting Season

The planting season shall be from September 1 through the following May 25,
with the exception that trees shall be planted from October 1 through the following
100 April 15, provided that trees are dormant. Crown vetch plants and seedlings shall be
planted only from April 15 through May 30, unless approved in writing. Bare rooted
plants shall be planted only when the outside air temperature exceeds 35°F. Unless
otherwise approved, deciduous plants, except those container grown, shall be dormant
at the time they arrive at the work or storage site. Evergreens shall not have active
terminal growth. At least 40% of the total number of balled and burlapped, and
container grown plants, not including crown vetch plants, shall be planted from the
beginning of the planting season through December 31. Bare root seedlings for
wildlife habitat shall be planted from October 1 through the following April 30.
Container grown seedlings for wildlife habitat shall be planted at any time.
110
The initial planting and spring replacements, in accordance with 622.18, shall be
completed satisfactorily within the planting season which expires prior to the
completion date of the contract. These plants shall have an establishment period which
shall be from the end of the specified planting period to the fall inspection. If the initial
planting and spring replacements are not completed within the specified time, the
completion date may be extended one year to provide an establishment period. If the
completion date is extended, all requirements of 622.18 shall apply until final
inspection and acceptance.

120 622.07 Pruning

Before the plant is placed in the plant hole, any bruised or broken parts of roots
shall be cut off smoothly as approved unless otherwise specified or directed. All plants
shall be pruned either before or after planting. Such pruning generally shall consist of
thinning out or cutting back secondary branching to reduce the foliage by 1/3 to 1/2 in
accordance with accepted horticultural practices. Pruning operations shall maintain the
general crown outline and characteristic branching pattern for each species. Pruning
or cutting back of terminal leaders which are over 3/8 in. in diameter at the point of
cut will not be allowed. Broken or dead branches, or any other objectionable parts of
the plant, shall be removed throughout the life of the contract. Pruning tools shall be
130 kept sharp and shall be sterilized in denatured alcohol after each hour of use. All cut
surfaces 3/8 in. or more in diameter shall be painted with a tree wound dressing.

Bare rooted shrubs shall be cut back to 1/2 their minimum specified height as
shown on the plans. Pruning shall be performed after the shrubs have been sealed with
Department seals and prior to the leaf buds breaking dormancy. At the time of the
spring and fall inspections, bare rooted shrubs will be accepted at their original
specified height provided they are healthy, in good growing condition, and are no less
than 1/2 the minimum specified height.

534
 622.08

140 622.08 Planting, Backfilling, and Watering

The plant shall be placed in the plant hole at the proper position for depth,
alignment, final grade of the surrounding ground level, and vertical position of the
trunk. The planting procedure shall be performed in such a manner that the top of the
ball of the plant is as shown on the plans at the time of planting. The planting procedure
shall be in accordance with the details as shown on the plans. Backfill material in
accordance with 914.01 shall be placed around all plants except seedlings. The
quantities of backfill material required per plant shall be as shown on the plans.

In areas which are designated on the plans as beds for group planting, the soil
150 shall be tilled to a minimum depth of 6 in. in such a manner that all sod and vegetation
is destroyed. These areas shall be tilled at least two times with an interval of 14 days
between tilling operations. Planting may be done immediately after the second tilling.
Additional tilling shall be performed if vegetation appears before mulch is applied.
Sod and vegetation shall be removed in lieu of the tilling operation when the soil
temperature or moisture conditions are such that the sod and vegetation would not be
destroyed by tilling. At other times, sod and vegetation may be removed in lieu of
tilling. If the excavation resulting from sod removal is greater than 1 in. deep, it shall
be backfilled with topsoil to 1 in. above the original ground. After sod and vegetation
removal and backfilling, the bed area shall be cultivated to a depth of 6 in. Large clods,
160 rocks, and other debris encountered in the cultivation work and any excess soil shall
be removed. The outline of beds for group plantings shall be no closer than 3 ft to the
center of any of the outer plants in the area.

In addition to the water applied at the time of planting, unless excessive moisture
prevails, the minimum supplemental waterings required shall be two between May 1
and June 15, and one every 14 days between June 15 and September 15. Sufficient
water shall be applied to individual plants to saturate the backfill and the mulch area.
Plants in beds shall receive water equivalent to the quantity used for individual plants.
Liquid fertilizer, in accordance with 622.09, may be applied with the supplemental
170 watering and the method of application shall be approved. Lance watering will not be
allowed.

Container grown seedlings for wildlife habitat which have been planted from
June 1 through August 31 shall be maintained after installation for 30 days.
Maintenance shall include watering the seedlings at the time of planting and once
every seven days.

(a) Plants with Bare Roots

With the plant in its proper position, the plant hole shall be backfilled with
180 material in accordance with 914.01. The backfill material shall be worked firmly
around the roots as the hole is gradually filled. The plant shall be raised gently and
lowered slightly as the soil is added to help eliminate air pockets around the roots. Soil
shall be added in layers of about 6 in. and each layer tamped to make it firm and to
hold the plant perpendicular. Water shall be used to settle the soil and to eliminate air

535
 622.09

pockets around the roots, unless otherwise directed. The top 4 in. of soil necessary to
fill the plant hole completely shall be a very fine mixture and shall be placed on top of
the firmed backfill and allowed to remain loose and untamped.

(b) Balled and Burlapped Plants

190 Balled and burlapped plants shall be handled by the ball and placed in the holes
in such a manner that the soil of the ball does not become loosened from the roots. The
soil directly beneath the ball shall be firmed to minimize settling. Guy stakes shall be
driven before backfilling operations begin. After the hole has been partially backfilled
and the material firmed under and around the ball, the burlap shall be cut away and
removed from the stem of the plant. Backfilling and firming shall then be completed
in a manner to avoid loosening the soil from the root ball. Watering shall be done in
accordance with 622.08(a). Backfill material shall be in accordance with 914.01.

(c) Seedlings for Wildlife Habitat

200 Seedlings shall be from 6 to 18 in. in height. Seedlings shall be planted as directed
in the locations shown on the plans. Species shall be selected from the list as shown
on the plans. Alternate species selection shall be subject to approval. Seedlings shall
be planted no closer to each other than the distance shown on the plans. Seedlings shall
not be planted in rows, but instead shall be planted in a natural appearing pattern.
Failure to comply with this procedure will require the replanting of the seedlings as
directed with no additional payment. All damaged seedlings shall be replaced with no
additional payment if replanting is required.

622.09 Liquid Fertilizer Application

210 All plants shall be fertilized with a water soluble 5-10-10 fertilizer, or an
equivalent amount of plant nutrients, at the rate of 0.75 lb/100 gal. of water. Fertilizer
shall be applied to each installed plant until the mulched area over the plant hole is
saturated. Three applications shall be made: one on or about July 1; one about August
1; and one about September 1.

622.10 Mulching
Mulch, in accordance with 914.05(b), shall be placed as a top layer around each
plant as soon as it has been installed. The mulch shall cover the entire area as described
in 622.08 and shall be placed around individual plants in accordance with the plans.
220
622.11 Guying and Staking
Guying and staking shall be in accordance with the details shown on the plans.
Guy wire shall be placed through rubber hose material around each tree then twisted
to secure the tree in a relatively stable position. Three wood stakes shall be spaced
equally about each tree. The guy wire shall be secured to each stake at an
approximately right angle. Support of multi-stem trees of 4 to 6 ft in height shall
consist of inner limb guying and bracing stakes. The securement point and placement
of guy wire shall be so as to avoid abrasion of tree limbs. The guys and stakes shall be
maintained for the duration of the contract. Prior to final inspection, all materials used
230 to support trees shall be removed and disposed of, except as otherwise directed for

536
 622.13

trees requiring additional bracing time. However, supports for fall replacement shall
remain in place. If approved, stakes may be left flush with the ground.

622.12 Plant Protection

(a) Borer Control Coatings

Within five days after planting and prior to wrapping, all trees, except evergreens,
shall be protected against borer attack with an insecticide mixture applied to the tree
trunk with a paint brush or a suitable hand sprayer. The application shall cover the
240 trunk from the root crown to the first major branches. The mixture shall consist of
enough powdered skim milk to form a smooth slurry when added to either dieldrin 18
at the rate of 2 qt to 50 gal. of water or thiodan 50 at the rate of 1 lb to 50 gal. of water.

(b) Wrapping for Rodent Protection

Within seven days after planting, all crabapple and shade trees with a 1/2 in.
diameter or larger, except for multi-stem forms, shall be wrapped with a double layer
of 18 by 14 mesh per in. aluminum mill finish screen wire mesh around the trunk of
each tree as shown on the plans. The height of screen wire shall be from the existing
grade to below the lowest branch. The screen wire shall be overlapped at the ends. The
250 screen wire shall be secured to itself with hog rings or other approved methods, and to
the rods by approved means.

Plastic coil type protective wrapping will be acceptable as an alternative to the

screen wire and reinforcement rod method of tree protection or staked trees of less
than 2 in. caliper. The wrapping shall be loosened twice each calendar year. The first
adjustment shall be made between May 15 and June 15. The second adjustment shall
be made between September 1 and September 30. The plastic tree protective wrapping
shall extend to the height of the bottom limb.

260 The Contractor may submit other proposed methods of rodent protection to the
Department’s landscape architect for approval prior to installation. The design of the
protection shall ensure an average air space diameter of 2 in. greater than the tree’s
callipered size at installation. The protection shall enable air movement through its
surface to dry the tree trunk following periods of precipitation. The protection shall
not damage the tree nor hinder its growth.

Multi-stem trees shall be wrapped with commercially available wrapping paper

wrapped tightly around the trunks from the ground to the lowest branch with a
minimum of 1/2 in. overlap. The wrapping paper shall be tied securely with stout cord
270 at top and bottom and at two intermediate intervals.

622.13 Retaining Walls and Tree Wells

Retaining walls around the roots of trees or shrubs, and tree wells around the
trunks of trees or shrubs shall be constructed at the locations and to the shape and
dimensions shown on the plans or as otherwise designated. They shall be of mortar
and masonry, or other type as specified. Mortar shall not be used in any portion of the

537
 622.14

tree well extending below the top of contiguous porous material used for tree root
protection. The inside face of a tree well shall be no less than 2 ft from the outside
edge of the trunk of the tree or shrub. No material shall be placed between the tree
280 trunk and the wall of the tree well.

622.14 Tree Root Protection

Where tree root protection is specified, the entire area of the root spread shall be
protected. The limits of this area shall be as designated, but in general this area
corresponds to the area of the ground surface lying beneath the limb spread of the tree.
The area shall be cleaned of all vegetation and debris. Porous material, in accordance
with 914.09(d), shall be placed uniformly over the area to a depth in proportion to the
height of fill, varying proportionally from 3 in. for fills of 1 ft or less to 12 in. for fills
of 4 ft or more, or to such other depth as may be designated. A layer of No. 23 sand or
290 other approved material shall then be placed in sufficient quantity to choke the top
layer of porous material and will be measured and paid for as porous material.

Where the earth fill is less than 12 in. and tree root protection is specified without
the construction of a tree well, the thickness of the porous material at the tree trunk
shall be increased to the height of the fill and extend outward from the tree truck in
collar form for a distance of 12 in., unless otherwise shown on the plans.

No fill shall be placed over the root spread of any tree or shrub that is to be
protected in the above manner until the required depth of porous material has been
300 placed.

622.15 Pipe Underdrains

Pipe underdrains, when shown on the plans or directed, shall be placed to drain
tree wells or porous material for tree root protection. These shall be placed in
accordance with applicable provisions of 718.

622.16 Damage to Plants

During all operations of tree protection, care shall be used to prevent unnecessary
cutting of roots and to prevent scarring or damage to selected trees or shrubs.
310 Motorized equipment shall not be operated within the drip line of trees unless
specified. Where trimming of branches or cutting of roots is necessary, all cuts shall
be made cleanly with proper sharp tools in accordance with generally accepted
horticultural practices. Scarred areas and cut surfaces 3/8 in. or more in diameter shall
be covered completely with a tree wound dressing.

622.17 Grass and Weed Control

Weeding and mowing of grass in and around all group plantings, beds, and
individual trees and shrubs shall be performed until final acceptance. The grass and
weed control areas shall be the areas within 2 ft of the outer limits of all group plantings
320 and shrub beds and within 2 ft of the outer limits of the mulch area of individual shrubs.
For the care of individual trees, the area shall extend to a perimeter centered from the

538
 622.18

point itself to 2 ft beyond the stub stakes of the guy wires or 2 ft beyond the mulched
area. In general, these areas shall be in accordance with the plans.

622.18 Care, Inspection, and Replacement

(a) Care
Watering, fertilizing, weeding, cultivating, spraying to control insect infestation
and disease, and all other good horticultural practices necessary to maintain the plants
330 in a living healthy condition shall be performed up to the time for termination of
responsibility for care as set out herein. The plants shall be cared for throughout the
life of the contract. All plants stolen, damaged, or destroyed by fire, automobiles,
vandalism, or any other cause, with the exception of plants damaged or destroyed by
Department maintenance operations, shall be replaced with no additional payment as
soon as practicable. Plants damaged or destroyed by the Department will be replaced
by the Department prior to the date of final acceptance.

(b) Inspection and Replacement

On or about May 1, a spring inspection of initial plantings will be made during
340 and before the end of the planting season and prior to the beginning of the
establishment period. Plants not living, unhealthy, in a poor growing condition, or
otherwise not meeting the specifications shall be replaced with no additional payment,
prior to May 15 for trees and prior to May 25 for other plants. These replacements
shall be in accordance with all other requirements of the initial planting. All plants
found to be not living or in an unhealthy condition between this replacement and final
inspection shall be removed from the project immediately, as directed, and shall be
replaced after September 15 as detailed below.

A fall inspection will be made on or about September 15, at which time the
350 condition of the materials planted within the specified planting season will be
determined. At the time of this inspection, all plants which are found to be dead,
unhealthy, in a poor growing condition, or otherwise not meeting the specifications
will be rejected. Rejected plants shall be removed and disposed of as soon as
practicable and replaced prior to November 15 with no additional payment.
Replacement materials and operations shall be in accordance with the requirements of
the initial planting.

A final inspection of the contract will be made as soon as possible after

replacement. All plants shall be cared for and maintained until final inspection and
360 acceptance.

All seedlings for wildlife habitat shall be in accordance with ASNS Seedling
Trees and Shrubs and will be inspected by a landscape architect within one week of
planting. Spring and fall inspections as described above will not be required. The
inspection, planting, and maintenance of seedlings as required will constitute final
acceptance.

539
 622.19

622.19 Crown Vetch Plants and Seedlings

The requirements of 622.09 and 622.18 will not apply to these items. Seedlings
370 shall be fertilized as specified on the plans. Crown vetch plants and seedlings,
including replacements, shall be watered as necessary to keep them in a living, healthy,
and good growing condition.

On or about June 5, these items will be inspected. If it is estimated that 90% or

more of the plan quantity of any individual item in a specific area is living, healthy,
and in a good growing condition, replacements will not be required. If less than 90%
are alive, healthy, and in a good growing condition, all items not meeting these
requirements shall be replaced. Replacements shall be marked in the same manner as
the original planting, except the markers shall be yellow.
380
Replacement planting shall be accomplished prior to June 15.

A final inspection will be made on or about the following September 15. If it is

estimated that 90% of the contract quantity of any individual item is living, healthy,
and in a good growing condition, payment will be made for the contract quantity. If
less than 90% meet these requirements, the pay quantity for the item will be
established.

622.20 “Do Not Mow or Spray” Signs and “Do Not Disturb” Signs
390 These signs shall be placed at the boundaries of areas where seedlings for wildlife
habitat have been placed. The locations and spacing of the signs shall be as shown on
the plans or as directed. The sign shall otherwise be in accordance with 621.06(h).

622.21 Method of Measurement

Furnishing and planting trees, shrubs, and vines will be measured by the number
of units of each type and size specified, installed, and accepted. Seedlings for wildlife
habitat, “Do Not Mow or Spray” signs, and “Do Not Disturb” signs will be measured
by the number installed and accepted. Retaining wall masonry, either mortared or not
mortared as specified, will be measured by the cubic yard. Porous material for root
400 protection will be measured by the ton.

622.22 Basis of Payment

The number of trees, shrubs, and vines of each variety planted, determined as
provided above, will be paid for at the contract unit price per each for plant, of the
type, form, and size shown in the Schedule of Pay Items. Seedlings for wildlife habitat,
“Do Not Mow or Spray” signs, and “Do Not Disturb” signs will be paid for at the
contract unit price per each.

Masonry wall and masonry tree well will be paid for at the contract unit price per
410 cubic yard. Porous material for root protection will be paid for at the contract unit price
per ton.

Payment will be made under:

540
 622.22

Pay Item Pay Unit Symbol

Masonry Tree Well .................................................................... CYS

Masonry Wall ............................................................................ CYS
Plant, Annual ............................................................................. EACH
420 Plant, Aquatic ............................................................................ EACH
Plant, Biannual .......................................................................... EACH
Plant, Broadleaf Evergreen, Cone, Broad Upright, _____ ........ EACH
size
Plant, Broadleaf Evergreen, Globe, Dwarf, _____ .................... EACH
size
Plant, Broadleaf Evergreen, Spreading, Semispreading, _____ EACH
size
Plant, Coniferous Evergreen, Cone, Broad Upright, _____ ...... EACH
size
430 Plant, Coniferous Evergreen, Globe, Dwarf, _____ .................. EACH
size
Plant, Coniferous Evergreen, Prostrate Broad Spreading,
Semispreading, _____ ........................................................ EACH
size
Plant, Deciduous Shrub, _____ ................................................. EACH
size
Plant, Deciduous Tree, Multi-Stem, _____ ............................... EACH
size
Plant, Deciduous Tree, Single Stem, _____ .............................. EACH
440 size
Plant, Ground Cover .................................................................. EACH
Plant, Perennial .......................................................................... EACH
Plant, Root Tuber, Corm, Bulb .................................................. EACH
Plant, Rose Grade ...................................................................... EACH
Porous Material for Root Protection .......................................... TON
Seedling ..................................................................................... EACH
Sign, “Do Not Disturb” ............................................................. EACH
Sign, “Do Not Mow or Spray” .................................................. EACH

450 The cost of furnishing all materials, labor, and necessary incidentals shall be
included in the cost of the pay items.

Progress payment for planting trees, shrubs, or vines will be based on the premise
that 75% of the work has been completed when such trees, shrubs, or vines have been
completely planted. The remaining portion of the payment will be for maintenance and
plant replacement.

541
 628.01

SECTION 623 – BLANK

SECTION 624 – BLANK

SECTION 625 – BLANK

SECTION 626 – BLANK

SECTION 627 – BLANK

SECTION 628 – FIELD OFFICE, FIELD LABORATORY, COMPUTER

SYSTEM, COMPUTER SYSTEM EQUIPMENT, OFFICE MACHINES AND
COMMUNICATIONS

628.01 Description
This work shall consist of providing the specified facilities, equipment, supplies
and services in accordance with 105.03.

628.02 Field Office and Laboratory Requirements

10 When specified, the Contractor shall provide a field office, computer systems,
computer system equipment, office machines, field laboratory, services, equipment
and supplies for the Department’s exclusive use in accordance with the minimum
requirements listed below.

All equipment shall be covered by normal manufacturer's warranties. All cellular

telephone units, computer systems, office machines and associated equipment
provided by the Contractor will remain the property of the Contractor and will be
returned to the Contractor upon completion of the contract.

20 (a) Field Office

The field office shall be located as mutually agreed by the Engineer and the
Contractor. If a building exists within the limits of the right-of-way that is acceptable
as a field office and the building is scheduled to be removed under the terms of the
contract, the building may be equipped and furnished as the field office. A building
within the right-of-way that is furnished under this specification shall be removed prior
to the date of the last work and other acceptable facilities for the field office shall then
be provided.

The field office may be a permanent building or a trailer and shall be of the type
30 shown on the Schedule of Pay Items. The building or trailer furnished for the field

542
 628.02

office shall be in accordance with all applicable State and local codes and applicable
IOSHA/OSHA requirements.

The field office shall be complete and ready for use by the Department, including
all utility connections, office machines, internet service, equipment and supplies, prior
to the start of work. If the Contractor is unable to provide the permanent field office
prior to the start of the work, the Engineer shall be notified in writing and the
Contractor and the Engineer will agree on temporary field office arrangements prior
to the start of work. A temporary field office will not be accepted by the Department
40 for more than two months, at which time a permanent field office shall be ready for
the Department’s use.

The field office shall at a minimum be the size listed below for the type field office
specified.

1. Type A – 400 sq ft
2. Type B – 550 sq ft
3. Type C – 650 sq ft.

50 Minimum dimensions shall be 8 ft wide and 7 ft in height, from floor to ceiling.

For a trailer, the calculation of minimum area will be based on the exterior box
dimensions.

The office shall have a solid and level floor with no holes, a weatherproof roof
and shall be dust-proof, and wind-tight. The field office shall have at least two doors
for ingress and egress and shall have a minimum of six windows for a type A field
office and eight windows for a type B or C field office, not including any windows in
the doors.

60 Exterior doors shall have a satisfactory locking system. At least one door shall
always be able to be unlocked and opened from inside the field office. If a padlock is
used to secure a door, it shall be a high security type and shall be made inaccessible to
bolt cutters, hacksaws, hammers, or prybars. The padlock shall be mounted in such a
manner that locking and unlocking the door can be made with minimal effort.
Installation of additional hardware to protect the lock or use of multiple padlocks on a
door will not be allowed. Additional hardware to receive the padlock will be
acceptable. The Contractor shall furnish the number of keys to the office as directed
by the Engineer. The Department will maintain a list of all Department personnel who
are given keys.
70
Windows shall be hinged or sliding and have a minimum area of 5 sq ft each.
Windows shall be provided with satisfactory locks and screens. Windows, including
windows in the doors, shall be provided with shades, blinds, or other approved
coverings.

543
 628.02

The field office shall have heating and air-conditioning equipment capable of
maintaining a uniform temperature between 68°F and 80°F.

The field office shall have a minimum 100 amp, 120/240 volt electrical service,
80 shall have sufficient receptacles to satisfactorily accommodate all required electrical
equipment without the use of extension cords or splitters and shall be provided with
satisfactory office type lighting.

The field office shall include a minimum of one separately lockable storage area.
The storage area shall have a minimum storage volume of 63 cu ft with a minimum
floor area of 9 sq ft.

If the field office is a trailer, the trailer shall be securely supported by adequate
blocking. The blocking shall provide a foundation to prevent settlement. The trailer
90 shall be secured to the ground with a trailer tie down system that is in accordance with
all State and local requirements. Each trailer shall be furnished with steps meeting
IOSHA/OSHA requirements at each doorway.

The field office location shall be selected in order to provide satisfactory parking
and trash disposal facilities for Department use. Parking spaces shall be either paved
or surfaced with compacted aggregate, size No. 53, or other acceptable materials
suitable for all-weather usage.

(b) Field Office Equipment and Supplies

100 The following minimum equipment and supplies shall be furnished for each field
office of the type specified.

Office Type
Equipment and Supplies A B C
Bloodborne Pathogen Kit 1 1 1
Bottled Drinking Water Yes Yes Yes
Broom and Dust Pan 1 1 1
Calculators 1 2 2
Carbon Monoxide Detector 1 1 1
Chairs 4 8 12
Cleaning Supplies Yes Yes Yes
Drafting Stools 1 1 1
Drafting Tables 1 1 1
File Cabinet Drawers 4 8 12
Fire Extinguishers 1 2 2
First-Aid Kit 1 1 1
Folding Office Tables 1 2 2
Microwave Oven 1 1 1
Office Desks and Office Chairs 2 4 4
Paper Shredder 1 1 1
Pencil Sharpener 1 1 1
544
 628.02

Refrigerator/Freezer 1 1 1
Shelving 16 lft 20 lft 24 lft
Six-hook Coat Rack 1 1 1
Smoke Detector 1 1 2
Telephones Lines 2 2 2
Telephones 2 2 3
Toilet Facilities Yes Yes Yes
Voice Mail 1 1 1
Waste Paper Baskets 2 4 4

The office and the equipment shall be furnished in a condition satisfactory to the
Department.

Adequate quantities of basic hygiene and office cleaning supplies shall be

provided. These supplies shall include, but are not limited to, hand soap, hand
sanitizer, paper towels, toilet paper, window cleaner, all-surface cleaner, toilet
110 disinfectant, toilet brush and a toilet plunger.

Bottled drinking water with a dispenser having both hot and cold water
capabilities shall be furnished. Drinking cups and paper towels shall be provided.

Fire extinguishers shall be 5 lb, Class ABC or higher rated and shall be maintained
in a fully charged and operable condition and shall meet all IOSHA/OSHA
requirements.

First-aid kits shall meet the requirements of ANSI Z308.1 current at the time of
120 letting.

Shelving shall have a minimum width of 10 in.

At least one telephone shall be a cordless phone having a frequency of at least 900
MHz.

The telephone voice mail system shall be capable of providing both a minimum
one minute outgoing message and 30 minutes total recording time for incoming
messages. It shall have a remote operation feature, which may be used to retrieve,
130 replay, erase, and save messages. An answering machine meeting these requirements
may be substituted for the voice mail system.

Filing cabinets shall at a minimum be fire resistant steel filing cabinets with a
class D or higher classification established by UL or Safe Manufacturers National
Association. Cabinet drawers shall have a filing depth of 25 in. All cabinets shall have
a lock and at least four drawers shall be fireproof.

Office desktops shall be at least 48 in. wide and 25 in. deep. All desks shall contain
at least two drawers, one of which shall be provided with a lock.

545
 628.02

140
Folding office tables shall be a minimum size of 30 in. by 60 in.

Office chairs shall be height adjustable and equipped with castors. Other required
chairs may be stackable or folding chairs.

Drafting tables shall contain a tilt top work table for drafting purposes.
Dimensions shall be at least 30 in. by 60 in. The drafting stool shall be proportional to
each drafting table.

150 Supplies to be furnished shall include all items required for proper operation of
the required equipment. This includes, but is not limited to, operating manuals and
paper supplies.

Calculators shall be electric powered, have a printer and a minimum 12-digit

capacity.

The paper shredder shall have a minimum capacity of 12 sheets of 20 lb paper,

shall be capable of shredding paper clips and staples, and shall include a five-gallon
capacity waste basket.
160
The microwave oven shall have a minimum 1 cu ft capacity with a minimum
1,100 watts and shall have digital controls.

The field office and all equipment and supplies shall be maintained and
replenished in a satisfactory manner during the term of the contract or until released
by the Engineer. If the field office or required equipment and supplies are not
maintained by the Contractor, the Engineer may withhold partial payments until the
field office is operational to the Department’s satisfaction.

170 (c) Computer System and Computer System Equipment

When specified in the Schedule of Pay Items, the Contractor shall provide the
computer system and computer system equipment in accordance with the minimum
requirements listed below for the Department’s exclusive use for each field office.

1. Computer System
a. Laptop computer
b. Processor – Intel or AMD compatible, 2.0 GHz
c. Memory – 8.0 GB, 1333 MHz
d. Hard Drive – 500 GB, 5,400 rpm or 128 GB SSD (Solid
180 State Drive)
e. Ports – Two USB 2.0 compliant ports
f. Network/Wireless – Ethernet or wireless card to be
compatible with the selected internet and office
network connections
g. Graphics – Integrated graphics card

546
 628.02

h. Display - 15 in. WX GA LCD panel

i. Battery - Nine cell Lithium ion
j. Miscellaneous - One compatible port replicator with
AC adapter, one additional AC adapter, one DC adapter
190 and one padded carrying case.

The initial condition of the computer system shall be nearly pristine. All owner
installed e-mail accounts, games, spyware, online services, applications, network or
other profiles previously set up on the system shall be removed prior to placement in
the field office. If the system was provided for a previous Department contract, all
software not specified shall be removed prior to placement in the current field office.

The Contractor shall provide a minimum 900 J, six-outlet surge protector for each
computer system specified in the contract.
200
2. Computer System Equipment
a. Monitor – 22 in. widescreen digital flat panel with
VGA and DVI connections
b. Keyboard – USB enhanced multimedia keyboard
c. Mouse – Optical USB 2-button scroll mouse
d. Miscellaneous - One port replicator with AC adapter,
one additional AC adapter, one DC adapter that is
compatible with the Department's provided laptop or
mobile device.
210
3. Computer Software
The Contractor shall provide software for the computer system in accordance with
the minimum requirements listed below.

a. Operating System Software – Windows 10

Professional.
b. Productivity Software – Microsoft Office 2013 Small
Business and Adobe Acrobat Professional XI.
c. Security Software – McAfee Virus Scan Plus.
220
All software shall include the most current updates and patches at the time the
computer system is provided to the Department. The Contractor shall provide for
installation of updates and patches for the operating system, productivity and security
software during the term of use of the computer system by the Department. Updates
and patches shall be provided by an automatic update method.

The Department may install and maintain proprietary software on the computer
in order to run the Department’s construction management programs.

547
 628.02

230 4. Miscellaneous Computer Requirements

The Contractor shall provide all cables, connections and software required to
connect the computer system provided by the Contractor or by the Department to the
printer and the scanner.

The Contractor shall provide an Ethernet and a wireless office network to enable
all computer systems in the field office to access the field office internet service, the
printer and the scanner.

The Contractor shall provide all manuals necessary for operation of the computer
240 system, computer system equipment and software with the system and shall include
all documentation normally furnished with the equipment and software when
purchased.

The Department will be utilizing the computer system to run or access Department
provided construction management software applications. These applications are
known to run on Intel and AMD compatible equipment when using the Windows 10
Professional operating system. If the Department experiences problems running these
applications due to hardware or software compatibility, the Contractor shall replace
the equipment to ensure compatibility to the satisfaction of the Engineer within five
250 business days.

The computer system shall be maintained in good working order. If a portion of

the system becomes defective, inoperable, damaged, or stolen, that portion shall be
repaired or replaced within five business days after the Contractor is notified by the
Engineer. If the computer system and related accessories are not maintained by the
Contractor as required, the Engineer may withhold partial payments until the computer
system is operational to the Department’s satisfaction.

(d) Field Office Internet Service

260 The Contractor shall provide broadband internet service for the field office.
Broadband internet service shall be capable of a minimum average upload speed of 5
Mbps and a minimum download speed of 50 Mbps, unless otherwise approved by the
Engineer.

(e) Field Office Machines

The Contractor shall provide a fully operational copier, printer, and document
scanner for the Department’s exclusive use in the field office in accordance with the
minimum requirements listed herein.

270 In lieu of separate copier, printer, and scanner, the Contractor may provide an all-
in-one unit that meets all the requirements for any combination of the individual
machines being provided. Separate machines shall be provided for those machine
functions that are not included in an all-in-one type machine.

548
 628.02

1. Copier
The copier shall be compatible with, and shall be connected to, the computer
system provided by the Contractor or the Department for use by the Department in the
field office. The copier shall be capable of using plain paper and of making full size,
black and white copies of letter, legal and ledger US paper size original documents.
280 The copier shall be capable of reducing and increasing copy sizes. The copier shall
have a self-feeding paper tray, an automatic document feeder and be capable of
producing at least 20 copies per minute.

2. Printer
The printer shall be compatible with, and shall be connected to, the computer
system provided by the Contractor or by the Department for use by the Department in
the field office. The printer shall be capable of printing single-sided, black and white
letter, legal and ledger US paper size documents at a rate of 20 pages per minute and
capable of automatic duplex printing. More than one printer may be used to meet this
290 requirement.

All printers shall be set to accommodate wireless printing from the Department's
provided laptop or mobile device.

3. Document Scanner
The document scanner shall be compatible with, and shall be connected to, the
computer system provided by the Contractor or the Department for use by the
Department in the field office. The scanner shall be capable of scanning letter and legal
size documents and shall have an automatic document feeder and be capable of 200 to
300 600 dpi black and white resolution, preset to 200 dpi.

4. Miscellaneous Office Machine Requirements

The Contractor shall provide letter, legal and ledger size paper, ink cartridges and
toner as required by the Engineer for the operation of each piece of equipment
provided.

If any office machine becomes defective, inoperable, damaged, or stolen, that

machine shall be repaired or replaced within five business days after the Contractor is
notified by the Engineer. If any of the office machines are not maintained by the
310 Contractor as required, the Engineer may withhold partial payments until the machine
is operational to the Department’s satisfaction.

(f) Field Laboratory

The field laboratory shall be located as mutually agreed by the Engineer and the
Contractor. The laboratory shall consist of an acceptable building or trailer in
accordance with 628.02(a) in which the Department will house and use equipment to
perform testing procedures for the contract.

549
 628.03

The following equipment and supplies shall be furnished for each field laboratory
320 of the type specified. The equipment and supplies shall meet the requirements of
628.02(a) as applicable.

Laboratory Type
Equipment and Supplies A B C
Bloodborne Pathogen Kit 1 1 1
Bottled Drinking Water Yes Yes Yes
Broom and Dust Pan 1 1 1
Carbon Monoxide Detector 1 1 1
Chairs 2 2 2
Cleaning Supplies Yes Yes Yes
File Cabinet Drawers 4 4 4
Fire Extinguishers 1 2 2
First-Aid Kit 1 1 1
Folding Office Tables 1 1 1
Office Desks and Office Chairs 1 1 1
Shelving 16 lft 20 lft 24 lft
Six-hook Coat Rack 1 1 1
Smoke Detector 1 1 2
Telephones Lines 1 1 1
Telephones 1 1 1
Toilet Facilities Yes Yes Yes
Voice Mail 1 1 1
Waste Paper Baskets 2 2 2

If a field office is provided that is large enough to include the required space for
the laboratory, the Engineer may agree to accept the field office for use as both office
and laboratory, in which case the equipment and supplies listed for the laboratory will
not be required.

If the field laboratory is a separate structure that is located directly adjacent to the
330 field office, the toilet facilities, drinking water, telephones, voice mail/answering
machine, telephone lines and cleaning supplies will not be required.

628.03 Mobile Internet Service

When specified, the Contractor shall provide mobile internet service for the
Department’s exclusive use.

The mobile broadband internet service access device will be used by the
Department in a laptop computer provided by either the Contractor or the Department.

340 The device shall connect to the laptop via a USB 2.0 compliant port, or by wireless
means. The device and service shall be capable of a minimum 3G speed. The internet
service rate plan shall include unlimited data and time usage with no roaming charge

550
 628.04

for national domestic use. All software necessary for the operation of the device shall
be provided to the Engineer.

The Contractor shall not purchase any device or enter into any service agreement
until authorized by the Engineer. The Engineer will provide a minimum of 10 business
days notice prior to the date the device will be required.

350 628.04 Cellular Telephones

The Contractor shall provide cellular telephone equipment and services, as
specified below, for use by the Department on the contract.

Each cellular telephone unit shall have a service coverage area that includes the
project limits. Each cellular telephone unit shall include a belt clip system, a 120V AC
charger, a 12V DC mobile charger, and a hands-free kit consisting of a speaker and a
microphone enabling the user to operate the unit with minimal need for the use of their
hands. The hands-free kit may be either wired or wireless.

360 All equipment shall be covered by normal manufacturer's warranties. All cellular
telephone units and associated equipment will remain the property of the Contractor
and will be returned to the Contractor upon completion of the contract.

Cellular telephone units shall meet the following minimum requirements:

(a) Type A
1. internet ready device with minimum 3.5 in. display,
measured diagonally
2. cellular telephone anytime minutes per month as shown in
370 the Schedule of Pay Items
3. unlimited nights and weekends service
4. voice mail and caller ID
5. protective case to prevent damage to the unit
6. rear facing camera with a minimum 4 MP resolution
7. minimum 720p video capture
8. 5 GB or higher data plan per unit
9. internal memory of 16 GB or higher
10. USB port for computer connection.

380 (b) Type B

1. a cellular telephone with anytime minutes per month as
shown in the Schedule of Pay Items
2. unlimited nights and weekends service
3. voice mail and caller ID
4. build-in camera with a minimum 3.2 MP resolution.

The Department will be responsible for damage or loss of the units beyond that
covered by normal manufacturer's warranties, while in use by the Department. The

551
 628.05

Contractor shall provide replacement cellular telephone units, batteries, chargers, and
390 equipment within one business day of notification of need for the item.

The Contractor shall not enter into any agreement with any service provider or
purchase any cellular telephone units for use by the Department until authorized by
the Engineer. The Engineer will notify the Contractor a minimum of 10 business days
prior to the need for the units.

628.05 Method of Measurement

Field office and field laboratory will be measured by the month for the specified
type. Partial months will be rounded up to the next 1/2 or whole month. The
400 Department will provide two weeks advanced notice prior to when the facility will be
vacated.

If a field laboratory is specified and is included in the same space as the field
office, the field laboratory will not be measured for payment.

Computer system and computer system equipment will be measured by the

number of units specified.

Cellular telephones will be measured by the number of units required for the type
410 specified.

Mobile internet service, and cellular telephone service will be measured by the
month for each system or service provided. Partial months will be rounded up to the
next 1/2 or whole month. The Department will provide two weeks advanced notice
prior to when mobile internet service and cellular telephone service will no longer be
required.

628.06 Basis of Payment

Field office and field laboratory will be paid for at the contract unit price per
420 month, complete in place until released.

Computer system and computer system equipment will be paid for at the contract
unit price per each for the units provided.

Mobile internet service will be paid by the month for each system or service
provided.

Cellular telephone units will be paid for at the contract unit price per each per each
type specified. Cellular telephone service will be paid for at the contract unit price per
430 month per each phone. Monthly charges for cellular telephone minutes and data in
excess of those specified in the contract will be paid for by the dollar amount for the
invoiced price per each occurrence as cellular telephone, additional charges.

Payment will be made under:

552
 628.06

Pay Item Pay Unit Symbol

Cellular Telephone Service, _____________............................ MOS

anytime minutes
440 Cellular Telephone, ______ ...................................................... EACH
type
Cellular Telephone, Additional Data ......................................... DOL
Cellular Telephone, Additional Minutes ................................... DOL
Computer System Equipment .................................................... EACH
Computer System ...................................................................... EACH
Field Laboratory, _____ ............................................................ MOS
type
Field Office, _____.................................................................... MOS
type
450 Mobile Internet Service, _____ Each ........................................ MOS
quantity

The cost of all heating, cooling, electrical service, telephone service and other
miscellaneous utility bills required for the field office or field laboratory shall be
included in the cost of the field office or the field laboratory.

If a field office smaller than the specified type is approved by the Engineer, a new
unit price will be established for the smaller field office. The new unit price will be
equal to the original contract unit price multiplied by the smaller floor area and divided
460 by the specified floor area.

If a temporary field office is provided in accordance with 628.02, payment will

be 65% of the unit price during the time the temporary field office is in use by the
Department.

The cost of all materials and labor necessary to setup, secure, maintain and remove
the field office or the field laboratory, including all required equipment and supplies
and any material required to provide parking, shall be included in the cost of the
respective pay items.
470
All costs necessary to provide and maintain the computer system, computer
system equipment, including the required software, manuals, technical support and
miscellaneous computer requirements shall be included in the cost of the computer
system or computer system equipment.

All costs necessary to establish, install and maintain field office internet service,
both wireless and Ethernet, field office network, including any required hardware,
software, fees, monthly charges, setup, installation and technical support shall be
included in the cost of the field office.
480

553
 628.06

All costs necessary to provide the copier, printer, and document scanner,
including setup, installation, all required connections to computers, technical support
and miscellaneous office machine requirements shall be included in the cost of the
field office.

All costs necessary to establish, install and maintain mobile internet service,
including required hardware, software, fees, monthly charges, setup, installation and
technical support shall be included in the cost of mobile internet service.

490 The Contractor shall provide a copy of the detailed invoice from the service
provider for each cellular telephone unit each month.

554
 701.02

DIVISION 700 – STRUCTURES

SECTION 701 – DRIVEN PILING

701.01 Description
This work shall consist of furnishing and driving foundation piles of the type and
dimensions specified including cutting off or building up foundation piles when
required. This work shall also consist of providing test piles and performing loading
tests when required. Piling shall be installed at the location and to the tip elevation, the
penetration depth, and nominal driving resistance shown on the plans in accordance
with 105.03.
10
MATERIALS

701.02 Materials
Materials shall be in accordance with the following:

B Borrow ..................................................................... 211

Bentonite Grout ........................................................... 913.06
Concrete Piles .............................................................. 707
Conical Pile Tips ......................................................... 915.01(a)2
20 End Plates .................................................................... 915.01(a)1
Epoxy Coating for Piles............................................... 915.01(d)
Pile Shoes .................................................................... 915.03
Reinforcing Bars.......................................................... 910.01
Steel H Piles ................................................................ 915.02
Steel Pipe Piles ............................................................ 915.01
Structural Concrete ...................................................... 702
Timber Piling, Treated................................................. 911.02(c)
Timber Piling, Untreated ............................................. 911.01(e)

30 Unless otherwise specified, reinforcing bars may be either plain or epoxy coated.

Steel pipe piles shall consist of a steel pipe which is driven into place and filled
with class A concrete.

The Contractor may furnish and drive steel pipe piles with thicker walls than
specified.

Treated and untreated timber piles shall be strapped with at least three straps: one
approximately 18 in. from the butt, one approximately 24 in. from the butt, and one
40 approximately 12 in. from the tip. Additional straps shall be provided at approximately
15 ft centers between the butt and tip. Strapping shall encircle the pile once and be
tensioned as tightly as possible. Straps shall be 1 1/4 in. wide, 0.031 in. thick, cold
rolled, fully heat treated, high tensile strapping, painted and waxed, with breaking

555
 701.03

strength of 5,500 lbs. The strap shall encircle the pile once and shall be crimped with
a notch type sealer to furnish a joint yielding 80% of the strap tensile strength. Treated
timber piles shall be strapped after treatment.

701.03 Handling of Epoxy Coated Piles

Epoxy coated piles shall be protected at all times from damage to the epoxy
50 coating. Damage to epoxy coated piles shall be repaired in accordance with 915.01(d).
Epoxy coated piles will be rejected if the total area of repair to the coating exceeds 2%
of the total coated surface area.

CONSTRUCTION REQUIREMENTS

701.04 Equipment for Driving Piles

(a) Approval of Pile Driving Equipment

All pile driving equipment, including the pile driving hammer, hammer cushion,
60 helmet or pile drive head, pile cushion, and other appurtenances furnished by the
Contractor shall be in working condition and approved in writing by the Engineer prior
to delivery of the pile driving equipment to the job site. All pile driving equipment
shall be sized such that the piles can be driven to the length required without damage.
Approval of pile driving equipment does not relieve the Contractor of the
responsibility to drive piles, free of damage, to the required nominal driving resistance
and, if specified, the minimum tip elevation shown on the plans. Pile driving
equipment will be subject to satisfactory performance during production.

The Contractor shall submit to the Office of Geotechnical Services, a completed

70 pile and driving equipment data form at least 15 calendar days prior to driving piles.
A copy shall also be furnished to the Engineer. The pile and driving equipment data
form is available on the Department’s website. The Contractor will be notified of the
acceptance of the proposed pile driving system within 15 calendar days of the receipt
of the pile and driving equipment data form. Acceptance of pile and driving equipment
does not relieve the Contractor of the responsibility to provide equipment suitable for
driving the specified piling to the required bearing without damage.

If the method of pile driving approval is in accordance with the dynamic formula
shown in 701.05(a) the dynamic formula method will be used to determine if the pile
80 driving equipment is acceptable for use. To be considered for approval, the proposed
driving system shall obtain the nominal driving resistance between the specified blow
count range of 30 and 120 blows per foot.

If the nominal driving resistance is to be determined by dynamic pile load test in

accordance with 701.05(b) or static load test in accordance with 701.05(c), the
Engineer will use the wave equation analysis method for driving system approval. To
be approved, the proposed driving system shall obtain the nominal driving resistance
between the specified blow count range of 30 and 120 blows per foot, and shall
maintain driving stresses below the specified driving stress limits for the pile type

556
 701.04

90 being driven. If wave equation predicted driving stresses are greater than specification
limits or the wave equation blow count for the nominal driving resistance is outside
the specified blow count range, the Contractor shall modify or replace the proposed
equipment until subsequent wave equation analyses indicate the piles can be driven to
the nominal driving resistance within the allowable blow count range and within
driving stress limits.

If the driving system requires revision, the Contractor will be notified of the
acceptance of the revised driving system within seven calendar days of receipt of a
revised pile and driving equipment data form.
100
The Contractor shall use the approved pile driving system. No changes shall be
made without prior written approval from the Engineer, with the exception that the
concrete pile cushion thickness may be increased to control driving stresses. A change
in the pile driving system will only be considered after the Contractor has submitted a
new pile and driving equipment data form. The Contractor will be notified of the
acceptance of a proposed change in driving equipment within three work days of
receipt of the pile and driving equipment data form. If the Engineer determines the
Contractor’s hammer is not functioning properly and is unable to drive the piles to the
required penetration depth or nominal driving resistance, the hammer shall be removed
110 from service.

1. Dynamic Formula Method

If the dynamic formula method is used, the energy of the pile driving equipment
shall be rated by the manufacturer at or above the appropriate minimum
manufacturer’s rated hammer energy for the corresponding nominal driving resistance
as shown in the table below. The table below will be used as the basis of approval of
pile driving equipment for the dynamic formula method.

Dynamic Formula Method

Minimum Pile Hammer Requirements
Nominal Driving Resistance Minimum Manufacturer’s Rated Energy
kips ftꞏlbs
≤ 180 12,000
181 - 300 21,000
301 - 400 28,800
> 400 Wave Equation Analysis required

120 The minimum rated energies do not account for losses and inefficiencies in the
pile driving system. If the hammer selected cannot satisfy all of the criteria, a wave
equation analysis shall be submitted by the Contractor for approval.

557
 701.04

2. Wave Equation Analysis Method

For the pile driving equipment to be acceptable, the driving stresses predicted by
the wave equation analysis shall not exceed the values where pile damage impends.
These limiting values shall be calculated as follows:

a. The maximum compressive and tensile driving

130 stresses for steel piles = 0.9Fy.

b. The maximum compressive driving stress for

prestressed concrete piles = (0.85f’c - fpe), where fpe is
the effective prestress value.

c. The maximum tensile driving stress, psi, for

prestressed concrete piles = 3 f ' c  fpe , where f’c
and fpe are expressed in psi.

140 d. The effective prestress, fpe, shall be obtained from the

approved working drawings.

e. The maximum driving stress, psi for timber piles shall

not exceed 3Fco, where Fco is the base resistance of
wood in compression parallel to the grain, in psi.

(b) Pile Hammers

Piles may be driven with air, steam, diesel, or hydraulic hammers. Gravity
hammers, vibratory hammers, and other pile driving methods shall be used only if
150 specified or approved in writing by the Engineer.

1. Gravity Hammers
Gravity or drop hammers shall be used to drive timber piles only. The ram shall
have a weight of between 2,000 and 3,500 lbs. The height of drop shall not exceed 12
ft. The weight of gravity hammers shall not be less than the combined weight of the
helmet and pile. All gravity hammers shall be equipped with hammer guides and
helmet to ensure concentric impact on the drive head.

2. Single or Double Acting Steam and Air Hammers

160 The plant and equipment furnished for steam and air hammers shall have
sufficient capacity to maintain, under working conditions, the volume and pressure
specified by the manufacturer of the hammer. The hose connecting the air compressor
to the hammer shall be at least the minimum size recommended by the manufacturer.
The plant and equipment shall be equipped with accurate chamber pressure gauges
which are easily accessible to the Engineer. If wave equation analysis is not used for
pre-approval, the weight of the striking parts of air and steam hammers shall not be
less than one-third the combined weights of the drive head and pile being driven. The
striking parts shall not weigh less than 2,800 lbs. Proximity switches and an electronic
readout device shall be provided prior to driving piling.

558
 701.04

170
3. Diesel Hammers
Open-end or single acting diesel hammers shall be equipped with a device such
as graduated rings or grooves on the ram to enable the Engineer to visually determine
hammer stroke at all times during pile driving operations. The Contractor shall provide
the Engineer a chart from the hammer manufacturer equating stroke, blows per minute,
and potential energy for the approved open-end diesel hammer. The Contractor shall
also provide and maintain in working order an approved device that automatically
measures and displays the ram stroke for open-end diesel hammers.

180 Closed-end double acting diesel hammers shall be equipped with an accurate
bounce chamber pressure gauge, easily accessible to the Engineer. The Contractor
shall provide the Engineer a calibrated chart equating bounce chamber pressure to
either equivalent energy or stroke for the closed-end diesel hammer to be used.
Calibration of actual hammer performance shall be performed no more than 90 days
prior to the beginning of the work.

4. Hydraulic Hammers
The power plant furnished for hydraulic hammers shall have sufficient capacity
to maintain at the hammer, under working conditions, the volume and pressure
190 specified by the manufacturer of the hammer. Hydraulic hammers shall also be
equipped with a controlled variable stroke system and a readout device to measure ram
energy. The plant and equipment shall be equipped with accurate pressure and velocity
gauges and an energy readout device which are easily accessible to the Engineer.

5. Vibratory Hammers
Except for pile lengths which have been evaluated from load test piles, the
nominal driving resistance of the piles driven with vibratory hammers shall be verified
by redriving the first pile driven in each group of 10 or fewer piles with an impact
hammer of suitable energy to measure the nominal driving resistance before driving
200 the remaining piles in the group. All piles which rely on point bearing capacity shall
be redriven with an impact hammer.

(c) Pile Driving Aids

Pile driving aids such as jets and followers, shall not be used unless specified or
approved in writing by the Engineer. If specified or approved, pile driving aids shall
be used for installing production piles only after the minimum pile tip elevation is
established by means of load testing or indicator test piles conventionally driven in
accordance with 701.05. The Contractor shall perform all extra load tests or extra work
required to drive indicator test piles as determined by the Engineer.
210
1. Hammer Cushion
All impact pile driving equipment, except gravity hammers, shall be equipped
with a suitable thickness of hammer cushion material to prevent damage to the hammer
or pile and to ensure uniform driving behavior. Impact hammers designed such that a
hammer cushion is not required are excluded from this requirement. Hammer cushions

559
 701.04

shall be made of durable, manufactured materials, provided in accordance with the

hammer manufacturer’s guidelines. Wood, wire rope, or asbestos hammer cushions
shall not be used. A striker plate, as recommended by the hammer manufacturer, shall
be placed on the hammer cushion to ensure uniform compression of the cushion
220 material. The condition of the hammer cushion shall be checked with the Engineer
when beginning pile driving at each structure or after each 100 h of pile driving,
whichever is less. A hammer cushion whose thickness has been reduced to less than
75% of the original thickness shall be replaced.

2. Helmet
Piles driven with impact hammers shall have an adequate helmet that adequately
distributes the hammer blow uniformly and concentrically to the pile head. The helmet
shall be axially aligned with the hammer and the pile shall be guided by the leads and
not be free-swinging. The helmet shall fit around the pile head and prevent transfer of
230 torsional forces during driving while maintaining proper alignment of hammer and
pile.

For steel and timber piling, the pile heads shall be cut squarely. For timber piles,
the least inside helmet horizontal dimension or hammer base horizontal dimension
shall not exceed the pile head diameter by more than 2 in. If the timber pile diameter
slightly exceeds the least helmet or hammer base dimension, the pile head shall be
trimmed to fit the helmet.

A helmet as recommended by the manufacturer shall be provided to hold the axis

240 of the pile in line with the axis of the hammer. The pile head shall be plane and
perpendicular to the longitudinal axis of the pile to prevent eccentric impacts from the
drive head.

3. Pile Cushion
The heads of concrete piles shall each be protected with a pile cushion made of
plywood, hardwood, or composite plywood and hardwood materials. The use of
manufactured pile cushion materials shall be by the hammer manufacturer’s
recommendation. The pile cushion dimensions shall equal or exceed the cross
sectional area of the pile top, and shall be sized to fit the dimensions of the pile cap.
250 The minimum pile cushion thickness placed on the pile head prior to driving shall be
either as recommended by wave equation analysis or not less than 4 in. if the dynamic
formula is used. A new pile cushion shall be provided for each pile. The pile cushion
shall be replaced if, during the driving of the pile, the cushion is either compressed
more than one-half the original thickness or begins to smolder or burn. Pile cushions
shall be protected from weather and kept dry prior to use. Pile cushions shall not be
soaked in liquid unless approved by the Engineer.

A used pile cushion in acceptable condition shall be used for restrike tests. The
used pile cushion shall be the same pile cushion from the end of initial driving on that
260 pile unless the condition of that pile cushion is no longer within specification limits.

560
 701.04

If the original pile cushion is not within specification limits, a used cushion of similar
thickness as the end of drive pile cushion shall be used.

4. Leads
Piles shall be supported in line and position with leads while being driven. Pile
driver leads shall be constructed in a manner that affords freedom of movement of the
hammer while maintaining alignment of the hammer and the pile to ensure concentric
impact for each blow. Leads may be either fixed or swinging type. Swinging leads,
when used, shall be fitted with a pile gate at the bottom of the leads. The leads shall
270 be adequately embedded in the ground, or the pile shall be constrained in a structural
frame such as a template to maintain alignment. The leads shall be of sufficient length
to make the use of a follower unnecessary, and shall be designed as to enable proper
alignment of battered piles.

5. Followers
Followers shall only be used if specified or approved in writing by the Engineer.
If a follower is allowed, the first pile in each bent and every tenth pile driven thereafter
shall be driven full length without a follower, to verify that adequate pile length is
being attained to develop the nominal driving resistance. The follower and pile shall
280 be held and maintained in equal and proper alignment during driving. The follower
shall be of such material and dimensions to enable the piles to be driven to the required
penetration depth determined necessary from the driving of the full length piles.

The final position and alignment of the first two piles installed with followers in
each substructure unit shall not exceed more than 3 in. from the locations shown on
the plans before additional piles are installed.

6. Jets
Jetting shall only be allowed if specified or approved in writing by the Engineer.
290 The Contractor shall determine the number of jets and the volume and pressure of
water at the jet nozzles necessary to freely erode the material adjacent to the pile
without affecting the lateral stability of the final in-place pile. The Contractor shall be
responsible for all damage to the site caused by unapproved or improper jetting
operations. If jetting is specified, the jetting plant shall have sufficient capacity to
enable installation to the required elevation, location, and alignment in accordance
with 701.09(b). Unless otherwise directed, external jet pipes shall be removed once
the pile tip is 5 ft above the prescribed tip elevation, depending on soil conditions. The
pile shall then be driven to the nominal driving resistance with an impact hammer. The
Contractor shall provide suitable sediment control measures for jet water in
300 accordance with the specifications. Where practical, all piles in a pile group shall be
jetted to the required penetration depth before beginning pile driving. Where large pile
groups or pile spacing and batter make this impractical, restrike tests on a select
number of previously driven piles shall be performed to check nominal driving
resistance after jetting operations are completed.

561
 701.05

Upon completion of driving a jetted pile, all voids around the pile shall be filled
with B borrow and saturated with water.

7. Collars
310 Where timber piles are used, collars, bands, or other devices shall be provided to
protect piles against splitting and brooming.

8. Pile Shoes, End Plates, and Conical Pile Tips

Pile shoes shall be used when specified. End plates or conical pile tips shall be
used on pipe piles. Steel pile shoes shall be used on H piles if specified.

If shoes are required on timber piles, the tips of timber piles shall conform to the
approved steel shoes to ensure a firm uniform contact and prevent local stresses
concentrations in the timber.
320
701.05 Nominal Driving Resistance of a Driven Pile
The Engineer will use one of the following methods as specified to determine the
nominal driving resistance of a driven pile.

(a) Dynamic Formula

The nominal driving resistance will be determined by means of a dynamic
formula. Piles shall be driven to the penetration depth necessary to obtain the nominal
driving resistance. The nominal driving resistance, as shown on the plans, can be
calculated from the formula as follows:
330
Rndr = 1.75√E x (log 10N) – 100

where:

Rndr = nominal driving resistance in kips

E = manufacturer’s rated energy in footꞏpounds at the field observed ram
stroke and not reduced for efficiency
log 10N = logarithm to the base 10 of the quantity 10 multiplied by N, where N
is the number of hammer blows per 1 in. at final penetration.

An indicator test pile shall be the first pile driven at each bent and pier and shall
be driven to the plan tip elevation or to the nominal driving resistance whichever
occurs first. All indicator test piles shall be driven with impact hammers unless
otherwise directed. The length of indicator test piles shall be greater than the estimated
340 length of production piles in order to provide for variation in soil conditions. Precast
concrete and treated timber test piles shall be a minimum of 10 ft longer than the
estimated length of piling shown on the plans. Steel piles shall be provided such that
additional 10 ft of driving will not require an additional splice.

The driving equipment used for driving indicator test piles shall be identical to
that proposed for use on the production piling and shall be subject to approval. The

562
 701.05

Contractor shall excavate the ground at each indicator test pile location to the elevation
of the bottom of the footing before the pile is driven, unless otherwise shown on the
plans.
350
To assess the effects of relaxation and setup, each indicator test pile shall be
restruck after number of hours specified unless otherwise approved. The hammer shall
be warmed up before driving begins by applying at least 20 blows to another fixed
object. The maximum amount of penetration required during restrike shall be 3 in., or
the total number of hammer blows shall be 20, whichever occurs first. If the indicator
test pile does attain the nominal driving resistance upon restriking, the penetration
resistance attained during initial driving shall be used to establish the adequacy of
production piles. If the nominal driving resistance is not attained upon restriking, the
Contractor shall redrive the indicator test pile until it achieves the nominal driving
360 resistance and repeat the restrike procedure described above. If the nominal driving
resistance is still not obtained, pile driving shall stop immediately and the Office of
Geotechnical Services shall be notified.

A record of driving indicator test piles, which includes the number of hammer
blows per 1 ft for the entire driven length, the as-driven length, cutoff elevation,
penetration, and all other pertinent information will be kept by the Engineer. The
penetration resistance at various hammer strokes versus nominal driving resistance
relationship will be determined based on the driving of representative indicator test
piles.
370
If indicator piles are not shown on the plans, all piles shall be driven to the nominal
driving resistance and restriking is not required.

(b) Dynamic Pile Load Test

Dynamic monitoring will be performed for the purpose of obtaining the nominal
driving resistance, pile driving stresses, pile integrity, and pile driving system
performance. Dynamic monitoring will be conducted by PDA in accordance with
ASTM D 4945. PDA will be performed on the first pile driven. The length of the pile
used in the dynamic pile load test shall be a minimum of 10 ft greater than the
380 estimated length of production piles in order to provide for variation in soil conditions.
The Contractor shall assist the Department in obtaining dynamic measurements with
the PDA during initial pile driving and during pile restrikes. If a static load test is
required, the dynamic pile load test shall be performed on the same pile as the pile
used in the static load test. The restrike for the dynamic pile load test on a static load
test pile shall be performed within 48 h of completion of the static load test.

1. Scheduling
The Contractor shall notify the Engineer at least seven calendar days before the
scheduled date of driving piles to be monitored by PDA. The Contractor shall confirm
390 the driving date three calendar days prior to the scheduled driving date. The Contractor
shall indicate at which foundation production pile driving is to begin. The Engineer
will provide final driving criteria for the indicated foundation first.

563
 701.05

2. Dynamic Monitoring
The Contractor shall make the steel piles available so that the Engineer can
predrill the required instrument attachment holes prior to the Contractor placing the
pile in the leads. Each pile to be tested shall be instrumented with force and
acceleration transducers provided by the Department. The Contractor shall install the
transducers before striking the pile. The pile driving may have to be temporarily
400 interrupted for the transducers to be adjusted or replaced, or for the monitoring results
assessed.

Prior to placement in the leads, the Contractor shall make each designated
concrete or timber pile available for taking of wave speed measurements and for
predrilling the required instrument attachment holes. When wave speed measurements
are made, the piling shall be in a horizontal position and not in contact with other
piling. Predriving wave speed measurements will not be required for steel piles. The
Contractor shall mount the instruments near the head of the pile after the pile is placed
in the leads.
410
The Contractor shall drive the test pile to the minimum tip elevation and to the
penetration depth at which the dynamic test equipment indicates that the nominal
driving resistance shown on the plans and in accordance with 701.04(a) has been
achieved. The Contractor may reduce the driving energy transmitted to the pile by
using additional cushions or reducing the energy output of the hammer in order to
maintain stresses below the values shown in 701.04(a)1. If non-axial driving is
indicated by the dynamic test equipment measurements, the Contractor shall
immediately realign the hammer system. Upon determination by the Engineer that
valid data have been secured, the Contractor shall assist the Engineer with the removal
420 of the instrumentation from the pile.

3. Restrike
The Contractor shall wait the specified minimum time period prior to the
restriking of a dynamic load test pile. The Contractor shall assist the Engineer with
reattachment of dynamic test instruments. The hammer shall be warmed up before
restriking begins by applying at least 20 blows to another pile or other fixed object.
The maximum amount of penetration required during restrike will be 3 in., or the total
number of hammer blows will be 20, whichever occurs first. If the pile does not
achieve the required nominal driving resistance during restrike, the Engineer will
430 either accept the tip elevation or specify additional pile penetration and testing.

Once the restrike test for the test pile is complete, the Engineer will run CAPWAP
analyses and will provide the final driving criteria within two business days of the
restrike test. Production piles driven prior to receipt of the final driving criteria shall
be done at the Contractor’s risk. Final driving criteria for additional structures will be
provided within two business days of the restrike test or, when multiple test piles are
restruck the same day, at a rate of one substructure location per business day in the
order requested by the Contractor.

564
 701.05

440 4. PDA on Local Public Agency Contract

The Contractor shall perform the PDA in accordance with ASTM D 4945. The
firm conducting the PDA shall have at least one geotechnical engineer who shall have
achieved one of the following certification levels: intermediate, advanced, master, or
expert, within the last three years through the Dynamic Measurement and Analyses
Proficiency Test conducted by Pile Dynamics, Inc., and the Pile Driving Contractors
Association. An engineer with a lower certification level can provide services so long
as this individual is under the direct supervision of an engineer with intermediate
certification level or higher. The Case Pile Wave Analysis Program, CAPWAP, shall
be utilized to determine the as-built pile capacity from the PDA data. The first pile
450 driven for each substructure unit shall be a PDA test pile. The pile driving criteria with
the PDA and CAPWAP results shall be submitted to the Department’s Office of
Geotechnical Services for approval.

(c) Static Load Test

A static load test shall be conducted on a non-production test pile at the location
shown on the plans. The test pile axial deflection in compression shall be verified by
performing actual loading tests of the designated static load test pile in accordance
with ASTM D 1143, Quick Load Test Method, with loads applied by hydraulic jack.
The test shall be continued until either plunging failure is achieved or the capacity of
460 the loading system is reached. The nominal pile resistance will be determined from the
settlement versus load curve generated by the incremental loading in accordance with
701.05(c)1.

The top elevation of all test piles shall be determined immediately after driving
and again just before load testing to check for heave. A pile which heaves more than
1/4 in. shall be redriven, or jacked, to the original elevation prior to testing. The
Contractor shall wait 36 h between the driving of a load test pile and the
commencement of the load testing unless otherwise specified.

470 The Contractor shall provide complete protection at all times for the pile,
supports, and reference beam from wind, direct sunlight, frost action, or other
disturbances. The Contractor shall maintain an air temperature in the immediate
vicinity of the test pile and reference beam of not less than 50°F and shall provide
adequate lighting for the duration of the test.

No production piles shall be driven until completion of the static pile load test
unless approved by the Engineer. Reaction piles shall be driven prior to driving the
static load test pile.

480 1. Load Test Procedure

The Contractor shall furnish and construct a suitable reaction frame or load
platform to provide a load on the pile having a capacity of 2,000 kips or 150% of the
nominal driving resistance, whichever is less. A minimum of seven days prior to
driving the static load test pile or construction of the reaction frame or load platform,

565
 701.05

the Contractor shall submit, for review and approval, detailed working drawings to
scale for the reaction frame or load platform and loading apparatus including the
distances between the load test pile and all reaction piles and reference beam supports.
The submittal shall also include a proposed load test and reaction pile driving
sequence, a scaled profile drawing of the loading apparatus detailing the ground
490 surface elevation, the pile cutoff elevation, and the dimensions and locations of all
bearing plates, the jack, the load cell, the spherical bearing plate, and the reaction beam
or platform. Working drawings for the reaction frame and loading apparatus shall be
submitted in accordance with 105.02. The submittal shall include calibration
certifications for the hydraulic jacks, load cell, pressure gauges, and hydraulic pumps
conducted within 30 days of the load test. If required by the Engineer, the jack, load
cell, and pressure gauge shall be recalibrated after the load test. The loading apparatus
shall be constructed to allow the various increments of the load to be placed gradually,
without causing vibration to the test pile. If the approved method requires the use of
tension or reaction piles, the reaction piles, if feasible, shall be of the same type and
500 dimensions as the production piles, and when possible shall be driven in the location
of permanent piles. Reaction piles that are the same type and dimensions as the
production piles and are driven in the location of permanent piles will be considered
permanent piles. Timber or tapered piles installed in permanent locations shall not be
used as tension piles. The primary method of determining the applied load shall be
from a calibrated load cell. Incremental loads of 5% of the nominal driving resistance
shall be placed on the pile at 5 minute intervals until continuous jacking is required to
maintain the incremental load or the capacity of the load frame is reached. Support for
the load test plates, jack, and ancillary devices shall be provided to prevent them from
falling in the event of a release of load due to hydraulic failure, test pile failure, or
510 other cause.

The Contractor shall furnish the hydraulic pump, load cell, spherical bearing plate,
and two reference beams. Each reference beam shall be a W or M section, of minimum
length of 20 ft, and a weight of 5 to 20 lbs/ft unless otherwise approved. The Engineer
will conduct the static load test and will provide the gauges to measure movement of
the test pile. The Contractor shall provide all assistance necessary to perform the static
load test. The Contractor shall furnish and install telltale rods encased in a lubricated
pipe in the test pile prior to the static load test.

520 If the nominal pile resistance of a pile from the load settlement curve does not
equal or exceed the nominal driving resistance shown on the plans, the Contractor shall
redrive the pile to an adequate nominal driving resistance. The increase in nominal
driving resistance will be determined by PDA. The pile shall be load tested again after
the appropriate waiting period. Load tests shall be repeated as many times as necessary
until the pile carries the required load. The pile axial resistance will be determined
from the test data in accordance with the Davisson Method as specified in the
AASHTO LRFD Bridge Design Specifications.

2. Hydraulic Jacks, Pressure Gauges, and Load Cell

530 Hydraulic jacks and pressure gauges shall be used for the superimposed load. The

566
 701.08

jacks, pressure gauges, load cell, and hydraulic pumps shall be calibrated with each
other within the last 30 days by an independent laboratory. When a jack, pressure
gauge, load cell, and hydraulic pump are calibrated, they shall be calibrated and used
as a unit. All calibration checks shall be within 5% of the applied load if calibrated as
a unit. Changing one of the four components shall require recalibration prior to use.
Pressure gauges shall be a minimum of 4 1/2 in. in diameter with gradations in
accordance with ASTM D 1143. Hydraulic jacks shall have a nominal load capacity
exceeding the maximum anticipated jack load by at least 20%. The jack, pump, and
any hoses, pipes, fittings, gauges, or transducers used shall be rated to a safe pressure
540 corresponding to the nominal jack capacity. The Contractor shall provide copies of the
most recent calibration certification a minimum of five days prior to the static load
test.

3. General Requirements
On completion of the static load test, a test pile or anchor pile which is not a part
of the finished structure shall be removed or cut off at least 1 ft below either the bottom
of footing or the finished ground elevation if not located within the footing area.

701.06 Blank
550
701.07 Piling Length
The lengths of piles shown on the plans and in the Schedule of Pay Items are
estimated lengths and are for bidding purposes only. The Contractor shall provide the
actual length of piles necessary to obtain the nominal driving resistance and
penetration depth required as determined from results obtained from driving
representative test piles or other pertinent data. There will be expected variations in
final tip elevations due to differences in nominal pile driving resistance. The final tip
elevation of each pile will be determined during the driving operation. If minimum tip
elevations are specified, the Contractor shall drive piles to a penetration depth that
560 satisfies this requirement in addition to the nominal driving resistance. If no
penetration depth or minimum tip elevation is specified, the pile shall be driven a
minimum of 10 ft below the bottom of the footing elevation. The Contractor shall also
furnish satisfactory evidence as to the identification, such as heat numbers for steel
piles, of all portions of a built-up pile.

The limits of the epoxy coated steel pipe portion of the pile, and the limits of the
reinforced concrete shall be as shown on the plans.

701.08 Nominal Driving Resistance of Production Piles

570 Production piles shall be driven the depth necessary to obtain the required nominal
driving resistance as determined by 701.05. If a minimum pile tip elevation is shown
on the plans, in addition to obtaining the required nominal driving resistance,
production piles shall also be driven to the minimum pile tip elevation or to practical
refusal.

When the nominal driving resistance is determined in accordance with 701.05(a),

567
 701.09

for acceptance, the Engineer will record at a minimum the number of hammer blows
per inch or per foot of pile movement for the last 24 in. of driving. When the nominal
driving resistance is determined in accordance with 701.05(b), for acceptance, the
580 Engineer will record the blow count per inch or foot of pile movement and the
associated hammer stroke for the last two consecutive feet of driving, and the final pile
tip elevation as per the pile driving criteria established through the dynamic pile load
test.

Practical refusal will be defined as 20 blows per inch of penetration with the
hammer operated at its maximum fuel or energy setting, or at a reduced fuel or energy
setting recommended by the Engineer based on pile installation stress control and less
than 1/4 in. rebound per blow. The Contractor shall stop driving as soon as the
Engineer determines that the pile has reached practical refusal.
590
The nominal driving resistance of jetted piles shall be based on impact driving
penetration resistance after the jet pipes have been removed. Jetted piles not attaining
the nominal driving resistance at the ordered length shall be spliced and driven with
an impact hammer until the nominal driving resistance is achieved in accordance with
the driving criteria in 701.05.

The required nominal driving resistance of piles driven with followers will only
be considered acceptable if the piles with followers attain the same tip elevation as the
full length piles driven without followers, installed in accordance with 701.04(c)5.
600
The required nominal driving resistance of piles driven with vibratory hammers
shall be based on the driving resistance recorded during impact driving after the
vibratory equipment has been removed from the first pile in each group of 10 piles.
Vibrated piles not attaining the nominal driving resistance at the ordered length shall
be spliced and driven with an impact hammer until the nominal driving resistance is
achieved in accordance with the driving criteria in 701.05. Once the nominal driving
resistance is attained, the remaining nine piles in the group shall be installed to similar
penetration depths with similar vibratory hammer power consumption and rate of
penetration as the first pile.
610
701.09 Preparation and Driving
For steel and timber piling, the pile heads shall be plane and perpendicular to the
longitudinal axis of the pile before the helmet is attached. The pile heads shall be
protected with a hammer cushion.

Precast concrete pile heads shall be flat, smooth, and perpendicular to the
longitudinal axis of the pile. Prestressing strands shall be cut off below the surface of
the end of the pile. The pile head shall be chamfered on all sides. The heads of all
concrete piles shall be protected with a pile cushion.
620
Approval of a pile hammer relative to driving stress damage will not relieve the
Contractor of responsibility for piles damaged due to misalignment of the leads, failure

568
 701.09

of hammer cushion or cushion material, failure of splices, malfunctioning of the pile

hammer, or improper construction methods. Piles damaged for such reasons will be
rejected and shall be replaced if the Engineer determines that the damage impairs the
strength of the pile.

(a) Pilot Holes

Pilot holes are prebored, predrilled, or cored. After a pile is driven thru a pilot
630 hole, all voids around the pile shall be filled with B borrow. Water shall be added to
the hole to saturate the final placement of B borrow.

If the Engineer determines that preboring or predrilling has disturbed the nominal
driving resistance of previously installed piles, those piles that have been disturbed
shall be restored by means of redriving or other approved remedial measures.
Redriving or other remedial measures shall be instituted after the preboring or
predrilling operations in the area have been completed.

1. Preboring
640 When shown in the plans, the Contractor shall prebore holes at the locations
shown and to the depth specified. Prebored holes shall be 2 in. smaller than the
diameter or diagonal of the pile cross section that is sufficient to allow penetration of
the pile to the specified penetration depth. If subsurface obstructions, such as boulders
or rock layers, are encountered, the hole diameter may be increased to the least
dimension which is adequate for pile installation.

Augering, wet-rotary drilling, spudding, or other methods of preboring shall be

used only when specified or approved in writing by the Engineer. The procedures shall
be carried out so as not to impair the nominal driving resistance of the piles already in
650 place or the safety of existing adjacent structures.

Except for end bearing piles, preboring shall be stopped at least 5 ft above the pile
tip elevation shown on the plans. The pile shall be driven with an impact hammer to
the specified penetration resistance. Where piles are to be end-bearing on rock or
hardpan, preboring may be carried to the surface of the rock or hardpan. The piles shall
then be driven with an impact hammer to ensure proper seating.

2. Predrilling
The hole shall have a minimum diameter of not less than the greatest dimension
660 of the pile cross section plus 4 in. The holes shall be drilled to the elevations shown
on the plans.

Before driving piles for end bents, holes to receive piling shall be predrilled or
spudded through new embankment to the original ground elevation if the new
embankment is 10 ft or more in height. If the new embankment is less than 10 ft in
height, predrilling is not required. If new embankment in the area of the end bents is
to be constructed of sand, gravel, or other permeable material in which a predrilled

569
 701.09

hole would not remain open, the piling shall be driven before the embankment is
constructed.
670
Pilot holes for end bent piles for structures with integral end bents shall be
predrilled to the depth specified in the plans, regardless of the height of new
embankment.

If pile sleeves are shown on the plans, the drilled holes shall be sleeved to maintain
the opening during the driving of the piles.

If bentonite grout is shown on the plans, it shall be used to fill the annular space
around the pile. The grout shall be placed at the depths shown on the plans or as
680 directed. The entire annular space shall be filled from the bottom upwards to the top
of the pile in one pumping operation using a tremie pipe.

Tremie-pipe construction shall include side discharge ports. The tremie pipe can
be terminated by means of a tee connection. Tremie-pipe may be PVC, however, joints
shall not be glued or cemented.

3. Cored Hole in Rock

When specified, holes shall be cored into rock to accommodate pile placement.
The approach grade shall be completed before coring is begun. Holes of the diameter
690 shown on the plans shall then be predrilled through the embankment into solid rock to
the elevations shown on the plans or as otherwise directed. The piles shall be driven
to practical refusal at the bottom of the cored holes. The holes in cored rock shall then
be filled with concrete.

(b) Location and Alignment Tolerance

A maximum deviation of 1 1/2 in. in any direction from the plan position will be
allowed in pile trestle bents and exposed pile bents. A maximum deviation of 6 in. in
any direction will be allowed for a foundation pile in footings for piers or abutments.
The tendency of concrete or steel piles to twist or rotate shall be prevented and
700 corrected. Piles to be swaybraced shall be aligned as necessary so that the swaybracing
may be properly welded to the piles by a welder qualified in accordance with 711.32.
No pile shall be closer than 4 in. from an edge of the pile cap. Pulling or pushing
laterally on installed piles to correct misalignment, or splicing a properly aligned
section on a misaligned section will not be allowed. The pile head at cutoff elevation
shall be within 2 in. of plan elevation for bent caps supported by piles.

Piles driven at integral end bents shall be installed so that the axial alignment of
the top 10 ft of the pile is within 2% of the specified alignment.

710 Battered piles shall be installed so that the alignment of the top 10 ft of the pile
does not vary by more than 3% from the batter rate shown in the plans.

570
 701.10

If the location or alignment tolerances are exceeded, the extent of overloading

shall be investigated. If the Engineer determines that corrective measures are
necessary, such corrective measures shall be designed and constructed by the
Contractor. Proposed corrective measures will be subject to approval by the Engineer.

(c) Heaved Piles

The Contractor shall take an elevation reading on each pile in a foundation
720 immediately after each pile in that foundation has been driven and again after all piles
in that foundation have been driven. Elevation readings for checking pile heave shall
continue until the Engineer determines that such checking is no longer required. All
piles which have heaved more than 1/4 in. shall be redriven to the required resistance
or penetration. If pile heave is detected for pipe piles, the piles shall be redriven to
original position prior to filling with concrete. A hammer-pile cushion system shall be
submitted and approved prior to redriving pipe piles which have been filled with
concrete.

(d) Installation Sequence

730 The order of placing individual piles within a pile group shall begin from the
center of the group and proceed outward in both directions unless an alternate
installation sequence is approved in writing. For a bent with a single row of piles, pile
driving shall begin at one end of the bent and proceed toward the opposite end.

(e) Inspection
The Engineer shall be given a minimum of 24 h notice before driving piling. No
pile shall be driven except in the presence of the Engineer.

Prior to placing concrete in driven pipe piles, the Contractor shall supply suitable
740 lighting for the inspection of each pipe pile by the Engineer throughout its entire
length.

(f) Pouring Concrete

After all water and other foreign substances have been removed from the pipe
piles and the final approval given, reinforcing bars, if specified, shall be placed, and
the pipe piles shall be filled with class A concrete in the presence of the Engineer.
Concrete shall be deposited into pipe piles in a stream with a cross-sectional area that
is no more than approximately 50% of the area of the pipe pile to prevent air pockets
from forming. At a minimum, concrete shall be vibrated in the upper 25 ft of the pipe
750 piles. Concrete shall not be placed in pipe piles until all pile driving has progressed
beyond a radius of 15 ft from the pile to be filled. All pile driving within the above
limits shall be discontinued until the concrete in the last pile cast has cured for a
minimum of 48 h.

701.10 Unsatisfactory Piles

The method used in driving piles shall not subject the piles to excessive or undue
abuse which produces deformation of the steel, injurious splitting, splintering, and
brooming of the wood, or crushing and spalling of the concrete. All piles damaged

571
 701.11

during driving due to internal defects, improper driving, being driven out of its proper
760 location, or being driven below the designated cutoff elevation shall be corrected as
directed.

Piles which have been bent, or otherwise damaged, during installation shall be
considered unsatisfactory unless the nominal driving resistance is proven by load tests
performed by the Contractor. If such tests indicate inadequate pile resistance,
corrective measures such as the use of the bent piles at reduced pile resistance,
installation of additional piles, strengthening of the bent piles, or replacement of the
bent piles shall be done as approved by the Engineer.

770 A concrete pile will be considered defective if a visible crack appears around the
entire periphery of the pile or if a defect is observed, as determined by the Engineer.

701.11 Splicing Piles

Full length piles shall be placed in the leads if practical. However, if splicing is
necessary, the following methods shall be used.

(a) Steel Piles

Splicing of steel piles shall be made as shown on the plans. The top of the pile to
be extended shall be restored to its original cross section shape. The mating end of the
780 other pile shall be beveled as shown on the plans. A wire brush or grinder shall be used
to remove any scale, dirt, slag, or other foreign material that is detrimental to
fabricating a sound weld from all surfaces to be welded. For H piles, a mechanical
splice shall not be used within 20 ft of the ground surface unless it is proven that the
splice can transfer the full pile strength in compression, tension, and bending. Splices
for pipe piles shall be watertight. All work shall be done with approved methods and
materials and by welders qualified in accordance with 711.32. If the temperature of
the piles is below 50°F, both piles to be spliced shall be preheated to a minimum
temperature of 70°F in the vicinity of the splice immediately prior to welding. The
temperature of the piles shall be maintained at a minimum of 50°F until the welding
790 is complete. There shall not be more than two splices exposed to view in each length
of piling after driving is completed. A mechanical splice shall not be used in integral
end bents.

(b) Timber Piles

Timber piles shall not be spliced.

(c) Concrete Piles

Full length concrete piles shall be used where practical. If splicing is necessary,
concrete splice details shall conform to the contract documents. Mechanical splices
800 including drive-fit splices may also be used if the splice can transfer the full pile
strength in compression, tension and bending.

701.12 Blank

572
 701.15

701.13 Cut-Off Lengths

The tops of all steel pile shall be cut off at the elevation shown on the plans. All
unused cut-off lengths shall become the property of the Contractor and shall be
removed from the project site.

810 The length of timber pile above the elevation of cut-off shall be sufficient to
enable the complete removal of all material injured by driving. Immediately after
making final cut-off on treated timber foundation piles, the cut area shall be treated
with copper naphthenate in accordance with AWPA Standard M4.

Timber piling supporting timber structures where the piles are cut off, but not
concrete capped, shall be treated with copper naphthenate in accordance with AWPA
Standard M4. A layer of saturated building felt or fiberglass cloth which overlaps the
side of the pile at least 2 in. shall be securely fastened and completely covered with 20
gauge thick galvanized metal or aluminum sheeting. All cuts, injuries, and holes,
820 which occur from removal of nails or spikes that penetrate the treating zone as well as
bolt holes for connections, shall be treated by applying coal-tar roof cement in
accordance with ASTM D 5643.

701.14 Method of Measurement

The driven length of treated timber piles, untreated timber piles, steel pipe piles,
steel H piles, and concrete piles will be measured by the linear foot to the nearest 0.1
ft. This includes piles used as indicator test piles, dynamic test piles, or static load test
piles. Measurement will be made only for the actual number of linear feet of piling
complete in place. For concrete piles, this length will not include extensions or the
830 portion of the pile cutoff to make the extension.

Dynamic pile load test, static pile load test, indicator test pile restrike, dynamic
test pile restrike, pile shoes, and conical pile tips will be measured per each.

Epoxy coated piles, prebored holes, and cored holes in rock will be measured by
the linear foot complete in place of the diameter specified.

Concrete encasement, class A concrete, reinforcing bars, epoxy coating, reaction

piles if not used as production piles, splices, end plates, predrilling, cleaning of drilled
840 holes, drilling fluids, sealing materials, casing, jetting, followers, spudding, or other
methods used to facilitating pile driving will not be measured for payment.

701.15 Basis of Payment

All treated timber piles, untreated timber piles, steel pipe piles, steel H piles, and
concrete piles driven will be paid for by the linear foot. Payment will be made only for
the actual number of linear feet of piling complete in place. Extensions for concrete
piles will be paid for in accordance with 109.05.

Driven piles used as indicator test piles or dynamic test piles that are left in place
850 and subsequently used as production piles will be paid for by the linear foot as either

573
 701.15

production indicator test piles or production dynamic test piles. Reaction piles used in
a static pile load test that are left in place and subsequently used as a production pile
will be paid for by the linear foot as the type of production pile they represent. Driven
piles used as indicator test piles, dynamic test piles, or static load test piles that are not
used as production piles will be paid for by the linear foot as non-production dynamic,
indicator, or static test piles respectively.

If the quantity of driven piling is less than the plan quantity or the quantity as
ordered by the Engineer, the Department will pay 50% of the cost to re-stock unused
860 piling if the Contractor elects to re-stock piling and provides a paid invoice showing
the re-stocking fee. Payment will be made for piling, restock.

Epoxy coated piles may be furnished and driven at lengths greater than those
shown on the plans. These additional lengths of epoxy coated piles left in place and
accepted will be paid for as either steel pipe piles or steel H piles.

Prebored holes and cored holes in rock will be paid for at the contract price in
linear feet.

870 Payment will be made under:

Pay Item Pay Unit Symbol

Conical Pile Tip, ________ ....................................................... EACH

pile size
Cored Hole in Rock, ______ in. ................................................ LFT
diameter
Dynamic Pile Load Test ............................................................ EACH
Pile Shoe, ________ .................................................................. EACH
880 pile size
Pile, Concrete _____ x _____.................................................... LFT
size
Pile, Prestressed Concrete _____ x _____ ................................. LFT
size
Pile, Steel H, Epoxy Coated, HP _____ x _____ ...................... LFT
size
Pile, Steel H, HP _____ x _____ ............................................... LFT
size
Pile, Steel H, Reinforced Concrete
890 Encased, HP _____ x _____ ............................................... LFT
size
Pile, Steel Pipe, ____________, ________ ............................... LFT
pipe wall thickness diameter
Pile, Steel Pipe, Epoxy Coated, ____________, ________ ...... LFT
pipe wall thickness diameter
Pile, Timber ............................................................................... LFT

574
 701.15

Pile, Timber, Treated ................................................................. LFT

Piling, Restock........................................................................... LS
Prebored Hole, _______ in. ....................................................... LFT
900 diameter
Static Pile Load Test, ________ ................................................ EACH
pile size
Test Pile, Dynamic, ________, Non-Production ....................... LFT
pile size
Test Pile, Dynamic, Production ................................................. LFT
Test Pile, Dynamic, Restrike ..................................................... EACH
Test Pile, Indicator, ________, Non-Production ....................... LFT
pile size
Test Pile, Indicator, Production ................................................. LFT
910 Test Pile, Indicator, Restrike ..................................................... EACH
Test Pile, Static Load, ________, Non-Production ................... LFT
pile size

All costs associated with the dynamic pile load test except the cost of the test pile
and test pile restrike shall be included in the cost of the dynamic pile load test.

All costs associated with the static pile load test except the cost of the test pile
shall be included in the cost of the static pile load test. The cost of reaction piles used
in the static load test and not incorporated into the work as production piles shall be
920 included in the cost of the static load test.

The cost of furnishing and placing concrete, B borrow, or bentonite grout

necessary to fill pilot holes, and all necessary incidentals shall be included in the cost
of the pay items of this section.

The cost of the following shall be included in the cost of the piling.

(a) predrilling pilot holes;

(b) pile sleeves;
930 (c) maintaining open holes during pile driving;
(d) broken, bent, damaged, or misplaced piles;
(e) concrete filling or concrete encasement;
(f) corrective location or alignment measures;
(g) epoxy coating;
(h) splicing piles and jetted sites;
(i) modifying or replacing pile driving equipment;
(j) redriving piles which have heaved more than 1/4 in.;
(k) plain and epoxy coated reinforcing bars;
(l) repairing epoxy coating;
940 (m) replacing epoxy coated piling;
(n) restriking production piles not shown as test piles;
(o) piles which are not acceptable or damaged during driving;

575
 702.01

(p) piles which were not driven in accordance with these

specifications;
(q) piles driven with the tops lower than the cutoff elevation;
(r) spudding or jetting of piles;
(s) end plates for pipe piles;
(t) all straps on treated and untreated timber piling; and
(u) all labor, equipment, and necessary incidentals.
950
No additional payment will be made if the Contractor elects to furnish and drive
thicker walled pipe piles than specified.

An increase in the size of a pile cap to satisfy edge distance clearance

requirements, when approved, shall be at no additional cost to the Department.

If the method for driving the piles is specified as 701.05(b) and the contract is a
local public agency contract, the Contractor shall include the cost of acquiring the PDA
consultant in the cost of the Dynamic Pile Load Test.
960
The cost of mobilization and demobilization for pile driving operations shall be
included in the cost of mobilization and demobilization in accordance with 110.04.

The cost to control sediment in water from jetting operations shall be included in
the cost of the piling.

SECTION 702 – STRUCTURAL CONCRETE

702.01 Description
This work shall consist of furnishing and placing portland cement concrete for
structures and incidental construction in accordance with 105.03.

702.02 Classes of Concrete

The following classes of concrete shall be used where specified.

Class of Concrete A B C
Cement content in lbs/cu yd 564 470 658
Maximum water/cement ratio in
0.450 0.620 0.443
lbs of water per lbs of cement
10
Unless specified otherwise, the concrete used shall be class A. When class A is
specified, class C may be used as a substitution. When class B is specified, class A or
class C may be used as a substitution.

Concrete in superstructure, integral bents, and railings shall be class C. Concrete

in bent caps, unless poured integrally with the superstructure; pier caps; abutment
caps; pier stems; abutment walls; mudwalls; columns; crashwalls; collision walls; and

576
 702.05

wingwalls, unless poured with integral end bents, shall be class A. Concrete in footings
shall be class B.
20
702.03 Materials
Materials shall be in accordance with the following:

Admixtures for Use in Concrete .................................. 912.03

Castings ....................................................................... 910.05
Coarse Aggregate
For exposed concrete, Class A or Higher,
Size No. 8 .................................................. 904
For non-exposed concrete, Class B or Higher,
30 Size No. 8 .................................................. 904
Curing Materials .......................................................... 912.01
Curing-Sealing Materials............................................. 912.02
Elastomeric Bearings ................................................... 915.04
Fabric for Waterproofing ............................................. 918.01
Fine Aggregate Size No. 23......................................... 904
Fly Ash ........................................................................ 901.02
Geotextile for Use With Underdrains .......................... 918.03
Ground Granulated Blast Furnace Slag ....................... 901.03
High Density Bearing Strips ........................................ 906.08
40 Permanent Metal Forms .............................................. 910.03
Polychloroprene Joint Membrane and Adhesive ......... 906.02(a)4
Portland Cement .......................................................... 901.01(b)
Utility Asphalt, UA-1 .................................................. 902.01(d)
Water ........................................................................... 913.01

Drainage pipe through concrete masonry shall be in accordance with 715.

Grout material for field drilled holes shall be either a high-strength, non-shrink,
non-metallic, cementitious grout in accordance with U.S. Army Corps of Engineers
50 Specification CRD-C 621 or an approved 100% solids chemical anchor system.

702.04 Shipping and Storage

The cement shall be well protected from rain and moisture. All cement damaged
by moisture or which fails to meet the specified requirements shall be rejected and
removed from the work. Cement stored for a period longer than 60 days shall be
retested before being used on the work. Cement of different brands, types, or from
different mills shall be stored separately.

CONSTRUCTION REQUIREMENTS
60
702.05 Proportioning
Control of PCC for air content, slump, or relative yield will be determined on the
basis of tests performed by the Engineer. Concrete and necessary labor for sampling

577
 702.05

shall be furnished by the Contractor as required by the Engineer. Testing will be in

accordance with the Frequency Manual.

A CMDS shall be submitted seven calendar days prior to production and be

approved by the Engineer except utilization of the Department provided spreadsheet
is not required for the CMDS. The absolute volume of the mix design shall be 27.0 cu
70 ft at the design air content of 6.5%.

The proportion of ingredients of each batch shall be within the following limits,
and shall be approved.

The relative yield of the concrete shall be determined in accordance with 505. The
concrete when produced shall provide a relative yield of 1.00 ±0.02. When the relative
yield is outside the tolerances, adjustments to the batch weights shall be made. The
minimum amount of cement shall be used for the desired class of concrete. The cement
content shall not be increased more than 60 lbs/cu yd. The relative yield of the concrete
80 shall be maintained as stated above. If type IP or type IP-A cements are to be used in
the structural concrete, the cement content shall be increased by a multiplier of 1.06
times the minimum amount of cement required or the desired increased cement content
for the specified class of concrete.

For example: 1.06 x 564 = 598 lbs/cu yd for class A concrete.

Fly ash from an approved source may be used as a partial replacement for portland
cement. The substitution of fly ash for portland cement will not be allowed in
conjunction with the use of ground granulated blast furnace slag or blended cement
90 types IP, IP-A, IS, or IS-A. Mix designs will be based on using a maximum 20%
cement reduction with a minimum 1.25:1 ash-to-cement replacement ratio by weight.

Ground granulated blast furnace slag from an approved source may be used as a
partial replacement for portland cement. The substitution of ground granulated blast
furnace slag for portland cement will not be allowed in conjunction with the use of
blended cement types IP, IP-A, IS, or IS-A or fly ash. Mix designs will be based on
using a maximum 30% cement substitution with a 1:1 slag-to-cement ratio, by weight.

Blended portland pozzolan cements, fly ash, and ground granulated blast furnace
100 slag used as a pozzolan may only be used in concrete bridge decks between April 1
and October 15 of the same calendar year.

Fine aggregate shall be no less than 35% nor more than 45% of the total weight
of aggregates used, except the limit may be increased to 50% when slag coarse
aggregate is used. The aggregates shall be proportioned to use the maximum amount
of coarse aggregate which produces a workable mix.

All concrete shall have an air content of 6.5% ±1.5% by volume. Air content shall
be determined in accordance with 505.

578
 702.06

110
Powdered admixtures shall be measured by weight, and paste or liquid admixtures
by weight or volume, and all shall be within 3% of the amount required. When
admixtures are used in small quantities in proportion to the cement, as is the case for
air-entraining admixtures, mechanical dispensing equipment shall be provided.

Class C concrete shall contain either a water-reducing admixture or both a

water-reducing admixture and a retarding admixture. The types used shall not be
changed during any individual contiguous pour. The types of admixtures to be used
shall be selected based on the expected concrete or air temperature. When either
120 temperature is expected to be 65°F or above, both a water-reducing admixture and a
retarding admixture shall be used. A water-reducing admixture shall be used when
both temperatures are expected to be below 65°F unless retardation is required due to
the structure design or the proposed pour sequence such as the requirements for floor
slab pours set out in 704.04. If class C concrete contains ground granulated blast
furnace slag, the producer may propose an alternate temperature threshold for
including a retarding admixture. Air-entraining cements will not be allowed in class C
concrete.

The manufacturer’s data, which relates recommended addition rates to ambient

130 temperatures, shall be furnished. The proposed addition rates and adjustments to the
rates, as conditions require, will be approved using this data and the anticipated
temperature. The addition rate shall not be reduced below the minimum rate
recommended by the manufacturer, regardless of the concrete or air temperature. The
air entraining admixture and water-reducing retarding admixture shall be added to the
batch separately. The method and equipment for adding water-reducing retarding
admixture will be approved.

If the contract requires stay-in-place metal forms for the bridge deck or if the
Contractor elects to use such forms, the bridge deck concrete shall incorporate class
140 AP coarse aggregate instead of class A.

702.06 Measuring and Batching

Unless otherwise specified, the minimum batch shall be 2 cu yd. Measuring and
batching of materials shall be done at a batching plant. Different kinds or sources of
coarse aggregate or different brands of cement shall not be used in any unit of the
structure except in an emergency and then only by written permission.

(a) Portland Cement

Either sacked or bulk cement may be used. No fraction of a sack of cement shall
150 be used in a batch of concrete unless the cement is weighed. All bulk cement shall be
weighed on an approved weighing device. The bulk cement weighing hopper shall be
sealed and vented to preclude dusting during operation. The discharge chute shall not
be suspended from the weighing hopper and shall be so arranged that cement does not
lodge in it or leak from it. Accuracy of batching shall be ±1% of the required weight.

579
 702.06

If fly ash is used as a pozzolan in portland cement concrete, the cement and fly
ash shall be weighed and discharged separately when a manual operation is utilized.
When an automatic batching plant is utilized, the fly ash may be weighed into the
cement weigh hopper in one cumulative operation with the portland cement always
160 being weighed in first.

(b) Water
Water may be measured either by volume or by weight. The accuracy of
measuring the water shall be within 1% of the required amount.

(c) Aggregates
The batch plant site, layout, equipment, and provisions for transporting material
shall be such as to assure a continuous supply of reasonably uniform material to the
work. Aggregate stockpiles shall be located in areas sufficiently well drained to
170 prevent the dirt underneath from becoming softened and pumping into the aggregate
to a level from which the aggregate is to be removed and used in the work. Stockpiles
shall be built in layers not to exceed 6 ft in depth. Upper layers shall be prevented from
spilling over the sides of the layers below.

The removal of aggregates from stockpiles shall be done in such a manner that
segregation will not occur. Aggregate which has become mixed with dirt shall not be
used in the work.

Washed aggregates shall drain for at least 12 h prior to use. An increase in the
180 drainage time may be required, as directed, at any time when the moisture becomes
non-uniform in aggregates from any source. Aggregates from different sources shall
not be stockpiled together without written approval.

Batching shall be conducted so as to obtain the weights of materials required

within a tolerance of ±2%.

(d) Bins and Scales

The batching plant shall include bins, weighing hoppers, and scales for the fine
aggregate and for each size of coarse aggregate. If cement is used in bulk, a bin,
190 hopper, and scale for cement shall be included. If fly ash is used, the separation of
cement and fly ash bins will be as approved. Bins with adequate separate
compartments for fine aggregate and for each size of coarse aggregate shall be
provided in the batching plant.

Means of control shall be provided so that as the quantity required in the weighing
hopper is approached the material may be added slowly and shut off with precision. A
port or other opening for removing an overload from the hopper shall be provided. A
port for sampling cement shall be provided and may be either the overload port or a
separate port located at any point from the bottom of the storage bin to the weigh
200 hopper. The sampling port shall be located and constructed so as to provide a
representative sample of the cement being used. Weighing hoppers shall be
constructed so as to eliminate accumulation of tare materials and to discharge fully.
580
 702.08

For applied loads of 1,000 lbs and greater on the cement scale and applied loads
of 4,000 lbs and greater on the aggregate scale, the scales shall be accurate to 0.5%.
For applied loads of less than 1,000 lbs and 4,000 lbs for the cement and aggregate
scales, respectively, the scales shall be accurate to 2.0% or one graduation, whichever
is larger. Poises shall be designed to be locked in any position to prevent unauthorized
change of position. Scales will be inspected as often as necessary to ensure their
210 continued accuracy. No less than ten 50 lb weights shall be provided at all times for
testing of scales.

Batching plants may be equipped with approved automatic weighing devices to

proportion aggregates and bulk cement.

(e) Batching
When batches are hauled to the mixer, bulk cement shall be transported either in
waterproof compartments or between the fine and coarse aggregates. When cement is
placed in contact with the aggregates, batches may be rejected unless mixed within
220 1 1/2 h of such contact. Sacked cement may be transported on top of the aggregates.

Batches shall be delivered to the mixer separate and intact. Each batch shall be
dumped cleanly into the mixer without loss and, when more than one batch is carried
on the truck, without spillage of material from one batch compartment into another.

702.07 Mixing
Concrete may be mixed at the site of construction, at a central point, or wholly or
in part in truck mixers. Retempering concrete by adding water or by other means will
not be allowed after initial set. When concrete is delivered in transit mixers, additional
230 water may be added occasionally to increase the slump, if allowed, and additional
mixing shall be performed as directed and all operations completed within the time
limits in accordance with 702.09(c). The amount of water added shall be determined
accurately and noted on the batch ticket. Such addition of water will not be allowed as
a continuing operation. The total of all water included in the mix shall not exceed the
maximum in accordance with 702.02.

Concrete that is not within the specified slump limits at time of placement shall
not be used. Except as required in 702.05 for class C concrete, chemical admixtures
type A, type B, type D, type F, and type G, may be used in the concrete. Chemical
240 admixtures type C and type E will be allowed only with prior written permission.

702.08 Mixing at Site of Work

For concrete to be acceptable, not more than 1 h shall elapse from the time mixing
water has entered the mixer until the mixed batch is deposited into the forms.

The concrete shall be mixed in an approved batch mixer which has a rated capacity
of not less than 188 lbs except for pours of 20 cu yds or less, or where otherwise
specified, a 94 lb minimum capacity mixer may be used. Mixers shall ensure a uniform

581
 702.09

distribution of ingredients throughout the mass. No mixer shall be operated beyond its
250 factory rated capacity.

The concrete shall be mixed no less than 60 s after all ingredients, including water,
are in the mixer.

During the period of mixing the drum shall rotate at the speed for which it was
designed, which shall be no less than 14 and no more than 20 revolutions per minute.
If this procedure does not mix the concrete thoroughly, a sufficient additional number
of turn at the same rate shall be made until a thorough mixing of the ingredients is
obtained.
260
The mixer shall be equipped with a batch meter for counting the number of
batches discharged and a timer for automatically locking the discharge chute to prevent
emptying the mixer prior to the specified minimum mixing time. Mixers shall be
equipped with mechanical means for preventing the addition of ingredients, including
water, after mixing is started. The first batch shall contain an additional quantity of
cement, fine aggregate, and water sufficient to coat the inside surface of the drum in
order to avoid diminishing the mortar content of the initial batch. The entire contents
of the drum shall be removed before the materials for the next batch are introduced.
Upon cessation of mixing for any considerable time, the drum shall be cleaned
270 thoroughly.

Structural concrete shall be mixed only in such quantities as are required for
immediate use and shall be placed while fresh before initial set has occurred. Hand
mixing will not be allowed except in an emergency and then only with permission.
Hand mixing shall be done on a watertight platform in such manner and so continued
to ensure a homogeneous mixture of the required consistency. Hand mixed batches
shall not exceed 1/2 cu yd in volume.

702.09 Ready-Mixed Concrete

280
(a) General Requirements
Ready-mixed concrete shall be mixed and delivered by means of one of the
following operations:

1. Mixed completely in a stationary mixer and the mixed

concrete transported to the point of delivery in a truck-
agitator or truck-mixer at agitating speed or in approved
non-agitating equipment in accordance with 702.09(d).
Concrete delivered under these provisions shall be known
290 as central-mixed concrete.

2. Mixed partially in a stationary mixer and the mixing

completed in a truck-mixer. Concrete delivered under these
provisions shall be known as shrink-mixed concrete.

582
 702.09

3. Mixed completely in a truck-mixer. Concrete delivered

under these conditions shall be known as transit-mixed
concrete.

300 The source of ready-mixed concrete shall be approved prior to delivery of the
concrete. This approval will be based on the capacity and condition of the equipment,
volume of production, and length of haul, with consideration of the use to which the
concrete is to be put. Original approval will not constitute continued approval if
satisfactory concrete or rate of delivery is not maintained.

Approval may be refused or previous approval may be withdrawn for a truck

mixer or for a part of equipment not functioning in such manner as to produce and
deliver uniform concrete to the site of the work at a uniform rate.

310 Before a pour is started, the number of trucks to be assigned to the work, the rate
of production, and all other conditions necessary for furnishing satisfactory concrete
shall be subject to approval. Such assigned equipment shall be in satisfactory operating
condition prior to the start of the pour. Equipment once assigned to a pour shall not be
diverted for another purpose without approval.

(b) Mixers and Agitators

Mixers and agitators shall be in accordance with the following:

1. Mixers may be stationary mixers or truck-mixers. Agitators

320 may be truck-mixers or truck-agitators. Each mixer and
agitator shall have attached to it in a prominent place a
metal plate or plates on which are plainly marked, for the
various uses for which the equipment is designed, the
capacity of the drum or container in terms of the volume of
mixed concrete, the speed of rotation of the mixing drum,
and manufacturer’s name and address. Stationary mixers
shall be equipped with an acceptable timing device which
does not enable the batch to be discharged until the
specified mixing time has elapsed. Truck-mixers shall be
330 equipped with means by which the number of revolutions
of the drum may be verified readily. The counters shall be
actuated at the time of starting mixing at mixing speed.

2. The mixer, when loaded to the manufacturer’s rated

capacity without overload, shall be capable of combining
the ingredients of the concrete within the specified time
into a thoroughly mixed and uniform mass and of
discharging the concrete with a satisfactory degree of
uniformity in accordance with requirement 4 of 702.09(b).
340

583
 702.09

3. The agitator, when loaded to the manufacturer’s rated

capacity without overload, shall be capable of maintaining
the mixed concrete in a thoroughly mixed and uniform
mass and of discharging the concrete with a satisfactory
degree of uniformity in accordance with requirement 4 of
702.09(b).

4. Slump tests may be made of individual samples taken when

discharged at approximately the one-quarter and three-
350 quarter points of each load. If the slumps differ by more
than 1 in. when the average slump is 3 in. or less, or by
more than 2 in. when the average slump is greater than 3
in., the mixer or agitator shall not be used until conditions
are corrected, except as set out in requirement 5 of
702.09(b).

5. Use of equipment may be allowed when operations with a

longer mixing time or with a smaller load will enable the
requirements in requirement 4 of 702.09(b) to be met.
360
6. Mixers and agitators shall be examined daily for changes
in conditions due to the accumulations of hardened
concrete or mortar or to wear of blades. When such change
of conditions is found, the tests described in requirement 4
of 702.09(b) shall be repeated.

(c) Mixing and Delivery

Mixers and agitators shall be operated within the limits of the capacity and speed
of rotations designated by the manufacturer. The following shall apply in fulfilling
370 these requirements.

1. The complete mixing time for a stationary mixer shall be

no less than 60 s. Mixing time shall be measured from the
time all cement and aggregates are in the drum. The batch
shall be so charged into the mixer that some of the water
enters in advance of the cement and aggregates. All
required water shall be in the drum by the end of the first
quarter of the specified mixing time.

380 2. If a stationary mixer is used for shrink mixing, the time in

the stationary mixer may be reduced to the minimum
required to intermingle the ingredients, or approximately
30 s. Mixing shall then be completed in a truck-mixer by
no less than 50 and no more than 100 revolutions of the
drum or blades at the rate of rotation designated by the
manufacturer of the equipment as mixing speed. Additional

584
 702.09

mixing, if required, shall be at the speed designated by the

manufacturer as agitating speed.

390 3. If the concrete is mixed in a truck-mixer loaded to its rated

capacity, the number of revolutions of the drum or blades
at mixing speed shall be no less than 70 and no more than
100, but not less than that recommended by the mixer
manufacturer.

4. If a truck-mixer or truck-agitator is used for transporting

concrete that has been completely mixed in a stationary
mixer, further mixing during transportation shall be at the
speed designated by the manufacturer of the equipment as
400 agitating speed.

5. If a truck-mixer or truck-agitator is used for transporting

concrete, the concrete shall be delivered to the site of the
work and its discharge completed within 90 minutes after
the introduction of the mixing water to the cement and
aggregates, or the introduction of cement to the aggregates,
unless a shorter time is otherwise specified. When a truck-
mixer is used for the complete mixing of the concrete, the
mixing operations shall begin within 30 minutes after the
410 cement has been added to the aggregates.

6. When authorized, a truck-mixer may be charged with

aggregates and water at the batching plant and with bagged
cement at the point of delivery, provided the truck-mixer is
then operated at mixing speed for the required additional
revolutions and satisfactory concrete is produced.

7. For truck-mixers, wash water shall not be used as a portion

of the mixing water for succeeding batches.
420
(d) Non-Agitating Equipment
Central mixed concrete may be transported from the mixing plant to the place of
use in non-agitating equipment when and as approved. The following shall apply in
fulfilling these requirements.

1. Bodies of non-agitating equipment shall be smooth,

watertight, metal containers equipped with gates that
enable control of the discharge of the concrete. Covers
shall be provided for protection of the concrete when
430 required.

585
 702.10

2. The concrete shall be delivered to the site of the work in a

thoroughly mixed and uniform mass and discharged with
the degree of uniformity in accordance with requirement 3
of 702.09(d). Discharge shall be completed within 30
minutes after the introduction of the mixing water to the
cement and aggregates.

3. Slump tests shall be taken in accordance with requirement

440 4 of 702.09(b). If the slump differs by more than these
tolerances the non-agitating equipment shall not be used
until the conditions are corrected in accordance with
requirement 4 of 702.09(d).

4. If the requirements of requirement 3 of 702.09(d) are not

met when the non-agitating equipment is operated at
minimum capacity for the maximum time of haul and with
the concrete mixed the minimum time, the equipment may
still be used when operated using smaller loads, shorter
450 hauls, or longer mixing times, or combinations thereof,
which enables the requirements in requirement 3 of
702.09(d) to be met.

702.10 Pumping Concrete

If the Contractor elects to convey concrete by means of pumping, the concrete
shall be handled so as to minimize disturbance to the concrete which significantly
alters the properties of the concrete being pumped, especially the loss or variability of
the air content. The pumping equipment shall be mechanically sound, suitable in kind,
and adequate in capacity for the proposed work. The concrete shall not be pumped
460 through aluminum or aluminum alloy pipe. All pipes used for pumping concrete shall
be kept clean and free from coatings of hardened concrete. Pump lines shall not rest
directly on epoxy coated reinforcing bars. The pumping equipment shall be located
such that operational vibrations will not damage freshly placed concrete.

When placing concrete directly from a truck mounted boom, the concrete pump
lines shall have a flexible end section at least 10 ft long. Methods of placement shall
be such as to result in a steady and continuous discharge. If necessary, this may require
the use of a restrictive device at or near the end of the discharge tube, the laying the
flexible end section horizontally, or other means. For the initial placement of concrete
470 pours which are predominantly vertical, the discharge end of the flexible end section
shall be within 2 ft of the bottom of the pour.

The Contractor shall submit a description of the pumping procedures which it

intends to use, and shall notify the Engineer as to the pumping procedure at least 24 h
in advance of concrete placement.

586
 702.11

702.11 Cold Weather Concrete

When it is necessary to place concrete at or below an atmospheric temperature of
35°F, or whenever it is determined that the temperature may fall below 35°F within
480 the curing period, the water, aggregates, or both shall be heated and suitable enclosures
and heating devices provided. Cold weather concrete shall be placed at the risk of the
Contractor and shall be removed and replaced with no additional payment if it
becomes frozen or otherwise damaged.

When aggregates or water are heated, the resulting concrete shall have a
temperature of at least 50°F and not more than 80°F at the time of placing. Heating
equipment or methods which alter or prevent the entrainment of the required amount
of air in the concrete shall not be used. The equipment shall be capable of heating the
materials uniformly. Neither aggregates nor water used for mixing shall be heated to
490 a temperature exceeding 150°F. When aggregates or water are heated to 100°F or
above, they shall be combined first in the mixer before the cement is added. The
maximum temperature of concrete produced with heated aggregates shall be 90°F.
Materials containing frost or lumps of frozen material shall not be used.

Stockpiled aggregates may be heated by the use of dry heat or steam. Aggregates
shall not be heated directly by gas or oil flame or on sheet metal over fire. However, a
drier may be used if approved.

When aggregates are heated in bins, steam-coil heating, water-coil heating, or

500 other methods which are not detrimental to the aggregates may be used. The use of
salt or other chemicals to accelerate hardening of the concrete will not be allowed
unless approved in writing.

Immediately after a pour is completed, the freshly poured concrete and forms shall
be covered so as to form a complete protective enclosure around the element being
poured. If the element is a bridge deck, the enclosure shall encompass the top, bottom,
and all sides. The air within the entire enclosure shall be maintained at a temperature
above 50°F for a minimum of 144 h for bridge decks, the top surface of reinforced
concrete slab bridges, and for a minimum of 72 h for all other concrete. If for any
510 reason this minimum temperature is not maintained, the heating period shall be
extended. When dry heat is used, means shall be provided to maintain adequate
moisture in the air within the enclosure.

All necessary measures shall be taken during protective heating to keep the
heating equipment in continuous operation and to ensure maintenance of the proper
temperature around all sides, top and bottom of the concrete. Adequate fire protection
shall be provided where heating is in progress and such protection shall be accessible
at all times.

520 Where practicable, forms insulated with at least 2 in. thick blankets made of
fiberglass, rock wool, balsam wool, or similar commercial material capable of
maintaining the surface of the concrete at no less than 50°F may be used in lieu of

587
 702.12

other protection of concrete involving housing and heating. When forms are insulated,
exposed horizontal surfaces shall be protected with a similar layer of the insulating
material fastened securely in place. If the insulated forms do not maintain the proper
temperature at the surface of the concrete, auxiliary protection and heat shall be used.

702.12 Consistency
Slump will be measured in accordance with 505 and shall be no less than 1 in. and
530 no more than 4 in. except for concrete placed in foundation seals.

702.13 Forms

(a) Construction
Forms shall be mortar tight and sufficiently rigid to prevent distortion due to the
pressure of the concrete and other loads incident to the construction operations,
including vibration. Forms shall be constructed and maintained so as to prevent the
opening of joints due to shrinkage of the lumber.

540 Unless otherwise provided, all forms for exposed surfaces except the undersides
of girders, slabs, and arch rings shall be lined with approved plywood, metal, or similar
satisfactory composition. The lining shall not be sprung into place. Before concrete is
placed, all open joints shall be filled with a satisfactory filler which is impervious to
moisture, does not stain or otherwise injure the concrete, and produces a tight joint.
The lining shall present a smooth uniform surface. Lining of sufficient thickness to
resist the pressure of the concrete without deflection may be applied directly to the
studding if it otherwise complies with the foregoing provisions for form lining.

In designing forms, fresh concrete shall be considered as a liquid weighing 150

550 lbs/cu ft for vertical loads and 100 lbs/cu ft for horizontal pressure. A live load
allowance of 50 lbs/sq ft shall be used on horizontal projections of surfaces. The
scheme of formwork for work on a span over active railroad tracks shall provide a
horizontal clearance of not less than 8 ft from the centerline of track and a clearance
height of not less than 22 ft from the top of the track rail.

Spreader blocks and bracing shall be removed from the inside of forms before
concrete is placed and a portion of wood shall not be left in the concrete.

Forms for exposed concrete edges shall be chamfered 3/4 in. Forms shall be given
560 a bevel or draft in the case of all projections, such as girders and copings, to ensure
easy removal.

(b) Ties
Approved ties or anchorages within the forms shall be so constructed as to enable
their removal to a depth of at least 1 in. from the face without injury to the concrete.
Ties may be metal or fiberglass. Ties shall be capable of supporting the designed loads.
Fiberglass ties shall be ground flush with the face of the concrete surfaces. The cavities
shall be filled with cement mortar and the surface left sound, smooth, even, and

588
 702.13

uniform in color. Filling of the cavities will not be required between the fascia beams
570 or girders on the underside of decks, the bottom surface of slab decks, or the bottom
deck surface of box culverts. In general, tie rods shall be designed to also act as struts
or spreaders. The use of wood struts will not be allowed in copings, railings, and walls
less than 2 ft thick. Devices which, when removed, leave an opening entirely through
the concrete will not be allowed unless approved in writing. Wire ties shall not be
used.

(c) Walls
Where the bottom of the forms is inaccessible, the lower form boards shall be left
loose or other provisions made so that extraneous material may be removed from the
580 forms immediately before placing the concrete.

(d) Surface Treatment

All forms shall be treated with a formulated form coating that allows them to be
released without adhering, discoloring, or otherwise damaging the concrete.

(e) Metal Forms

1. Removable
The specifications for forms as they regard design, mortar tightness, filleted
590 corners, beveled projections, bracing, alignment, removal, re-use, and oiling apply to
metal forms. The metal used for forms shall be of such thickness that the forms remain
true to shape. All bolt and rivet heads shall be countersunk. Clamps, pins, or other
connecting devices shall be designed to hold the forms together rigidly and to allow
removal without injury to the concrete. Metal forms which do not present a smooth
surface or do not line up properly shall not be used. Care shall be exercised to keep
metal forms free from rust, grease, or other foreign matter.

2. Permanent
Fabricated permanent metal forms for concrete deck slabs may be used as an
600 alternate method of forming on a steel beam, steel girder, prestressed concrete I-beam,
prestressed concrete spread box beam, or prestressed concrete bulb-T beam bridge.
Permanent metal forms shall not be removed, and shall otherwise be in accordance
with the applicable requirements of this section.

The metal forms shall be designed on the basis of dead load of form, reinforcing
bars, and plastic concrete plus 50 lbs/sq ft for construction loads. The unit working
stress in the steel sheet shall be not more than 0.725 of the specified minimum yield
strength of the material furnished but not to exceed 36,000 psi. Deflection under the
weight of the forms, the plastic concrete and reinforcing bars shall not exceed 1/180
610 of the form span or 1/2 in. whichever is less. However, the deflection loading shall not
be less than 120 lbs/sq ft total. The allowable form camber shall be based on the actual
dead load condition. Camber shall not be used to compensate for deflection in excess
of the foregoing limits. The design span of the form sheets shall be the clear span of
the form plus 2 in. measured parallel to the form flutes. If the design span of the form

589
 702.13

sheets exceeds 9.5 ft, concrete will not be allowed to be placed in the valleys of the
corrugations of the metal forms. Physical design properties shall be computed in
accordance with requirements of the American Iron and Steel Institute Specifications
for the Design of Cold Formed Steel Structural Members.

620 All reinforcing bars shall have a minimum clearance of 1 in. from the forms. The
plan dimensions from the top surface for all primary deck reinforcing bars shall be
maintained. The deck reinforcing bars shall be tied down at a maximum of 6 ft centers.
Permanent metal forms shall not remain in place closer than 1 ft from any joint exposed
to the underside of the slab, except when an overlay is used on the deck.

Fabricator’s working drawings shall be submitted for approval. These drawings

shall indicate the grade of steel and the physical and section properties for all
permanent metal bridge deck form sheets. If the bridge is a steel beam or steel girder
structure, these drawings shall also include a clear indication of locations where the
630 forms are supported by steel beam flanges subject to tensile stress. The drawings shall
be certified by a registered professional engineer prior to submittal.

Form sheets shall not rest directly on the top of the beam flanges. Sheets shall be
securely fastened to the form supports and shall have a minimum bearing length of 1
in. at each end. All attachments shall be made by welds, bolts, clips, or other approved
means. Except as amended by these specifications, welding and welds shall be in
accordance with the requirements of 711.32 pertaining to fillet welds. However, 1/8
in. fillet welds will be allowed. The vertical leg of angles used as form supports shall
not extend higher than the top of the permanent metal form.
640
Form supports at steel beam or girder bridges shall be placed in direct contact with
the top flange of the beam or girder and shall be adjusted to maintain the required deck
thickness. If straps are used on the top flanges, the straps shall be No. 8 gage thick, fit
tight, and shall not be galvanized. Form supports shall not be welded to flanges of non-
weldable grades of steel or to steel flanges subject to tensile stresses.

Form supports at prestressed concrete I-beam, prestressed concrete spread box

beam, and prestressed concrete bulb-T beam bridges shall be placed in direct contact
with the sides of the box or edge of the I-beam or bulb-T beam flange and shall be
650 adjusted to maintain the required deck thickness. The form supports may be attached
to steel inserts cast into the top of the box, I-beam, or bulb-T beam, straps extending
across the top of the flange, hangers mechanically attached to reinforcing bars
extending from the top flange, or by other approved methods. If straps are used across
the top flange, they shall be No. 8 gage thick, fit tight, and shall not be galvanized.
Attachments shall not be welded directly to beam reinforcement. In addition, the use
of recesses cast into the beam to serve as a form supports will not be allowed.

All permanently exposed form metal, where the galvanized coating has been
damaged, shall be thoroughly and satisfactorily cleaned, wire brushed, and painted
660 with two coats of zinc oxide-zinc dust primer in accordance with Federal Specification

590
 702.13

MIL-P-2441, type II, with no color added. Minor heat discoloration in areas of welds
need not be touched up.

Concrete shall be placed in accordance with 702.20. Particular emphasis shall be

placed on proper vibration of the concrete to avoid honeycombs and voids, especially
at construction joints, expansion joints, attachment hardware, and valleys and ends of
form sheets. Pouring sequences, procedures, and mixes shall be submitted for
approval.

670 If it is determined that the procedures used during the placement of the concrete
warrant inspection of the underside of the deck, at least one section of the forms shall
be removed at a location and time selected for each span in the contract. This is to be
done as soon after placing the concrete as practical in order to provide visual evidence
that the concrete mix and the procedures are obtaining the desired results. An
additional section shall be removed if it is determined that there has been any change
in the concrete mix or in the procedures warranting additional inspection.

After the deck concrete has been in place for a minimum of two days, the concrete
shall be tested for soundness and bonding to the forms by sounding with a hammer as
680 directed. If areas of doubtful soundness are disclosed by this procedure, the forms shall
be removed from such areas for visual inspection after the pour has attained adequate
strength. This removal of the permanent metal bridge deck forms shall be with no
additional payment. At locations where sections of the forms are removed, form
replacement will not be required, but the adjacent metal forms and supports shall be
repaired to present a neat appearance and ensure their satisfactory retention. As soon
as the form is removed, the concrete surfaces will be examined for cavities,
honeycombs, and other defects. If irregularities are found, and it is determined that
these irregularities do not justify rejection of the work, the concrete shall be repaired
as directed and shall be given a finish in accordance with 702.21. If the concrete where
690 the form is removed is unsatisfactory, additional forms, as necessary, shall be removed
to inspect and repair the slab, and the methods of construction shall be modified as
required to obtain satisfactory concrete in the slab. All unsatisfactory concrete shall be
removed or repaired as directed.

The amount of sounding and form removal may be moderated as directed after a
substantial amount of slab has been constructed and inspected, if the methods of
construction and the results of the inspections as outlined above indicate that sound
concrete is being obtained throughout the slabs. All facilities shall be provided as are
required for the safe and convenient conduct of inspection procedures.
700
(f) Blank

(g) Removal and Re-Use of Forms

The forms for any portion of the structure shall not be removed until the concrete
is strong enough to withstand damage. If field operations are not controlled by beam

591
 702.14

or cylinder tests, the following periods, exclusive of days when the ambient
temperature is below 40°F, for removal of forms and supports may be used as a guide.

Centering under beams ....................................................... 15 days

710 Roadway Slabs ................................................................... 7 days
Walls, Columns, Sides of Beams, and all other parts ......... 12 h

If high-early strength cement is used, these periods may be reduced as directed. If

portland-pozzolan cement, type IP or IP-A, fly ash or ground granulated blast furnace
slag as a pozzolan is used in the structural concrete, these periods shall not apply and
the removal of forms and supports shall be controlled by test beams in accordance with
702.13(h).

In order to obtain a satisfactory surface finish, forms for railings, parapets, and
720 exposed vertical surfaces shall be removed no less than 12 h and no more than 48 h
after the concrete is placed, depending on weather conditions.

Copings, corners, and projections shall not be cracked or injured during the
removal of the forms. If damage occurs, the amount of concrete adjacent to the
damaged portion shall be removed and replaced as directed with no additional
payment.

The shape, strength, rigidity, water-tightness, and surface smoothness of re-used

forms shall be maintained at all times. Any warped or bulged lumber shall be re-sized
730 before being used. Unsatisfactory forms shall not be used.

(h) Test Beams

When portland-pozzolan cement, type IP or IP-A, is incorporated into the
structural concrete elements listed below, when fly ash or ground granulated blast
furnace slag is incorporated into the structural concrete elements listed below, or when
field operations are being controlled by beam tests, the removal of forms will be
allowed when the modulus of rupture reaches or exceeds the following values:

Required Flexural Strength, psi,

Concrete used in
Dead Load Only
Girders, Arches, and similar units 390
Interior Bent or Pier Caps 480

740 The beams will be cured under the same conditions as the concrete which they
represent. Beams will be tested for flexural strength as simple beams with third-point
loading in accordance with 505.

702.14 Falsework and Centering

Detailed working drawings for falsework and arch centering shall be submitted in
accordance with 105.02. Since the quality of the lumber is not known and because of
the uncertainty of computing nailed joints, no responsibility will be assumed by the

592
 702.14

Department for the strength of falsework and centering.

750 Working drawings for falsework shall include details for support of interior bent
caps, hammerhead piers, and the portion of the bridge floor and coping beyond fascia
girders or beams if the overhang is 18 in. or more, or if a finishing machine, concrete
spreader, or other equipment is to be supported by the overhang.

The scheme of falsework for work on a span over active railroad tracks shall
provide a minimum horizontal clearance of 13 ft from the centerline of the nearest
tangent track or 14 ft from the centerline of the nearest track on a horizontal curve and
a minimum vertical clearance of 22 ft from the top of the highest track rail unless
different clearance values are approved by the railroad.
760
(a) Design and Construction
Falsework shall be designed and constructed so as to safely carry the full load
coming upon it with a minimum settlement and deflection and with sufficient camber
to counteract unavoidable shrinkage, deformation, and settlement. Structures shall
have a permanent camber only when so shown on the plans, and the falsework shall
be set to provide it.

For designing falsework and centering, a weight of 150 lbs/cu ft shall be assumed
for plastic concrete. A live load allowance of 50 lbs/sq ft shall be added for horizontal
770 projections of surfaces. All beams supporting plastic concrete shall be so designed that
there are no appreciable deflection under full load. The beams shall be considered as
being unsupported by knee-bracing, such bracing to be considered as relieving sagging
and bending only. The use of inclined columns, where properly braced, will be
allowed.

The unsupported lengths of wooden columns and compression members shall not
exceed 30 times the dimensions of the least side, or 30 times the least diameter.

Unit stresses in timber shall not exceed the following:

780
For Douglas fir, white oak, long-leaf yellow pine:
Bending .................................................. 1,800 psi
Columns .................................................. 1,800 (1-L/60D) psi
For spruce, cypress, short-leaf pine, white pine, western hemlock:
Bending .................................................. 1,500 psi
Columns .................................................. 1,500 (1-L/60D) psi
In the above:
L = length of column in inches
D = least diameter or least dimension in inches.
790
Hardwood wedges may be required to take up any settlement in the falsework,
either before or during the placing of concrete.

593
 702.14

Arch centering shall be constructed so as to enable it to be lowered or released

gradually and uniformly after pouring arch ribs and rings. Lagging for arch centering
shall be of uniform thickness. Unless otherwise specified, the nominal thickness shall
be no less than 2 in. A smooth surface shall be produced on the undersides of arch
rings. The upper sides of all lagging shall be oiled before concrete is placed.

800 Unless driving of piles for falsework bents is precluded by soil or other special
conditions or unless otherwise specified, all bents for falsework shall have driven piles.
These shall be so driven to support the required loads without settlement, spacing, and
subsequent removal shall be satisfactory.

If permission is given to place frame bents, they shall be placed on continuous

concrete mudsills, or as approved.

(b) Removal
Unless otherwise specified, the following shall apply to the removal of falsework
810 and centering:

1. Falsework under a reinforced concrete slab top not

supported by beams or girders shall remain in place at least
seven days after concrete placement and until attaining or
exceeding 480 psi flexural strength. Operations on the slab
may continue after achieving the required flexural strength.
No additional concrete shall be cast until the falsework has
been released.

820 2. Falsework under a bridge deck supported by beams or

girders including the bridge deck overhang shall remain in
place at least three days after concrete placement and until
attaining or exceeding 480 psi flexural strength. Falsework
jacks may be loosened, but not removed, and operations
may continue on overhangs three days after concrete
placement and achieving the required flexural strength.
Falsework jacks may be removed after seven days.

3. Falsework for substructure concrete, such as interior bents

830 and pier caps, shall remain in place at least three days after
concrete placement and until attaining or exceeding 480 psi
flexural strength.

4. Falsework and arch centering under multiple-span arch

bridges shall not be released from any one span until the
adjacent and spandrel walls have cured for the required
time and the next adjacent arch ring has been poured for at
least 48 h.

594
 702.15

840 5. Falsework under continuously reinforced concrete slab and

girder units shall not be released from any span until the
entire continuous unit has been completed and all concrete
cured for the required period.

6. For concrete poured during March, April, October, and

November, or any time between April and October when
the average temperature is less than 50°F, the above
periods shall be increased 20%. For concrete poured during
December, January, and February, they shall be increased
850 40%.

7. Removal of supports shall be such that it enables the

concrete to take the stresses, due to its own weight,
uniformly and gradually.

8. The removal of falsework shall be at the risk of the

Contractor. Permission for removal may be refused if it is
determined that there may be resulting damage to the
structure.
860
702.15 Joints

(a) Construction Joints

Construction joints shall be located across regions of low shearing stress and, so
far as possible, where they are hidden from view in the finished structure. They shall
be made only where shown on the plans, unless otherwise specified in writing, in
accordance with this specification.

Placing of concrete shall be continuous between construction joints. If placing is

870 interrupted and a construction joint becomes necessary, provisions shall be made for
interlocking with the preceding layer by constructing raised keyways as shown on the
plans or as directed.

When fresh concrete is to be joined to that in place which has already set, the
surface of the concrete in place shall be cut over with a suitable tool to remove all
loose and foreign material. This surface shall then be scrubbed with wire brooms and
kept wet until the new concrete is placed thereon. Immediately before the new concrete
is placed, the forms shall be drawn tight against the concrete in place and the exposed
surface of the concrete shall be coated with a thin coating of mortar composed on one
880 part cement and two parts No. 23 sand.

All concrete for slabs, beams, girders, cantilevered brackets, and footings shall be
placed in one continuous operation to form monolithic construction. However, if,
because of rain or other unavoidable reasons, concreting is interrupted where
monolithic construction is required, the concrete shall be kept plastic by placing

595
 702.15

frequent small batches until this part of the work is completed or until normal
operations can be resumed. If the interruption is such that even partial operations
cannot be carried on and construction joints are unavoidable, the joints shall be made
in planes exactly normal to the main reinforcing bars and only where the shear is a
890 minimum. In simply supported slabs, beams, and girders, such regions of minimum
shear are at or near the center of the span.

Unless otherwise provided, pours in all abutments for an arch bridge shall be
continuous from the top of footing to the skewback. If it is advisable to pour only a
portion of the abutment at one time, a vertical construction joint may be placed parallel
to the major reinforcement of the arch ring with written permission.

Horizontal construction joints will not be allowed in footings. If there is a

probability that the entire amount of concrete cannot be poured monolithically, vertical
900 or other construction joints shall be provided as directed.

Horizontal construction joints in the shafts of reinforced piers, retaining walls,

and abutments, other than abutments for arch bridges, may be made only if approved.
Where such joints show on an exposed surface, special care shall be taken to make the
joints truly straight, clean, and watertight. To avoid visible joints so far as possible on
exposed faces, the top surface of the concrete shall be finished to the underside of a
strip nailed to the form work for the exposed surface of the concrete, the strip to be
placed as directed. If such a horizontal joint intersects any coping or any sloping
surface where a featheredge would be formed, an inclined bulkhead shall be placed so
910 as to make the joint normal to the sloping surface for a distance of no less than 6 in.
or, if there is a coping, no less than the depth of the coping. Horizontal construction
joints will not be allowed in the stems of concrete T-beams or at the junction of T-
beam stems and flanges.

(b) Expansion Joints

Structural expansion joints shall be of the form, dimensions, material, and design
shown on the plans. Open expansion joints shall be completely open for the
dimensions specified and for their entire length. Preformed expansion joint material
shall be placed true and even and with abutting sections pressed together tightly. The
920 material shall be of the size shown on the plans and shall be in accordance with 906.01.

(c) Folded Metal Joints

These joints shall be free from kinks and watertight. At bends, the strip shall be
one piece if possible. Unless otherwise shown on the plans, the joints shall be soldered.
Copper shall be in accordance with 910.16. Lead sheets shall be no less than 1/8 in.
thick.

(d) Sliding Joints

The surface of the supporting concrete for a sliding joint shall be troweled to a
930 smooth finish and then covered with the required thickness of bituminous material, or
otherwise treated if so designated.

596
 702.20

(e) Polychloroprene Joint Membrane

Polychloroprene joint membrane used for semi-integral end bents shall be secured
to the concrete with an adhesive. The polychloroprene joint membrane shall be
centered vertically on the joint and shall have no gaps. Any field joint in the
polychloroprene membrane shall be lapped a minimum of 12 in.

702.16 Drainage Pipes Through Concrete Masonry

940 At all enclosures where water could not otherwise escape through the concrete,
drainage pipes shall be installed as shown on the plans. Before fill is placed around
these pipes, geotextile for use with underdrains shall be placed over the drain pipe and
securely held in place and loose stone shall be laid by hand over the inlet end to provide
a cover which shall be sufficient to retain the fill and enable free drainage. Drains
through abutments and retaining walls shall be placed with a slight incline downward
towards the exposed face.

702.17 Incased Pipes and Conduits

Pipes and conduits which are to be encased in the concrete shall be installed before
950 the concrete is placed. Unless otherwise provided, such pipes and conduits shall be
delivered at the site of the work by those for whose use they are intended. No direct
compensation will be allowed for their installation. However, no deduction in concrete
quantities will be made for the volume occupied.

702.18 Roadway Surface Drainage

Drainage grates and basins, necessary fittings, and connections to drainage pipes
shall be placed as shown on the plans or as directed.

702.19 Pouring Bent Caps

960 Caps shall not be poured on end bents or on any other bents falling within the
limits of the approach grade until the filling material has been placed.

702.20 Placing Concrete

(a) General Requirements

Concrete shall not be placed until forms and reinforcing bars have been checked
and approved. The forms shall be clean of all debris before concrete is placed. The
method and sequence of placing concrete shall be approved.

970 Where concrete floor slabs are to be poured, walkways shall be provided to protect
reinforcement from pedestrian traffic. Before placing concrete, continuous walkways
shall be placed parallel to the section of floor to be poured and shall remain in place
until after the concrete is placed and hardened sufficiently so as not to be injured.
Walkways shall be constructed so as not to come in contact with the reinforcement
and be of sufficient width to provide for finishing operations entirely from the
walkway.

597
 702.20

Except as otherwise provided, concrete shall be placed in horizontal layers of no

more than 24 in. thick. When less than a complete layer is placed in one operation, it
980 shall be terminated by a vertical bulkhead. Each layer shall be placed and consolidated
before the preceding layer has taken initial set in order to avoid planes of separation
between the layers and injury to the plastic concrete underneath. On horizontal
surfaces and at horizontal construction joints, the forms shall be overfilled
approximately 1/2 in. and then struck off to the required elevation prior to the initial
set of the concrete.

When placing is temporarily discontinued and as soon as it becomes firm enough

to retain its shape, the concrete shall be cleaned of all laitance and other objectionable
material to a depth sufficient to expose sound concrete. Unless otherwise authorized,
990 depositing concrete shall not be discontinued within 18 in. of the top of a face.
However, if provisions have been made for a coping of less than 18 in. thick, a
construction joint may be made at the underside of the coping.

Where new concrete is to abut existing concrete, the existing concrete surfaces
and existing exposed reinforcement shall be cleaned free of dust, chips and water.
Epoxy resin adhesive, in accordance with 909.11, shall be used to coat the existing
concrete surfaces. The epoxy coating shall be tacky at the time that the new concrete
is placed. If the epoxy coating has cured beyond the obvious tacky condition, it shall
be reapplied prior to placing the new concrete.
1000
After initial set of the concrete, the forms shall not be jarred and no strain shall be
placed on the ends of projecting reinforcement.

The external surface of all concrete shall be worked thoroughly, during placing,
by means of tools of an approved type. The working shall be such as to force all coarse
aggregate from the surface and to bring mortar against the forms to produce a smooth
finish substantially free from water and air pockets or honeycomb.

(b) Chutes and Troughs

1010 Concrete shall be placed so as to avoid segregation of the materials and the
displacement of the reinforcement. Where steep slopes are required, the chutes shall
be equipped with baffle boards or be in short lengths that reverse the direction of
movement. Open troughs and chutes shall extend as nearly as possible to the point of
deposit. Equipment made of or coated with aluminum alloys shall not be used to
transport concrete. Pumping of concrete shall be in accordance with 702.10. When the
discharge needs to be intermittent, a hopper or other device for regulating the discharge
shall be provided. Placement of supplementary bins or hoppers may be ordered above
the point where concrete is being deposited. The concrete shall be allowed to
accumulate in these containers in considerable quantity and shall be discharged
1020 immediately through pipes extending from the bottoms of these bins or hoppers. All
chutes, troughs, and pipes shall be kept clean and free from coatings of hardened
concrete. The water used for flushing shall be discharged clear of the concrete already
in place.

598
 702.20

Concrete shall not be dropped in the forms a distance of more than 5 ft except
when confined by closed chutes or pipes. Each part of the form shall be filled by
depositing the concrete as near final position as possible. The coarse aggregate shall
be worked back from the forms and worked around the reinforcement without
displacing the bars. After initial set of the concrete, the forms shall not be jarred and
1030 no strain shall be placed on the ends of projecting reinforcement.

(c) Vibrating
Unless otherwise directed, the concrete shall be compacted with mechanical
vibrators operating within the concrete. When required, vibrating shall be
supplemented by hand spading with suitable tools to ensure proper and adequate
compaction. Vibrators shall be of an approved type and design, adequately powered
and capable of transmitting 10,800 impulses per minute in air. The diameter of the
head of the vibrator shall be 1 1/4 to 2 1/2 in. Vibrators shall be manipulated so that
the concrete is thoroughly worked around the reinforcement and imbedded fixtures
1040 and into corners and angles of the forms. Vibrators shall not be used as a means to
cause concrete to flow or run into position in lieu of placing. The vibration at any point
shall be of sufficient duration to accomplish compaction but shall not be prolonged to
the point where segregation occurs. Vibrators shall not be attached to or allowed to
contact forms or reinforcement or to penetrate beyond any layer of fresh concrete.

(d) Depositing Concrete Under Water

No concrete except for foundation seals shall be deposited under water, without
written permission. If such permission is granted, care shall be exercised to prevent
the formation of laitance. Concrete shall not be deposited until any laitance, which
1050 may have formed on concrete previously placed, has been removed. Pumping shall be
discontinued while depositing foundation concrete if it results in a flow of water inside
the forms. If concrete, except for foundation seals, is deposited under water, the
proportion of cement used shall be increased at least 25% with no additional payment
to compensate for losses due to water. Concrete deposited under water shall be placed
in a compact mass in its final position by means of a tremie, a closed bottom dump
bucket, or other approved method and shall not be disturbed after being deposited.

A tremie shall consist of a tube having a diameter of no less than 10 in. and
constructed in sections having flanged couplings fitted with gaskets. Support of the
1060 tremie shall be such that it enables free movement of the discharge end over the entire
top surface of the area on which the concrete is to be deposited and also enables rapid
lowering when necessary to retard or stop the flow of the concrete. The discharge end
shall be kept closed until immediately prior to depositing in order to prevent water
entering the tube and shall be completely sealed except when concrete is actually being
deposited. The tremie tube shall be kept full to the bottom of the hopper. When a batch
is dumped into the hopper, the flow of concrete through the tube shall be started by
slightly raising the discharge end, but always keeping it in the previously deposited
concrete. The flow shall be continuous until all the required concrete is deposited.

599
 702.20

1070 (e) Placing Footing Concrete

Except as otherwise provided for a foundation seal, footing concrete shall not be
placed except when the cofferdam is dewatered and so maintained during placement.

If it is necessary to operate the pump while placing footing concrete, or

immediately thereafter, the seepage water shall be conducted to a sump at the pump
intake in such manner that it does not flow over the fresh concrete. Special care shall
be taken to prevent pumping cement out of the fresh concrete.

Footing concrete may be placed directly against sheet piling of the cofferdam
1080 when so shown on the plans or authorized in writing. Where class X excavation has
been extended beyond established neat lines of a footing, the bottom 12 in. of such
footing shall be poured to the actual limits of the excavation. When necessary, the
foundation material on which the footing is to rest shall be protected from freezing.
Where an existing structure is to be extended, the existing footings shall be protected
from damage. Damaged footings shall be repaired as directed with no additional
payment.

Piling, if any, shall be driven to or cut off at the proper elevation to enable
embedment in the footing concrete equal to that shown on the plans. All laitance or
1090 other unsatisfactory material shall be removed from the exposed surface of the
concrete in place by some means which does not injure the concrete. If a footing is to
be constructed on a foundation seal, it shall be to the dimensions shown on the plans
and, if necessary, the height of the shaft adjusted to bring the bridge seat to the required
elevation.

Placing concrete in footings shall start at one end of the footing and be continued
until the surface of the concrete is brought to the elevation of the top of the footing.
The concrete shall be allowed to work forward, displacing any water with as little help
as possible. The concrete shall not be dragged through or shoveled into water or
1100 deposited into running water. Placing concrete in more than a few inches of water shall
be done only with written permission.

(f) Concrete Foundation Seal

A foundation seal may be required by the plans, as requested, or as directed. When
required by the plans, the seal shall be constructed to the size shown, or as specified
in writing. Where adverse dewatering conditions are encountered as described in
206.09, a foundation seal may be required to be placed to such dimensions as are
necessary. If a foundation seal is requested, written permission shall be obtained before
starting such work. If approval is given, the seal shall be placed to designated
1110 dimensions.

Seals shall be of class A concrete having a slump of from 5 to 8 in., placed

continuously from start to finish, and in accordance with 702.20(d). To ensure
thorough bonding, each successive layer shall be placed before the preceding layer has
taken initial set. The cofferdam shall have been vented or ported at low-water level.

600
 702.22

The surface of the concrete shall be kept as nearly horizontal at all times as practicable.
The seal shall be of the thickness ordered. When the seal has hardened sufficiently to
withstand the hydrostatic pressure, the cofferdam shall be dewatered and the remainder
of the concrete poured in the dry.
1120
702.21 Finishing Concrete Surfaces
Unless otherwise authorized, the surface of the concrete shall be finished
immediately after form removal. Only the minimum amount of covering necessary to
allow finishing operations to be carried on shall be removed at one time. Subject to
approval, metal ties may be left in the concrete for the purpose of supporting or bracing
subsequent work. Such ties shall be in accordance with 702.13(b) and shall be of a
type which uses a cone and rod as both spreader and tie. Before final acceptance of the
work, the cones shall be removed and the cavities filled, in accordance with 702.13(b).

1130 All concrete surfaces shall be given a finish immediately following the removal
of any forms.

At the time of the removal of forms, the concrete surface shall be scraped to
remove all fins and irregular projections. The surface shall then be power ground to
smooth all joints and chamfers.

After grinding is completed, a paste of grout shall be applied to the concrete

surface with a sponge float to fill all air holes and small irregularities. The paste grout
shall be six parts of pre-mix mortar mix for masonry and one part white portland
1140 cement in accordance with ASTM C 150, type 1.

After the paste grout takes its initial set, the surface of the concrete shall be
scraped with a steel drywall knife to remove the paste from the surface.

The concrete surfaces of pier and bent caps, the front face of mudwalls, and any
other concrete surfaces specified shall be sealed. The material used for sealing shall
be in accordance with 709. It shall be applied so as to obtain a finished film thickness
of at least 10 mils. Mixing, surface preparation, and method of application shall be in
accordance with the manufacturer’s recommendations. However, the surfaces to be
1150 sealed shall be prepared in accordance with 709 prior to applying the sealer.

702.22 Curing Concrete

Concrete in bridge decks or the top surface of reinforced concrete slab bridges
shall be cured continuously 24 h per day for a minimum of 168 h commencing
immediately after the surface is able to support the protective covering without
deformation. Water curing in accordance with 702.22(a)1 shall be initiated within 60
minutes after the finishing machine completes the final strike off of any portion of the
concrete surface. Curing or other protective efforts which may include the use of
evaporative retardants shall begin sooner if adverse conditions exist. Adverse
1160 conditions include, but are not limited to, high winds, extreme temperatures or low
humidity. A work bridge shall be used following the finishing machine to facilitate the

601
 702.22

placement of curing materials, if necessary. Curing time for bridge decks and the top
surface of reinforced concrete slab bridges are not controlled by beam tests and the
cure time shall not be reduced. In addition to the minimum of 168 h cure period, curing
shall continue until a flexural strength of 550 psi has been attained. Curing of patches
or small full depth deck replacement areas on existing bridge decks that are to be
overlaid, may be controlled by test beams in accordance with 702.24(a).

Unless otherwise specified, all other concrete shall be cured continuously 24 h per
1170 day for at least 96 h commencing immediately after the surface is able to support the
protective covering without deformation. In addition to the required hours, curing shall
continue until the flexural strength stated in 702.13(h) and 702.24 has been attained.

Membrane forming curing compound may be used in lieu of protective covering

curing methods. Where it has been determined that a surface treatment is to be used,
the membrane forming curing compound shall not be used. Membrane forming curing
compound shall not be used on bridge decks nor on reinforced concrete slab bridges.

The curing of surfaces to be waterproofed may be discontinued when

1180 waterproofing is started.

If further precautions are necessary to ensure strength, they shall be taken as

directed.

(a) Protective Covering Curing Methods

1. Water Curing Method

Surfaces to be cured shall be protected and kept continuously and thoroughly wet
during the curing period. Curing shall consist of pre-wetted burlap underneath a layer
1190 of white plastic sheeting with a network of soaker hoses. Other wet curing systems
including engineered mats or blankets shall be submitted to the Engineer for approval
at least 14 days prior to use. Burlap shall be free of contamination and shall be prepared
by soaking in clean water for at least 2 h before beginning concrete placement. New
burlap shall be soaked at least 12 h prior to use. Immediately before use, the burlap
shall be draped or suspended vertically to remove excess water that may dilute or
damage plastic concrete. Soaker hoses shall be placed after the concrete is hard enough
to walk on without deformation. The protective covering shall be suitably anchored to
keep the protective materials in place during the curing period. Curbs, walls, handrails,
copings, and other surfaces requiring a finish in accordance with 702.21 may have the
1200 covering temporarily removed for finishing, but the covering shall be restored as soon
as possible.

2. Membrane Forming Curing Compound

All surfaces shall be given the required surface finish prior to application of the
curing compound. During the finishing period, the concrete shall be protected by the
water curing method.

602
 702.22

The curing compound shall be mixed thoroughly within 1 h before use. The rate
of application shall be as approved, with a minimum spreading rate per application of
1210 1 gal. of liquid coating for 150 sq ft of concrete surface. Curing compound shall be
applied to provide a uniform, solid, white opaque coverage on all surfaces, similar to
a white sheet of paper. All concrete cured by this method shall receive two applications
of the curing compound. The first coat shall be applied immediately after stripping of
forms and acceptance of the concrete finish. If the surface is dry, the concrete shall be
wetted with water and the curing compound applied just as the surface film of water
disappears. The second application shall be applied after the first application has set.
During curing operations all unsprayed surfaces shall be kept wet with water.

The coating shall be protected against marring for at least 10 days after
1220 application. All coatings marred or otherwise disturbed shall be given an additional
coating. If the surface coating is continuously subjected to injury, immediate
application of water curing may be required. If the use of a curing compound results
in a streaked or blotchy appearance, the method shall be stopped and water curing
applied until the cause of the defective appearance is corrected.

(b) Curing-Sealing Materials

Curing-sealing materials may be used in lieu of protective covering curing
methods when surface seal is required. These materials may only be used on concrete
surfaces that are not subjected to vehicular wear and that have been formed using the
1230 slip form method. Curing-sealing material shall not be applied to cast-in-place
concrete.

When curing-sealing materials are used for curing concrete, surface seal will not
be required.

The curing-sealing material shall be mixed in accordance with the manufacturer’s

instructions prior to application. The rate of application shall be as specified in the list
of approved Curing-Sealing Materials. All concrete cured-sealed by this method shall
receive two applications of the curing-sealing compound. The first coat shall be spray
1240 applied after the finished surface has been achieved. The second coat shall be applied
while the first coat is still tacky.

The use of curing-sealing material shall be discontinued if plastic shrinkage cracks

occur that cannot be corrected by decreasing the application rate. The concrete shall
then be cured and surface sealed in accordance with 702.22(a)1 and 709, respectively.

The coating shall be protected against damage after application. All coatings that
have been disturbed shall be given an additional coating. If the surface coating is
continuously subjected to injury, immediate application of curing in accordance with
1250 702.22(a)1 may be required. The concrete shall then be surface sealed in accordance
with 709.

603
 702.23

702.23 Waterproofing
The expansion joint shall be waterproofed on the following: the back surfaces of
retaining walls; the top surface of all slabs under fills; the extrados of arches; the inside
faces of spandrel walls; and abutments up to the finish grade line. The inside face of
spandrel walls and extrados of arches shall be waterproofed.

A firmly bonded membrane consisting of two layers of dry fabric and three
1260 applications of waterproofing material, shall be placed at all expansion joints set out
herein. One uncoated layer of fabric shall not touch another layer or the concrete at
any point. There shall be at least three complete and separate applications of the
waterproofing material. The application shall be sufficiently heavy to conceal the
weave in the fabric. Sufficient fabric shall be placed in V-strips at the joints to enable
the movement of adjacent sections of concrete without tearing the fabric. The
membrane shall be carefully flashed at all exposed edges and laps sealed down
thoroughly. Waterproofing shall be planned so that, at the close of work each day, all
fabric placed shall have received the final application of waterproofing material.

1270 Concrete surfaces to be waterproofed shall be reasonably smooth and free from
projections and holes. Immediately before the application, the surface shall be cleaned
of dust and loose materials. Waterproofing shall be done only when the surface is at
least dry enough to prevent the formation of steam when the hot material is applied.
When the air temperature is below 35°F, waterproofing shall not be done, unless
otherwise specified.

The material shall be applied so as to cover the area completely. If necessary,

more than one coat shall be applied in order to secure a satisfactory coating and proper
adhesion. Coating and fabric shall stop a uniform distance below the top surfaces of
1280 walls. The material shall not be splattered over surfaces or faces of concrete which
subsequently are exposed in the finished structure. Utility asphalt for waterproofing
shall be heated to a temperature of between 300°F and 350°F. The material shall be
stirred frequently to prevent local overheating. The waterproofing material shall not
be damaged when backfill is placed against a waterproofed joint.

702.24 Application of Loads to and Acceptance of New Concrete

Except as otherwise hereinafter provided, application of loads to new concrete
shall be in accordance with the following:

1290 (a) Equipment or traffic will not be allowed on structures until test
beams representing all concrete required to carry live loads have
attained a flexural strength of 550 psi for third-point loading.

(b) Unbalanced backfill will not be allowed until test beams

representing the concrete required to resist it have attained a
flexural strength of 440 psi for third-point loading. The
unbalanced height shall not exceed 10 ft until test beams

604
 702.25

representing the concrete have attained a flexural strength of

480 psi for third-point loading.
1300
(c) The dead weight of steel or precast concrete superstructure shall
not be placed on concrete until test beams representing the
concrete have attained a flexural strength of 400 psi for third-
point loading. A dead load shall not be placed on hammer-head
piers until test beams representing have attained a flexural
strength of at least 480 psi for third-point loading. The concrete
floor, if to be placed thereon, shall not be poured until test
beams representing the concrete supporting the superstructure
have attained a flexural strength of at least 440 psi for third-
1310 point loading.

(d) Test beams representing concrete anchoring inserts to support

falsework shall attain a flexural strength of a minimum of 480
psi for third-point loading, before a dead load of concrete is
applied.

No time extension will be considered for delays due to time necessary to attain
specified strengths.

1320 Beams will be prepared and tested in accordance with 702.13(h). Before traffic is
allowed over a concrete structure built to be under fill, it shall be covered with 9 in. or
more of earth or other suitable material, or otherwise protected. All other structures
shall be properly protected against impact or other damage.

When compressive strength is used as a basis for acceptance of concrete, for

determining when a latex modified concrete overlaid bridge deck may be opened to
traffic, for determining form removal time, or for determining when a structure may
be put into service, standard specimens shall be made and cured in accordance with
ASTM C 31, and shall be tested in accordance with ASTM C 39. Strength
1330 requirements shall be in accordance with ASTM C 94, with the exception as follows:
the strength shall be the average of the strengths of all cylinders tested at the age
specified, with a minimum of two cylinders. This average shall be equal to or greater
than the required strength. If the compressive strength of one or more cylinders in a
strength test is below 75% of the required strength, the entire test will be considered
as failed.

Failure to meet the strength requirements will be cause for rejection of the quantity
of concrete represented by the cylinders. All molds, facilities, and materials necessary
to prepare and cure the specimens shall be furnished with no additional payment.
1340
702.25 Field Drilled Holes in Concrete
This work shall consist of field drilling holes of the diameter and length shown on
the plans or as directed.

605
 702.26

When vertical holes are to be drilled into the top of a concrete bridge deck, a
minimum clearance of 2 in. shall be maintained between the bottoms of holes and
bottom of slab. When vertical holes are to be drilled over a steel beam flange, the holes
may be extended to the top of the beam flange. When vertical holes are to be drilled
over a concrete I-beam, concrete box beam, concrete bulb-T beam, or concrete girder,
1350 the depths of the holes shall be as shown on the plans. If breakout occurs on the bottom
of slab during the drilling process, the work shall be stopped, the breakout shall be
repaired as directed, and an approved alternate drilling method shall be used to prevent
breakout.

When grouted holes are specified, the diameter and length of the holes shall be in
accordance with the grout manufacturer’s recommendations.

702.26 Artificial Lighting

No portion of the work which cannot be finished during daylight hours shall be
1360 started unless written permission to the contrary is given, in which case adequate
lighting shall be provided and maintained.

702.27 Method of Measurement

Concrete will be measured by the cubic yard in accordance with the neat lines
shown on the plans or as directed. No deductions will be made for the volume of joint
material, embedded reinforcement, encased piles, or for a pipe with an area of less
than 1 sq ft.

Cast iron grates, basins, and fittings will be measured by the number of complete
1370 assemblies installed. Drainage pipe through concrete masonry will be measured in
accordance with 715. Field drilled holes will be measured by the number of holes
drilled.

Concrete in railings will be measured in accordance with 706.07. Reinforcing bars

will be measured in accordance with 703.07.

702.28 Basis of Payment

The accepted quantities of structural concrete will be paid for at the contract unit
price per cubic yard of concrete, for the class and use specified. Cast iron grates,
1380 basins, and fittings will be paid for at the contract unit price per each assembly,
complete in place. Steel drain pipe will be paid for at the contract lump sum price.
Field drilled holes in concrete will be paid for at the contract unit price per each.

Concrete in railings will be paid for in accordance with 706.08. Reinforcing bars
will be paid for in accordance with 703.08. Drainage pipe through concrete masonry
will be paid for in accordance with 715.

If a foundation seal is constructed as shown on the plans, it will be paid for at the
contract price per cubic yard for concrete, foundation seal. If ordered to be done, or

606
 702.28

1390 allowed to be done, payment will be made at a unit price per cubic yard equal to 75%
of the contract unit price per cubic yard for class B concrete in footings. The
excavation for the foundation seal will be paid for at the contract unit price per cubic
yard for the class of excavation specified for the footing. Unless otherwise provided,
the pay quantity for excavation for foundation seal will be equal to the theoretical
volume bounded by the bottom of the proposed footing, the bottom of the approved
excavation, and vertical planes 18 in. outside the neat line of the footing and parallel
thereto, regardless of the quantity actually removed. If design of the structure requires
sheeting to be outside these limits, the limits will be extended to 6 in. beyond the neat
lines required by the design of the structure. If the Contractor chooses to construct a
1400 rectangular cofferdam around a U-shaped abutment in lieu of following the outline of
the footing, the maximum allowable increase in the pay quantity above the theoretical
shall not exceed 25%. The pay quantity for the foundation seal will be equal to the
excavation volume described above.

Payment will be made under:

Pay Item Pay Unit Symbol

Concrete, A, Substructure.......................................................... CYS

1410 Concrete, A, Superstructure....................................................... CYS
Concrete, B, Above Footings .................................................... CYS
Concrete, B, Footings ................................................................ CYS
Concrete, C, ____ ...................................................................... CYS
use
Concrete, Foundation Seal......................................................... CYS
Field Drilled Hole in Concrete .................................................. EACH
Grates, Basins, and Fittings, Cast Iron ...................................... EACH

The cost of forms, PVC for bridge floor drains, falsework, falsework piling,
1420 centering, expansion joints, waterproofing, curing, finishing, and necessary incidentals
shall be included in the cost of the pay items. The cost of placing epoxy resin adhesive
on existing concrete surfaces shall be included in the cost of new concrete which abuts
the existing concrete. Payment for concrete used in footings in class X excavation will
be made at the contract unit price only for the cubic yards placed within the neat lines
of the footings as shown on the plans or as revised.

If the Contractor elects to increase the cement content as allowed herein, no

additional compensation will be made.

1430 The cost of permanent metal forms shall be included in the cost of concrete, C,
superstructure. The pay quantity of concrete in the slab will be computed from the
dimensions shown on the plans, with no allowance for form deflection or geometry.

Elastomeric bearings will not be paid for directly, unless otherwise specified. The
cost thereof shall be included in the cost of the structural member they support. The

607
 703.01

cost of protecting existing footings to be extended shall be included in the cost of

concrete, B, footings, unless otherwise specified.

The cost of grout for grouting reinforcing bars in place, the length of grouted hole
1440 recommended by the grout manufacturer in excess of the length shown on the plans,
and the additional length of reinforcing bars required shall be included in the cost of
field drilled hole in concrete.

The cost of furnishing and installing polychloroprene sheeting shall be included

in the cost of concrete, A, substructure.

The cost of high density plastic bearing strips shall be included in the cost of
concrete, A, substructure.

SECTION 703 – REINFORCING BARS

703.01 Description
This work shall consist of furnishing and placing reinforcing bars and threaded tie
bar assemblies with reinforcing bars in accordance with 105.03.

703.02 Materials
Materials shall be in accordance with the following:

10 Reinforcing Bars, Plain or Epoxy Coated.................... 910.01

Reinforcing Bar Splicing System ................................ 910.01(b)3
Support Devices .......................................................... 910.01(b)9
Threaded Tie Bar Assembly ........................................ 910.01(b)2

The sizes and lengths of reinforcing bars shall be marked plainly to facilitate
inspection and checking.

703.03 Bar List

The Contractor shall verify the quantity and size of reinforcing bars against the
20 structure drawings prior to ordering. Errors in the bar list and bending schedule will
not be cause for adjustment of the contract unit price.

703.04 Protection of Materials

Plain and epoxy coated reinforcing bars shall be protected from damage during
storage, handling, installation and concrete placement. Plain and epoxy coated
reinforcing bars shall not be stored in direct contact with the ground. Epoxy coated
reinforcing bars shall be protected from exposure to ultraviolet light and moisture
during storage. Once placed into the work, epoxy coated reinforcing bars shall not be
exposed to ultraviolet light for a total of more than 21 days prior to placement of
30 concrete. At the time of concrete placement, reinforcing bars shall be free of dirt, loose
rust or scale, grease, oil, or other foreign substance. If the Engineer suspects the epoxy

608
 703.06

coating has been damaged by exposure to ultraviolet light, a sample will be obtained
and will be tested in accordance with 910.01(b)9.

Damage to the epoxy coating of epoxy coated reinforcing bars shall be repaired
or the bars shall be replaced. Repairs to the epoxy coating shall be performed on all
damaged areas larger than 1/4 by 1/4 in. A bar will be rejected if the accumulated area
of damaged coating exceeds 2% of the nominal surface area of the bar or if the total
area of repaired coating exceeds 5% of the nominal surface area of the bar. All
40 damaged areas shall be cleaned and the repair shall be performed before visible
oxidation appears. Coating repair material shall be in accordance with 910.01(b)9.

CONSTRUCTION REQUIREMENTS

703.05 Bending
Reinforcing bars required to be bent shall be accurately cold bent in a bending
machine to the shapes shown on the plans. All bars in which cracks or splits occur at
bends will be rejected.

50 703.06 Placing and Fastening

Reinforcing bars shall not be ordered for piers or bents to be founded on soil or
rock until the foundation conditions have been investigated. The bottom elevations of
such footings will then be determined. Written permission will then be given to order
such reinforcing bars. Sufficient excavation and all necessary soundings shall be made
as directed so that exact bottom elevations of footings may be determined.

All dimensions shown on the plans for spacing of reinforcing bars apply to centers
of bars unless otherwise noted. All bars shall be accurately placed and, during placing
of the concrete, held firmly in the position as shown on the plans. Distances from the
60 forms shall be maintained by means of chairs, ties, hangers, or other approved support
devices. All reinforcing bars shall be wired rigidly or fastened securely at sufficient
intervals to hold the bars in place. Chairs and supports holding upper layers of
reinforcing bars shall support the transverse bars. The upper layer of reinforcing bars
in bridge floors shall be tied or fastened at such intervals as necessary to prevent an
upward or a lateral movement of a bar from the planned position.

Layers of reinforcing bars shall be separated by spacers. Reinforcing bars shall be

separated from horizontal surfaces by being suspended or supported on approved
chairs and spacers capable of supporting the designed loads. Supports and spacers shall
70 be of such shape as to be easily encased in concrete. That portion which is in contact
with the forms shall be non-corrosive and non-staining material. They shall be of an
approved type. Vertical stirrups shall always pass around main tension members and
shall be securely attached thereto. The use of pebbles, pieces of broken stone or bricks,
metal pipe, wooden blocks, and similar devices for holding bars in position will not be
allowed.

609
 703.07

After being placed, reinforcing bars will be inspected and approved before the
concrete is deposited. The positions of the reinforcing bars shall not be disturbed both
during and after depositing the concrete. All concrete placed in violation of this
80 requirement may be rejected and its removal will be required. Where reinforcing bars
project from construction joints, all mortar clinging to the reinforcing bars from
previous pours shall be removed before the next enveloping pour is made.

All reinforcing bars shall be furnished in the full lengths shown on the plans unless
splices are indicated. No other splicing will be allowed except with written permission.
Unless otherwise shown on the plans, reinforcing bars shall be lapped 32 diameters to
make a splice. Construction joints shall not be made within the limits of lapped bars.
For lapped splices, reinforcing bars shall be placed in contact and rigidly clamped or
wired in an approved manner. Insofar as possible, splices shall be staggered and well
90 distributed or located at points of low tensile stress. Splices will not be allowed at
points where the section does not provide a distance of at least 2 in. between the splice
and the nearest adjacent bar or surface of the concrete.

When splicing is indicated or allowed, an appropriate splice system on the list of

approved Reinforcing Bar Splicing Systems may be used in lieu of lapped bars. The
splicing system shall be installed in accordance with the manufacturer’s
recommendations. If an offset splicing system is selected, it shall only be used on
spiral, hoop, or ring-type reinforcement.

100 WWR, when required, shall be placed as shown on the plans or as otherwise
directed. The sheets shall overlap sufficiently to maintain uniform strength and shall
be securely fastened at lapped ends and edges. The laps shall be no less than one mesh
in width.

Spiral reinforcement, consisting of evenly spaced continuous spirals, shall be held

firmly in place by attachment to vertical reinforcement. The spirals shall be held true
to line by vertical spacers. Anchorage for spiral reinforcement shall be provided with
1 1/2 extra turns of the spiral rod or wire at each end of the spiral unit. Splices in spiral
rods or wire shall be made with a lap of 1 1/2 turns.
110
Threaded tie bar assemblies may be used in lieu of spliced reinforcing bars shown
on the plans. Threaded tie bar assemblies shall achieve the minimum strength in
accordance with 910.01(b)2. The Contractor shall coat any exposed part of threaded
bar assemblies in accordance with 910.01(b)2.

703.07 Method of Measurement

Reinforcing bars will be measured by the pound based on the theoretical number
of pounds complete in place as shown on the plans or placed as ordered. The quantities
of materials furnished and placed shall be based upon the calculated weights of the
120 reinforcing bars actually placed in accordance with these specifications. The weights
calculated shall be based upon the following table:

610
 703.08

Bar Designation Weight per linear Bar Designation Weight per linear
No. foot, pounds No. foot, pounds
1/4 in. 0.167 8 2.670
3 0.376 9 3.400
4 0.668 10 4.303
5 1.043 11 5.313
6 1.502 14 7.65
7 2.044 18 13.60

Threaded tie bar assemblies will be measured by the number of assemblies placed.

WWR will not be measured.

703.08 Basis of Payment

The accepted quantities of reinforcing bars will be paid for at the contract price
130 per pound, complete in place.

If the substitution of reinforcing bars larger than those specified is allowed,

payment will be made for only that weight which would be required if the specified
bars had been used.

If the use of reinforcing bar lengths shorter than those shown on the plans is
allowed for convenience in transporting or placing the bars, payment will be based on
the weight of the lengths shown on the plans.

140 Payment for threaded tie bar assemblies will be at the contract unit price per each,
complete in place, If epoxy coating is specified, payment for the assemblies will be at
the contract unit price per each for threaded tie bar assembly, epoxy coated.

Payment will be made under:

Pay Item Pay Unit Symbol

Reinforcing Bars........................................................................ LBS

Reinforcing Bars, Epoxy Coated ............................................... LBS
150 Threaded Tie Bar Assembly ...................................................... EACH
Threaded Tie Bar Assembly, Epoxy Coated ............................. EACH

The cost of metal chairs, spacers, clips, wire, or other mechanical means used for
fastening or holding reinforcement in place, and laps shall be included in the cost of
reinforcing bars. The cost of coating materials and repair of damaged or removed
coating materials on reinforcing bars and on metal chairs, spacers, clips, or other
mechanical means used for fastening or holding reinforcement in place, and laps shall
be included in the cost of epoxy coated reinforcing bars. If threaded tie bar assemblies
are used in lieu of spliced reinforcing bars as shown on the plans, the cost of such
160 assemblies shall be included in the cost of reinforcing bars.

611
 704.01

If WWR is required, the cost of furnishing and placing it shall be included in the
cost of the concrete in which it is placed.

SECTION 704 – CONCRETE FLOOR SLABS

704.01 Description
This work shall consist of placing cement concrete and reinforcing bars as a bridge
floor in accordance with 105.03.

704.02 Materials
Materials shall be in accordance with the following:

10 Castings ....................................................................... 910.05

Concrete, Class C ........................................................ 702
Joint Materials ............................................................. 906
Profile Wall PVC Pipe................................................. 907.22
Reinforcing Bars.......................................................... 910.01
Smooth Wall PVC Pipe ............................................... 907.23

CONSTRUCTION REQUIREMENTS

704.03 Forms
20 Forms shall be in accordance with 702.13.

The forms for transverse and longitudinal construction joints shall have a top plate
conforming to either or both the grade and crown shown on the plans or as established.
When forms are unsatisfactory in any way, either before or during placing of concrete,
the placing shall be suspended until defects are corrected.

The welding of angles, clips, rods, or other designs for form supports to the
flanges of steel beams or girders in the areas where flanges are designed to carry tensile
stress will not be allowed. The areas where welding will be allowed will be established
30 in writing.

704.04 Placing Reinforcement and Concrete

Applicable provisions of 703 shall apply to placing reinforcing bars. No concrete
shall be placed until the reinforcement is entirely and securely in place and has been
inspected and approved. Walkways shall be in accordance with 702.20(a). Placing of
reinforcement during placing of concrete will not be allowed without prior written
approval. Splices, when allowed, shall be at locations of least tension in the steel.

The concrete deck pour sequence and procedure shall be submitted for approval
40 a minimum of 14 days prior to the planned deck pour. The submittal shall include the
following information:

612
 704.05

(a) the contract number;

(b) the Contractor’s name;
(c) the bridge file number;
(d) the Contractor’s proposed pour sequence;
(e) the Contractor’ proposed pour rate;
(f) the approved concrete mix design; and
(g) the delivery time from the concrete batching location to the jobsite.
50
Bridge approaches shall not be poured continuous with deck pours.

If, during the pour, the approved pour rate is not achieved, placement of transverse
construction joints may be directed as shown on the plans. Placement of concrete shall
be continuous between joints. Horizontal joints will not be allowed.

Floor drains shall be placed in gutters at locations shown on the plans and fastened
securely before placing the surrounding concrete. The tops of the floor drains shall be
no more than 1/2 in. below the adjacent gutter grade. The drains shall be constructed
60 so drainage water is not discharged against portions of the structure.

Expansion joints shall be constructed as shown on the plans and the material shall
be in accordance with 906.01.

704.05 Finishing Concrete

Concrete shall be placed and spread to the approximate contour for the full width
being placed. The concrete may then be consolidated by the use of mechanical internal
vibrators in accordance with applicable provisions of 702.20(c). Vibrators shall not be
used to spread or move the concrete horizontally to the extent that they cause
70 segregation. Excessive vibration shall be avoided.

The use of a self-propelled finishing machine shall be used on all structures when
either a new floor or an overlay is placed. Concrete for the full width of all traffic lanes
shall then be struck off to proper profile grade and cross section by an approved, self-
propelled, oscillating, finishing machine. The finishing machine may be for traffic lane
widths or full width of the structure when approved. Manually operated strike-off may
be used on areas outside of the width of traffic lanes or where required construction
joints limit the length of deck pours to 60 ft or less.

80 The finishing machine shall be in accordance with the applicable requirements of

508.04(b) except it shall have a minimum of one reciprocating non-vibrating screed.
The weight of the machine shall not cause undue deflection of the bridge members or
falsework. The machine shall travel on steel rails, pipe, or other approved grade
control, which shall be adequately supported by adjustable support securely fastened
in place at spacing sufficiently close to prevent any appreciable deflection of the
screed. Welding of supports to structural bridge members will not be allowed. Prior to
the placing of concrete, rails for the machine support shall be set to correct elevations

613
 704.05

shown on the plans or as approved. Rails shall extend a sufficient distance beyond the
area to be placed so that the machine clears all finishing operations. The screed or
90 strike-off beam shall be made of metal or the bottom shall be metal-clad. The bottom
of the screed or strike-off shall be adjusted to the true cross section of the floor surface.
The machine shall make only the number of passes over the slab as required to obtain
a uniform surface free of voids and reasonably true to the planned profiles and cross
section. Any necessary hand finishing after removing the rails and rail supports shall
be accomplished promptly, in order to fill any depressions and remove any roughness
of the surface in the area from which the supports are removed. The longitudinal
mechanical screeding method may be used when approved. A mechanical bridge deck
finishing machine using a rotating cylinder setting approximately parallel to the
longitudinal movement of the machine and operating transversely may be used for
100 screeding the bridge deck, when approved.

When a finishing machine is not required or used, as soon as the concrete is placed
and consolidated it shall be struck-off to the specified cross section and grade by means
of a steel template or other satisfactory metal clad implement having a minimum width
of 9 in. or greater.

For all methods of striking off the surface, an excess of concrete shall be kept in
front of the cutting edge at all times. The strike-off shall go over the entire area only
for the number of times necessary to produce the required profile and cross section. In
110 general, the strike-off process shall be in accordance with 508.04 except a vibrator on
the strike-off will not be required.

Immediately after screeding to the required cross section, the surface shall be
checked with a long handled 10 ft straightedge of light construction laid parallel to the
centerline at intervals of no more than 2 ft transversely and 5 ft longitudinally. In case
it is impracticable to operate the straightedge otherwise, it shall be operated from a
footbridge or from bridges on the floor. All high spots shall be removed and
depressions filled with fresh concrete and then leveled with a float having a blade
approximately 5 ft long and 8 in. wide. Floating and manipulating concrete to fill
120 depressions shall be held to a minimum. Checking and leveling shall continue until the
surface has the required contour and is free of voids. The application of water to the
surface for the purpose of lubricating the floats and straight edges may be used only
when absolutely necessary and shall be held to a minimum. The water applied for this
purpose shall be limited to such quantity as may be applied by heavy fogging as
approved.

As soon as the water begins to leave, the surface shall be given a final check with
the lightweight straightedge. The required cross section shall be preserved. The final
surface shall be free from porous spots caused by the disturbance of coarse aggregate
130 particles during the final checking and brooming. After final checking, the surface
shall be tined in accordance with 504.03. If a new bridge deck is to be overlaid with
latex modified concrete, the surface of such deck shall be heavily broom textured to
provide maximum bonding of the overlay material.

614
 704.08

Just before the concrete has taken the initial set, the ends of slabs, exposed edges,
and transverse construction joints shall be rounded to a 1/4 in. radius. Longitudinal
construction joints shall not be edged unless otherwise directed.

Smoothness shall be in accordance with 502.20. If, after the above requirements
140 have been met, portions of the floor are not entirely satisfactory, the removal and
replacement of such portions may be ordered to secure a satisfactory floor. Such
removal and replacement shall be done with no additional payment.

704.06 Curing
Floor slabs shall be cured in accordance with 702.22(a)1. Where it has been
determined that a surface treatment to prevent scaling is to be used, the Engineer may
prohibit the use of the membrane forming curing compound on any part of the
superstructure. All vertical surfaces with exposed reinforcement shall be cured in
accordance with 702.22. The floor shall be protected from pedestrian and vehicular
150 traffic. If walking is necessary, the surface shall be timber laid on a double burlap
cushion or approved equivalent.

Opening to traffic shall be in accordance with the applicable provisions of 702.24.

704.07 Method of Measurement

Concrete floor slab will be measured by the cubic yard in accordance with 702.27.
However, no allowance will be made for variations in beam fillet depths, coping
depths, or diaphragm depths, which are deemed necessary due to the beam camber, as
constructed, which varies from that shown on the plans. Reinforcing bars will be
160 measured in accordance with 703.07. Castings will be measured in accordance with
702.27.

704.08 Basis of Payment

The accepted quantities of concrete floor slab will be paid for at the contract unit
price per cubic yard for concrete, C, superstructure. Reinforcing bars will be paid for
in accordance with 703.08. Castings will be paid for in accordance with 702.28.

Payment will be made under:

170 Pay Item Pay Unit Symbol

Concrete, C, Superstructure ....................................................... CYS

The cost of forms, curing, finishing, preformed expansion joints within structure
limits, slab bridge floor drains, and necessary incidentals shall be included in the cost
of the pay items.

615
 705.01

SECTION 705 – SIDEWALKS ON STRUCTURES

705.01 Description
This work shall consist of placing cement concrete sidewalks as an integral part
of structures and reinforced concrete bridge approaches in accordance with 105.03.

705.02 Materials
Materials shall be in accordance with the following:

10 Concrete, Class C ........................................................ 702

Joint Filler ................................................................... 906.01
Reinforcing Bars.......................................................... 910.01

705.03 Construction Requirements

The concrete shall be placed in the forms in such amount that, after being tamped
and struck off, the full required thickness results. Reinforcing bars shall be in
accordance with 703.

After floating, the surface shall be marked into uniform rectangles by transverse
20 markings formed with a jointer having 1/4 in. radii, if shown on the plans. On
cantilevered sidewalks, a marking shall be placed over the center of each bracket and
the space between brackets divided into uniformly marked rectangles as directed.

At expansion joints, the sidewalk and curb shall be cut entirely through and the
specified type of joint installed. All edges shall be finished to a 1/4 in. radius.

As soon as finished, the sidewalk shall be cured for no less than 96 h in accordance
with 704.06.

30 The surface shall be checked with a 10 ft straightedge placed parallel to the

centerline at sufficient transverse intervals to check the general contour. An acceptable
surface shall vary no more than 1/8 in. from the straightedge, except at grade changes,
and shall be free from blemishes.

705.04 Method of Measurement

Sidewalks on structures and reinforced concrete bridge approaches will be
measured by the cubic yard in accordance with the dimensions shown on the plans or
as ordered. Reinforcing bars will be measured by the pound in accordance with 703.07.

40 705.05 Basis of Payment

The accepted quantities of sidewalks on structures and reinforced concrete bridge
approaches will be paid for at the contract unit price per cubic yard for concrete, C,
superstructure. Reinforcing bars will be paid for at the contract unit price per pound in
accordance with 703.08.

Payment will be made under:

616
 706.03

Pay Item Pay Unit Symbol

50 Concrete, C, Superstructure ....................................................... CYS

SECTION 706 – BRIDGE RAILINGS

706.01 Description
This work shall consist of the furnishing and placing of concrete or steel railings
on bridges, atop or aside of wingwalls and retaining walls, furnishing and placing
bridge railing pedestrian fences on new existing bridge railings, and furnishing and
placing reinforced concrete moment slabs in accordance with 105.03.

706.02 Materials
10 Materials shall be in accordance with the following:

Barrier Delineators ...................................................... 926.02(c)

Bridge Railing Pedestrian Fence ................................. 910.18(b)5
Coarse Aggregate, Class B or Higher,
Size No. 8 or 9 ...................................................... 904
Concrete, Class C ........................................................ 702
Dowel Bars .................................................................. 910.01(b)10
Joint Materials ............................................................. 906
Organic Zinc Primer .................................................... 909.02(a)2
20 Polyurethane Finish Coat ............................................ 909.02(c)
Reinforcing Bars, Epoxy Coated ................................. 910.01
Steel Bridge Railing Components ............................... 910.20

Concrete for reinforced concrete moment slabs shall be QC/QA PCCP in

accordance with 501 or PCCP in accordance with 502.

Thrie-beam railing and guardrail elements for retrofit bridge railing shall be steel
and shall be in accordance with the applicable requirements of 910.09 and 910.11 for
steel beam guardrail.
30
CONSTRUCTION REQUIREMENTS

706.03 Concrete Railing

Concrete railings shall not be placed until the falsework for all of the spans have
been removed and the spans are self supporting. Concrete railings shall be constructed
in accordance with 702 and 703.

Forms shall be smooth, tight fitting, held true to line and grade, and be removed
without damaging the concrete. These forms shall be made from selected dressed
40 lumber or steel. Moldings, panel work, and bevel strips shall be constructed according

617
 706.04

to the detail plans with mitered joints, true corners and be sharp, clean-cut, and free
from cracks, spalls, or other defects. The forms shall be constructed with a plate at the
base of the copings. Lumber which is 2 in. thick shall be used for coping forms.

Concrete bridge railing shall be built monolithically and continuous from support
to support. A joint shall be provided at the end of the bridge between the bridge railing
and the railing transition as shown on the plans.

Unless otherwise specified the slip form method may be used as a means to place
50 concrete railing on bridge structures. If the slip form method is chosen, a signed and
dated QCP shall be prepared and submitted to the Engineer for acceptance at least 15
days prior to the start of slip form barrier rail placement. The QCP shall include, as a
minimum, the Contractor’s concrete mix design, including materials sources and
admixtures; the Contractor’s methods of materials control and testing; the Contractor’s
proposed method of placement, including finishing and curing; and the corrective
action that will be taken when defects are found. The QCP shall also contain
documentation that shows the Contractor had a successful trial demonstration of the
slip form machine previously and that proper consolidation around the reinforcing bars
in the wall was achieved. The slip form paver shall consolidate, screed, and finish the
60 freshly placed concrete in one complete pass in such a manner that a minimum of hand
finishing will be necessary to provide a dense and homogeneous railing in
conformance with the plans and specifications. The requirement to include a water–
reducing admixture in accordance with 702.05 will be waived if the railing is both
slipformed and the concrete contains silica fume in accordance with 709.05(e). The
slump shall be 1 3/4 in. ±3/4 in. The joints may be formed or sawed as long as a
satisfactory joint is attained. If joints are to be sawed, the full depth saw cut shall be
made before uncontrolled shrinkage cracking occurs and within 48 h of concrete
placement. Before full depth sawing, partial depth saw cuts of 2 1/2 in. ±1/2 in. at the
joint locations may be made as soon as the concrete has hardened sufficiently to enable
70 sawing without raveling. All saw cuts shall be made at the locations shown on the
plans or as directed.

All concrete bridge railings shall be reflectorized in accordance with 602.03(f).

Posts and joints shall be constructed perpendicular to grade. The line and grade
shall not follow any unevenness of the superstructure.

If concrete railing is not in compliance with the specified design, does not present
a uniform appearance of smoothness or color, or is not otherwise a workmanlike job,
80 the Engineer may require such railing to be removed and replaced. The surface of the
concrete shall vary no more than 1/4 in. in 10 ft from the specified cross section, as
measured longitudinally.

706.04 Concrete Railing With Reinforced Concrete Moment Slab

The railing portion shall be constructed in accordance with 602.03 except it shall
be cast-in-place. Type D-1 contraction joints in the moment slab shall match the

618
 706.07

locations of the joints in the abutting PCC pavement. If the abutting pavement is HMA,
the D-1 contraction joints shall be spaced at 18 ft. The locations of the transverse joints
in the moment slab and the railing shall be the same.
90
Moment slabs shall be formed with either steel or wood forms in accordance with
508.04(c)1 or 508.04(c)2. Vibration of the concrete shall be in accordance with
702.20(c). The thickness of the moment slab shall match that of the adjoining PCCP,
but it shall not be less than 12 in.

The underdrains for MSE walls layer shall be compacted in accordance with
302.06(b). The MSE-wall coping may be precast or cast-in-place.

Type D-1 contraction joints and dowel bar assemblies shall be in accordance with
100 503.

Finishing and curing the moment slab shall be in accordance with 504. Finishing
and curing the railing shall be in accordance with 702.

Job control testing for acceptance shall be in accordance with 502.05.

706.05 Steel Railings

Fabrication and placement of steel railings shall be completed in accordance with
the applicable requirements of 711. Ends of tube sections shall be milled or sawed.
110 Cut ends shall be true, smooth, and free from burrs and ragged edges. The rail system
shall be continuous except as shown on the plans. Joints shall be spliced as detailed on
the plans. Welding of steel shall be in accordance with 711.32. Radiographic, magnetic
particle, and dye penetrant inspection will not be required. Anchor bolts shall be pre-
set in concrete.

706.06 Bridge Railing Pedestrian Fence

Posts shall be installed plumb. They may be shimmed with an approved metallic
shim. Base plate anchor bolts shall be galvanized, positioned as shown on the plans,
and shall be anchored by means of epoxy adhesive.
120
The fabric shall be connected to the tension bar with brace bands and tension
bands as shown on the plans.

The top and bottom fabric selvedges shall be knuckled. If the coating is damaged
during handling or placement, such portion of the fabric shall be replaced.

706.07 Method of Measurement

Concrete railing, including all concrete work above the top of curb, will be
measured by the linear foot or by the cubic yard in accordance with the dimensions
130 shown on the plans. No deductions will be made for reinforcing bars or joints.
Concrete bridge railing transition will be measured per each for the type specified.

619
 706.08

Bridge railing pedestrian fence will be measured by the linear foot along the
bottom of the fence, from center to center of end posts.

Reinforced concrete moment slabs will be measured by the square yard for the
thickness specified. Underdrains for MSE walls placed under moment slabs will be
measured in accordance with 718.09. Type D-1 contraction joints will be measured in
accordance with 503.07.
140
Reinforcing bars in the railing will be measured in accordance with 703.07.

Barrier delineators will be measured in accordance with 602.05.

Steel railing will be measured by the linear foot in accordance with the dimensions
shown on the plans or as directed.

Linear measurements will be made from end to end of the railing along the
centerline.
150
706.08 Basis of Payment
The accepted quantities of concrete railing will be paid for at the contract price
per linear foot or cubic yard, for railing, concrete, of the type specified. Steel railing
will be paid for at the contract unit price per linear foot of the type specified. Concrete
bridge railing transitions will be paid for at the contract unit price per each for the type
specified. Bridge railing pedestrian fence will be paid for at the contract unit price per
linear foot. Reinforced concrete moment slabs will be paid for at the contract unit price
per square yard for the thickness specified, complete in place. Underdrains for MSE
walls placed under moment slabs will be paid for in accordance with 718.10. Type D-
160 1 contraction joints will be paid for in accordance with 503.08. Reinforcing bars for
concrete railings and concrete bridge railing transitions will be paid for in accordance
with 703.08. Barrier delineator will be paid for in accordance with 602.06.

Payment will be made under:

Pay Item Pay Unit Symbol

Bridge Railing Pedestrian Fence ............................................... LFT

Concrete Bridge Railing Transition, ____ ................................. EACH
170 type
Railing, Concrete ____ .............................................................. LFT
type CYS
Railing, Steel ____ .................................................................... LFT
type
Reinforced Concrete Moment Slab, ____ ................................. SYS
thickness

620
 707.02

The cost of painting, washers, rivets, welding, anchor bolts, and necessary
incidentals shall be included in the cost of the pay items in this section.
180
The cost of all miscellaneous hardware including anchor bolts, base plates, fence
post caps, horizontal rail end cups, fence post loop caps, tension bars, tension bands,
brace bands, and fabric ties, and replacement fence due to damaging coating during
handling or placement shall be included in the cost of bridge railing pedestrian fence.

The cost of the epoxy coated reinforcing bars and tie bars in the moment slab shall
be included in the cost of the reinforced concrete moment slab.

The cost of all labor and materials required to provide for the monolithic concrete
190 coping with moment slabs shall be included in the cost of the moment slab.

The cost of furnishing and placing all materials not specified as pay items shall
be included in the cost of the pay items in this section.

SECTION 707 – PRECAST AND PRECAST PRESTRESSED CONCRETE

STRUCTURAL MEMBERS

707.01 Description
This work shall consist of fabricating, furnishing, and installing reinforced precast
concrete structural members cast outside the structure, transported to, and incorporated
into the structure, or precast prestressed concrete structural members having a design
28-day concrete compressive strength, f’c, of up to and including 8,000 psi, all in
accordance with 105.03.
10
707.02 Materials
Materials shall be in accordance with the following:

Admixtures for Concrete ............................................. 912.03

Backer Rod .................................................................. 906.02(b)
Coarse Aggregates, Class A or Higher,
Size No. 91 ........................................................... 904
Concrete Curing Materials .......................................... 912
Non-Epoxy PCC Sealers ............................................. 909.10
20 Elastomeric Bearings ................................................... 915.04
Fine Aggregates, Size No. 23 ...................................... 904
Fly Ash ........................................................................ 901.02
Ground Granulated Blast Furnace Slag ....................... 901.03
PCC Sealer/Healer ....................................................... 901.06
Portland Cement .......................................................... 901.01(b)
Reinforcing Bars.......................................................... 910.01
Silica Fume .................................................................. 901.04
Uncoated Seven-Wire Strand ...................................... 910.01(b)7

621
 707.03

30 Structural steel for steel intermediate diaphragms shall be in accordance with

910.02(a) and shall be galvanized in accordance with ASTM A 123 after cutting,
bending, and welding. Bolts for steel intermediate diaphragms shall be 7/8 in. and in
accordance with 910.02(g), except they shall be type 1. All bolts, nuts, washers, and
similar threaded fasteners shall be galvanized in accordance with ASTM A 123 or may
be mechanically zinc coated in accordance with ASTM B 695, class 50.

All precast non-prestressed structural members shall be manufactured by a

Department Certified Precast Concrete Producer in accordance with ITM 813. All
precast prestressed structural members including, but not limited to concrete box-
40 beams, I-beams, U-beams, and bulb-T beams shall be manufactured in a Department
approved plant in accordance with ITM 814.

CONSTRUCTION REQUIREMENTS

707.03 General Requirements

Dimensions and design requirements for structural members shall be as shown on
the plans. Lengths and dimension tolerances shall be as shown on the plans or as
otherwise specified. A beam which is to include a field attached curb shall have curb
reinforcement located longitudinally within 3/4 in. of the locations shown on the plans.
50 If detailed drawings are not included in the plans, working drawings shall be submitted
for approval in accordance with 105.02. Certified mill test reports shall be furnished
for all uncoated seven-wire strands.

Where temperature requirements are specified herein, the Contractor shall provide
the Department with written verification that the temperature requirements have been
met.

Prior to the beginning of fabrication, a prefabrication meeting shall be held at the

fabrication facility or another agreed upon location. The meeting shall be conducted
60 by the Contractor and attended by the fabricator’s production supervisor and quality
control inspector, and the Engineer. The Contractor shall take notes of the meeting and
distribute copies to all attending parties within five days of the date of the meeting.
Items to be discussed at the meeting shall include a minimum of: fabrication and
shipping schedule including hours of operation; line of communication between the
Contractor and the Engineer; material test reports; working drawings; special
fabrication methods; fabrication hold points for inspection; final inspection and
acceptance of materials; method of shipment. The requirement to hold prefabrication
meetings may be waived by the Department.

70 A type A field office in accordance with 628 shall be provided at any facility that
fabricates precast prestressed structural members for the Department’s exclusive use.
In lieu of a field office, a work area and the following items in accordance with 628
for the exclusive use by the Department shall be provided on the property where the
structural members are being fabricated.

622
 707.04

(a) office desktop

(b) office chair
(c) broadband internet service
(d) telephone
80 (e) fax machine
(f) copier
(g) filling cabinet.

707.04 Steel and Concrete Requirements

(a) Reinforcing Bars

A tight coat of concrete grout extending 1/2 in. maximum from the top of precast
and precast prestressed concrete structural members will be allowed to remain on
reinforcing bars extending from precast and precast prestressed structural members.
90 All loose and flaky material on these reinforcing bars shall be removed. Lap splices
shall be in accordance with 703.06.

(b) Prestressing Strands

Uncoated seven-wire strands shall be used as prestressing strands. The splicing of
straight prestressing strands is acceptable provided that the location of the splice does
not occur within a concrete structural member. Splicing of draped strands is not
allowed. Spliced prestressing strands shall have the same twist or lap. For single strand
tensioning, slippage of the splices shall be considered in computing the elongation.
For multiple strand tensioning, either all of the strands shall be spliced or not more
100 than 10% of the strands. If all of the strands are spliced the average splice slippage
shall be considered in computing the elongation. If 10% or less of the strands are
spliced, no slippage allowance will be required.

Wire breaks will be allowed to remain on the prestressed concrete casting bed as
follows:

Number of Strands in Bed Wire Breaks

19 or fewer 0
20 through 39 1
40 through 59 2
60 or more 3

The ends of each allowable wire break shall be tied to the strand. If more than the
allowable number of wire breaks appears in a particular strand pattern, or if more than
110 one broken wire appears in an individual strand, such strands shall be removed and
replaced.

The tolerance for the center of gravity for a prestressing strand group shall be ±1/4
in. The tolerance for the longitudinal position of handling devices shall be ±6 in.

623
 707.04

(c) Concrete
Concrete shall be air entrained and in accordance with the applicable requirements
of 702.05. The concrete shall have a minimum temperature of 50°F and a maximum
temperature of 90°F at the time of placement. When a chemical admixture type A, D,
120 F, or G is used, it shall be used in combination with an air entraining admixture. A
high range water reducing, HRWR, or high range water reducing retarding, HRWRR,
admixture system may be used. Chemical admixture types B, C, and E will only be
allowed with prior written permission. Air-entraining cement will not be allowed. The
cement content of the mixed concrete shall be sufficient to obtain the specified
minimum 28 day compressive strength. The total of portland cement and other
cementitious materials shall be a minimum of 564 lbs/cu yd and shall not exceed 800
lbs/cu yd. Silica fume may be added in an amount not to exceed 5% of the total
cementitious material.

130 When a type A, D, or E admixture is not used, or if a type B or C chemical

admixture is used, slump shall be no less than 1 in. or more than 3 in. When concrete
admixtures type A, D, or E is used, slump shall be no less than 2 in. or more than 5 in.
When concrete containing admixture type F, G, or admixture systems is used, the
concrete shall have a slump no less than 3 in. or more than 8 in. The amount of time
from mixing to placement and consolidation shall be a maximum of 30 minutes. The
concrete shall not be retempered with additional amounts of chemical admixture types
F or G after the initial mixing has been completed.

1. Cold Weather Concrete

140 Cold weather concrete shall be in accordance with 702.11.

2. Hot Weather Concrete

When it is necessary to fabricate concrete structural members during times of hot
weather the mix water may be chilled or an appropriate amount of ice may be added
to the concrete mix in order to produce concrete of the temperature specified herein.

3. Acceptance Testing
Acceptance of precast and precast prestressed structural members will be based
on tests for slump, air content, and compressive strength. All slump, air content, and
150 compressive strength tests shall be performed in the presence of the Engineer. Slump
and air content measurements shall be obtained each time cylinders are made.
Compressive strengths of the structural members shall be determined from cylinder
sets described herein. The 28-day compressive strength shall be equal to or greater
than the specified concrete compressive strength. The compressive strength of the
concrete for each structural member will be determined from the average strength of
the cylinder set representing that member. No individual strength within a cylinder set
representing a structural member shall be less than 90% of the specified concrete
compressive strength.

160 All molds, facilities, labor, and materials necessary to prepare, cure, and test the
cylinder sets shall be furnished.

624
 707.04

a. Cylinder Set
A cylinder set shall consist of at least three cylinders obtained from three separate
batches or loads of concrete used in casting a structural member. The batches or loads
to be sampled may be as directed by the Engineer. All cylinders for acceptance shall
be 6 in. diameter by 12 in., molded and field cured in accordance with ASTM C 31.
The Contractor may make additional cylinder sets for use in acceptance testing.

170 All cylinders shall be identified by use of Department-marked cylinder

identification tags which are inserted a maximum of 3/8 in. into the top of each freshly
molded cylinder. The cylinder number, a unique structural member identification
number, temperature, air content, and slump of the concrete represented by each
cylinder shall be referenced to the numbers on these cylinder identification tags and
provided to the Engineer by the end of each day in which cylinders are cast.

Cylinders shall be stored as near as possible to the point of deposit of the concrete
represented. All surfaces of the cylinders shall be protected from the elements in the
same manner as the formed structural members. Cylinders shall be cured at the same
180 temperature and moisture environment as the structural members.

Cylinders shall be in the moisture condition resulting from the selected curing
treatment prior to testing. To meet these conditions, the cylinders shall be removed
from the molds at the time the structural member is removed from the form work.
Cylinders shall be tested in accordance with ASTM C 39. The Contractor shall have
on file a certificate of calibration for the testing machine. All cylinders in a cylinder
set, for a given age, shall be broken within the time tolerances shown in ASTM C 39.
The Department will remove cylinder identification tags prior to the Contractor testing
the cylinders.
190
b. Precast, Non-Prestressed Structural Members
When fabricating precast non-prestressed structural members, a minimum of one
cylinder set shall be made per member cast. The 28-day compressive strength of the
concrete for each structural member will be determined by the average strength of the
cylinder set representing that member. The fabricator may elect to make additional
cylinder sets for use in acceptance testing prior to 28 days.

c. Precast, Prestressed Structural Members

A minimum of two cylinder sets shall be made for each structural member cast.
200 One cylinder set shall be tested and used to determine when the precast prestressed
structural member has met or exceeded the required strength for detensioning the
prestressing bed. If an additional cylinder set as described above has been made, the
Contractor may test this set to determine if the required strength for detensioning of
the prestressing bed has been met or exceeded, or if the required 28-day compressive
strength has been met or exceeded prior to an age of 28 days. The Engineer will accept
the results from the compression testing on the additional cylinder set, in place of either
the detensioning strength test results, or the 28-day compressive strength test results,

625
 707.05

if the results equal or exceed the respective compressive strength requirements. If an

additional cylinder set was not made, or if the additional cylinder set does not meet or
210 exceed the 28-day compressive strength requirement, the remaining cylinder set shall
be tested at 28 days of age to determine the acceptability of the structural members.

Coring of precast prestressed structural members shall not be performed. Precast

prestressed structural members that have been cored will not be accepted. Compressive
strength results for cylinders that exceed 28 days in age or results from cylinders that
do not have the Department-marked cylinder identification tag intact will result in the
structural members not being accepted.

(d) Other Requirements

220 Precast concrete structural members which are not prestressed shall have a
minimum compressive strength of 4,500 psi in 28 days. Precast prestressed structural
members shall be in accordance with the following unless otherwise shown on the
plans:

1. Maximum water/cementitious ratio in pounds of water per

pound of cementitious material shall be 0.420.

2. Minimum 28-day compressive strength of concrete shall be

5,000 psi.
230
3. Minimum compressive strength of concrete at time of
prestressing shall be 4,000 psi.

4. Initial tension of prestressing strands shall be as shown on

the plans.

Inspection of the precast prestressed structural member during manufacture and

checking and testing aggregates, cement, concrete, and steel specimens shall be
performed. All specimens shall be furnished without cost to the Department.
240 Inspection, checking, and testing performed by the Department will not relieve the
Contractor or the fabricator from performing their own quality control inspection,
testing, and checking as necessary to maintain quality control over the manufacturing,
handling, and curing procedure. A permanent record of the force applied to and
measured elongation obtained for each prestressing strand and the identification of the
strand and structural member to which the record applies shall be provided. This record
shall be certified that it accurately represents the force applied and measured
elongation by the fabricator’s production supervisor and provided to the Engineer prior
to shipment.

250 707.05 Forms

Structural members shall be manufactured in steel forms which are unyielding,
smooth, mortar-tight, and of sufficient rigidity to prevent distortion due to pressure of
the concrete. They shall be so designed that the finished concrete is in accordance with

626
 707.06

the required dimensions and contours. The design of the forms shall take into account
the effect of vibration of the concrete as it is placed. Forms shall be chamfered in
accordance with 702.13(a). Exposed edges of curbs shall be beveled or edged. Forms
shall be set and maintained true to the lines designated until the concrete is sufficiently
hardened or for periods hereinafter specified. Interiors of forms shall be treated with
an approved formulated form coating which allows them to be released without
260 adhering, discoloring, or otherwise damaging the concrete. Form coating materials
shall not come in contact with either reinforcing bars or prestressing strands.

707.06 Placing and Finishing Concrete

The temperature of the prestressing strands and forms shall be monitored between
the time of the application of prestressing force and the placement of the concrete.
During hot weather, approved means shall be undertaken to cool the forms
immediately prior to placement of the concrete.

When abutment anchorage set-ups where prestressing strands are anchored to

270 abutments that are independent from the form, thermal adjustments shall be made if
the temperature of the prestressing strands at the time of tensioning differs by more
than 25°F from the temperature of the concrete mixture during placement. This
requirement will not apply to self-stressing beds.

Void boxes, inserts, and attachments shall be securely fastened in order to

maintain the proper position during concrete placement and consolidation. All voids
shall have weep holes or otherwise be vented during beam production until after the
initial concrete set, then sealed before the beams are shipped.

280 Concrete, during and immediately after depositing, shall be consolidated with
vibrators and suitable spading tools. Vibration shall be applied at the point of deposit
and in the area of freshly deposited concrete. The vibrators used may be internal,
external, or a combination of both. Internal vibration shall be of sufficient duration and
intensity to consolidate thoroughly, but shall not be continued so as to cause
segregation. Vibration shall not be continued at any one point so that localized areas
of grout are formed.

The entire operation of depositing and consolidating the concrete shall be

conducted so that the concrete will be smooth, dense, and free from any honeycomb
290 or pockets of segregated aggregates. The concrete in each structural member shall be
placed in one continuous operation. The outside vertical faces of fascia structural
members and the exposed face and top of the curb section, if applicable, shall be
finished in accordance with 702.21.

The tops of all beams and the outside faces and bottom flanges of the fascia beams
shall be sealed in accordance with 709.

627
 707.07

707.07 Removal of Forms and Curing

Curing shall be in an enclosure designed to minimize heat and moisture loss.
300 Insulated blankets may be used. The concrete in the form shall be maintained at a
minimum temperature of 50°F during the entire curing cycle. Curing for precast or
precast prestressed structural members shall be done by wet curing without
supplemental heat or by accelerated curing. During the period of initial set of the
structural member and during the accelerated curing by radiant heat, the concrete shall
be kept wet by the method outlined below for wet curing without supplemental heat.

Approval shall be obtained before curing is done by any means other than those
outlined below.

310 Side forms may be removed when no distortion, slump, or misalignment of the
concrete will result. Precast structural members which are not prestressed shall remain
on the bottom supporting forms for the span until the concrete has reached a strength
of at least 2,000 psi as evidenced by cylinders sets made and cured in the same manner
as the slab.

(a) Wet Curing without Supplemental Heat

When wet curing without supplemental heat is used, the exposed surfaces of the
structural members shall be covered by two layers of wet burlap and the burlap shall
be kept wet to ensure that free water is present at all times. In lieu of using wet burlap,
320 the Contractor may propose an alternate method which provides a moist environment
with free water being present at all times. Written approval from the Engineer will be
required prior to use of the proposed alternate method. Additional curing of precast or
precast prestressed structural members will not be required provided the minimum
specified ultimate strength can be obtained.

In precast prestressed concrete structural members, wet curing without

supplemental heat shall continue until such time as the compressive strength of the
concrete reaches or exceeds the strength specified for transfer of prestress or
detensioning. At this point wet curing is considered to have concluded. Detensioning
330 shall be performed within 6 h after wet curing has concluded. In precast non-
prestressed structural members, wet curing without supplemental heat shall continue
until such time as the compressive strength of the concrete reaches the strength
specified for stripping of forms.

(b) Accelerated Curing

When accelerated curing of the concrete is used, it shall be done by low pressure
steam or radiant heat curing. Radiant heat may be applied by means of pipes circulating
steam, hot oil or hot water, or by electric heating elements. When steam is used, the
jets shall be positioned so that they do not discharge directly on the concrete, forms,
340 or cylinders. The steam shall be at 100% relative humidity to prevent loss of moisture
and to provide moisture for proper hydration of the cement.

628
 707.07

Except to maintain a minimum concrete temperature of 50°F, heat shall not be

applied until the concrete has attained initial set. The time of initial set may be
determined by ASTM C 403. Once the penetration resistance, as performed in
accordance with ASTM C 403, equals or exceeds 500 psi accelerated curing may
begin. When the initial set is not determined by ASTM C 403, the initial application
of heat shall be a minimum of 4 h after final concrete placement. When retarders are
used and the initial set is not determined by ASTM C 403, this time shall be increased
350 to a minimum of 6 h after final concrete placement. Heat shall always be applied at a
controlled rate following the initial set of the concrete, and an effective method of
retaining the heat and moisture in the concrete shall be used during the entire curing
cycle.

During the initial application of radiant heat or live steam, the temperature
measured in the concrete shall increase at an average rate not exceeding 36°F/h. The
maximum concrete temperature shall not exceed 158°F. A minimum of three time and
temperature recording devices capable of recording temperatures in degrees
Fahrenheit at intervals not exceeding 15 minutes shall be provided throughout a
360 contiguous form group and common heat source. The time and temperature recording
devices shall be located at the portions of the contiguous form group likely to
experience the maximum temperatures during curing.

The curing temperature shall be sustained until the concrete has reached the
minimum required compressive strength for detensioning the structural members.
Once the concrete has achieved the required compressive strength, detensioning shall
be performed while the concrete is still warm and moist. Detensioning operations shall
not interfere with the curing of the structural member.

370 As the application of heat is discontinued, the concrete temperature shall decrease
at a rate not to exceed 50°F/h. When the concrete temperature has reached 40°F or less
above the ambient temperature outside the curing enclosure, accelerated curing is
considered to have concluded. A thermometer shall be provided to monitor ambient
air temperatures. This thermometer does not have to have recording capabilities.

The time and temperature recording devices shall be used to verify compliance
with the heating and cooling rates contained herein.

When multiple structural members are cast in the same bed, all members shall
380 meet or exceed the specified release strength prior to detensioning. Additional curing
of precast or precast prestressed structural members will not be required provided the
minimum specified ultimate strength can be obtained.

A grinder or other methods that induce minimal amounts of heat into the
prestressing strand shall be used to cut off prestressing strands. The ends of the
concrete structural member where prestressing strands have been cut to be flush with
the end of the member shall be coated with bituminous mastic sealant in accordance
with 907.11. All prestressing strands that are exposed and protrude from the end of the

629
 707.08

beam shall be protected from rusting by use of a spray, brush, or roller-applied rust-
390 inhibiting paint or other material that is not considered detrimental to bonding with
concrete.

707.08 Handling and Shipping

Precast and precast prestressed structural members shall not be subjected to
excessive abuse which produces crushing or undue marring of the concrete. All
structural members damaged during handling, storing, transporting, or erecting shall
be replaced. Unless otherwise approved, precast and precast prestressed structural
members shall be handled with a suitable hoisting device provided with a spreader
sling. The spreader shall be of sufficient length to prevent horizontal forces being
400 produced in the structural member due to lifting and shall be equipped with leads and
hooks at each end. The structural members shall be lifted by the devices shown on the
plans. Proposed alternate lifting devices and procedures shall be approved prior to use
and shown on the working drawings. If any other method of handling is used, it shall
be shown on the working drawings and approved prior to use. If the method produces
horizontal forces in the precast or precast prestressed structural member, sufficient
reinforcement shall be added to compensate for them.

The structural members shall remain in an upright position at all times and shall
be supported as indicated herein when in storage and during transportation to the
410 construction site.

In storage, all structural members shall be fully supported across their width on
battens not less than 4 in. wide with one being placed at each end at the centerline of
the bearing. The supports of the structural members while in storage shall be
maintained in a level position so no twisting occurs.

Precast structural members shall not be shipped or used until the concrete
compressive strength reaches a minimum of 4,500 psi for members which are not
prestressed and 5,000 psi for members which are prestressed.
420
During transportation, the structural members shall be supported with truck
bolsters or battens no less than 4 in. wide which are padded with no less than 1/2 in.
of rubber. The ends of I-beams, U-beams, and bulb-T beams shall extend no more than
the depth of the beam and not more than 3 ft 6 in. beyond the supports. The ends of
box-beams shall extend no more than 1 1/2 times their depth and not more than 3 ft
beyond the supports. The ends of slabs shall extend no more than the depth of the beam
beyond the supports. Supports of cantilever beams shall be as shown on the plans.
Trucks with double bolsters will be allowed, provided the beams are fully seated on
the outer bolsters and the inner bolsters are no more than 8 ft from the ends of the
430 beams. Wood blocks or other suitable material shall be placed under the tie chains to
prevent chipping the concrete.

707.09 Placing Structural Members

Erection of precast prestressed structural members shall commence at the

630
 707.11

centerline and proceed out to the curb, one member at a time. As each structural
member is placed, the transverse tie bars, if shown on the plans, shall be inserted and
secured. Any shifting of the structural members shall be done while they are held free
of the supports by the hoisting device. The use of a steel pinch bar will not be allowed.
Structural members shall be set to proper line and grade with uniform bearing on
440 bridge seats, mortar joints, or bearing pads as required on the plans. When required,
structural members shall be secured to the pier or bent with dowel rods. Holes for
dowels shall be filled with mortar at fixed ends and with crack or joint filler at
expansion ends. Longitudinal keyway joints shall be cleaned. A coat of cement mortar
shall be scrubbed on the surface. The joint shall be filled with a non-shrinking grout
composed of 1 part portland cement, 2 parts No. 23 fine aggregate, and an approved
non-shrinking additive or a non-shrink, non-metallic cementation grout in accordance
with ASTM C 1107. All bolts or drains shown on the plans as necessary or desirable
to be placed in the concrete shall be placed by the methods and at the locations shown
on the plans. Necessary tie rods, tie bolts, and hardware for tying structural members
450 together shall be furnished.

Dowel holes shall not be grouted nor concrete or the forming thereof, be placed
in floor slabs, diaphragms, or shear keys prior to receipt of complete documentation
of the acceptability of the structural members and bearing pads, including the
satisfactory laboratory reports and certifications in accordance with 915.04(f). Neither
the structural members, nor the bearings will be considered incorporated into the work,
and neither will be paid for until this documentation is accomplished satisfactorily.

Railing, when required, shall be of the type shown on the plans. The component
460 parts shall be in accordance with 706, unless otherwise indicated on the plans. Other
precast or precast prestressed structural members shall be placed in the structure in
accordance with the plans and the specifications or special provisions indicated for the
type of structure being built.

Cranes or other heavy erection equipment may be operated on the precast or

precast prestressed structural members only if approved in writing and if a proposed
operating procedure is submitted showing loading, distribution of loads, resulting
stresses, and that the design of the structural members is satisfactory to handle these
loads. However, such approval shall not relieve the Contractor of any damage from
470 this operation.

707.10 Blank

707.11 Method of Measurement

Precast or precast prestressed concrete structural members will be measured by
the linear foot. Railing will be measured in accordance with 706.07 if specified as a
pay item. Structural steel for intermediate diaphragms will not be measured.

631
 707.12

707.12 Basis of Payment

480 The accepted quantities of precast or precast prestressed concrete structural
members will be paid for at the contract unit price per linear foot for structural
member, concrete, of the type and size specified.

Railing will be paid for in accordance with 706.08 when specified as a pay item.

Payment will be made under:

Pay Item Pay Unit Symbol

490 Structural Member, Concrete, ____, ____................................. LFT

type size

Reinforcing bars, prestressing strands, elastomeric bearing pads, modifications to

bearing pads, bearing beams required for box beams, bearing assemblies required for
I-beams, bulb-T beams, U-beams, and box beams, bearing plates, expanded
polystyrene, threaded reinforcing bars, threaded inserts in fascia beams, hex bolts,
sealer on the outside face and bottom flange of fascia beams and on the tops of all
beams, and necessary incidentals shall be included in the cost of the pay items of this
section. The cost of tensioning rods and steel plates shall be included in the cost of the
500 pay items of this section. The cost for providing all molds, cylinder identification tags,
facilities, labor, and materials necessary to prepare and cure the test specimens
required for work in this section shall be included in the cost of the pay items in this
section.

No payment will be made for removing and replacing prestressing strands due to
excessive wire breakage, or replacing precast or precast prestressed structural
members damaged during handling, storing, transporting or erecting.

The cost of railing shall be included in the cost of the pay items of this section if
510 such railing is not specified as a pay item.

The cost of all materials, including galvanizing, labor, and equipment for
furnishing and installing steel intermediate diaphragms shall be included in the cost of
structural member, concrete of the type and size specified.

The cost of time and temperature recording devices and their monitoring shall be
included in the cost of the structural members.

The cost of a field office or of providing the field office items listed herein shall
520 be included in the cost of the pay items of this section.

632
 708.04

SECTION 708 – PNEUMATICALLY PLACED MORTAR

708.01 Description
This work shall consist of preparing stone, concrete, or other surfaces for and the
pneumatic application of mortar as a plain or reinforced coating in accordance with
these specifications and as shown on the plans or as directed.

708.02 Materials
Materials shall be in accordance with the following:
10
Deformed and Smooth Steel WWR............................. 910.01(b)5
Fine Aggregate ............................................................ 904.02(d)
Fly Ash ........................................................................ 901.02
Portland Cement .......................................................... 901.01(b)
Water ........................................................................... 913.01

WWR shall consist of wire, size W 1.5 or approximately No. 10 gage, spaced and
welded at 3 in. intervals, or wire, size W 1 or approximately No. 12 gage, spaced and
welded at 2 in. intervals.
20
CONSTRUCTION REQUIREMENTS

708.03 Preparing Surface

The surface of all steel to be covered shall be thoroughly cleaned of all paint, rust,
grease, dirt, or other foreign materials. All loose or defective portions of masonry to
be covered shall be removed and the surface thus exposed cleaned. The use of a sand
blast as an aid in cleaning any surface may be required.

708.04 Reinforcement
30 If WWR is required, it shall be cut into sheets of the proper sizes and bent
carefully over a template so that the mesh closely follows the outline of the member
to be covered. It shall be attached to such members at intervals of not to exceed 2 ft.

Insofar as feasible, the mesh shall parallel the surface of steel members 3/4 in. out
from the face. Where sheets meet, they shall lap at least 4 in. and shall be fastened
together securely.

WWR shall be used in all areas where the thickness of the mortar exceeds 3 in.
and also if the present steel reinforcement is exposed after the disintegrated concrete
40 has been removed. WWR shall be fastened to the concrete masonry with 1/4 in.
machine bolts screwed into lead anchors driven into holes drilled into the concrete, or
by pins or nails shot into the concrete by an impact gun. Such bolts or pins shall be
spaced on 8 in. centers in each direction and shall be of sufficient length to space the
WWR approximately 2 in. from the surface being repaired. Where WWR can be
fastened to the reinforcing bars, the bolts, pins, or nails may be omitted.

633
 708.05

708.05 Proportioning and Mixing

The dry mixture shall consist of 1 part portland cement to 3 parts sand. The cement
and sand shall be dry mixed in an approved proportioning plant or in batch boxes.
50 Measurement may be by volume or weight. Before placing the proportioned materials
in the hopper of the application gun, all lumps 1/4 in. or over shall be removed by
screening.

708.06 Placing Mortar

This work shall be done only by experienced personnel. No one operating the
nozzle will be deemed experienced unless they have satisfactorily completed similar
work on other structures of like type.

Just prior to placing mortar, the surface shall be washed with water and
60 compressed air. The mortar shall be placed on a wet surface.

The equipment for placing the mortar shall be operated in accordance with the
recommendations of the manufacturer.

In shooting any surface, the nozzle shall be held at such distance and in such
position that the flowing stream of material impinges, as nearly as possible, at right
angles to the surface being covered. All deposits of loose sand shall be removed.
Shooting shall start on those areas where the greatest thickness is required. Mortar
shall not be applied more than 2 in. thick in one operation. Where a finished thickness
70 of more than 2 in. is required, it shall be obtained in successive operations and enough
time allowed to enable the previous layer to set. During application, the required
thickness shall be maintained by shooting strips. A full thickness shall be obtained
over thin edges of steel.

After completion of a section of coating, all high spots shall be cut off with a sharp
trowel or screeded to a true plane as determined by the shooting strips. Finished edges
shall be true and even.

708.07 Finishing
80 After all surfaces have been brought to the required contour and smoothness, they
shall be finished with a flash coat approximately 1/8 in. thick. This coat shall produce
a uniform color and finish and an approved appearance on all exposed surfaces.
Proportioning and mixing of the flash coat shall be in accordance with 708.05 except
white portland cement shall be used. Before placing the proportioned materials in the
hopper of the application gun, all lumps 1/8 in. or larger shall be removed by screening.
No less than one bag of the white cement to each 300 sq ft of surface shall be used.

Immediately after completion, the surface shall be covered with wet burlap or wet
cotton mats and these shall be kept wet for at least 96 h. No mortar shall be placed
90 when the air temperature is below 50°F or against a surface which contains frost. After
the work has been completed, all rebound and other debris shall be removed from the
work.

634
 709.01

708.08 Method of Measurement

Pneumatically placed mortar will be measured by the square foot, complete in
place. The area measured will be the actual finished surface. WWR, where used, will
be measured by the square foot, complete in place.

708.09 Basis of Payment

100 The accepted quantities of pneumatically placed mortar and WWR will be paid
for at the contract unit price per square foot, complete in place.

Payment will be made under:

Pay Item Pay Unit Symbol

Pneumatically Placed Mortar..................................................... SFT

Welded Steel Wire Reinforcement ............................................ SFT

110 The areas where loose or defective portions of masonry exceed an average of 4 in.
in depth will be paid for at a price to be determined by multiplying the contract unit
price for pneumatically placed mortar, respectively, by the factors as follows:

(a) for portions thereof whose average depth is greater than 4 in.
but less than 6 in. ................................................................ 1.25

(b) for portions thereof whose average depth is greater than or equal
to 6 in. but less than 8 in. .................................................... 1.50

120 (c) for portions thereof whose average depth is greater than or equal
to 8 in. but less than 10 in. .................................................. 1.75

(d) for portions thereof whose average depth is greater than or equal
to 10 in. but less than 12 in. ................................................ 2.00

(e) for all portions thereof whose average depth is greater than or
equal to 12 in., the work shall be done as extra work. Payment
will be made in accordance with 104.03.

SECTION 709 – PORTLAND CEMENT CONCRETE SEALERS

709.01 Description
This work shall consist of cleaning the concrete surface by sandblasting and
applying a concrete sealer in accordance with 105.03. Surfaces to be sealed with PCC
sealers shall be given a finish in accordance with 702.21. Where existing concrete or
bridge decks are to be sealed, their surfaces shall be sandblasted to remove all foreign
materials.

635
 709.02

10 709.02 Materials
Materials shall be in accordance with the following:

Non-Epoxy PCC Sealers ............................................. 909.10

CONSTRUCTION REQUIREMENTS

709.03 General Requirements

Concrete surfaces shall be 28 days or older prior to application. The concrete
surface shall be allowed to dry at least 48 h immediately prior to sealing. Sealer shall
20 be applied only when the concrete surface, sealer, and ambient temperatures are all
between 40°F and 100°F. The sealer shall be applied at the manufacturer’s specified
application rate and shall not exceed the maximum rate stated on the list of approved
Non-Epoxy Portland Cement Concrete Sealers. Spray applications shall be
accomplished using low pressure, non-atomizing spray equipment adjusted to the wet
spray condition, approximately 15 psi. The sealer shall be applied to vertical surfaces
such that the spray pattern will be 6 to 8 in. wide, and all surfaces shall achieve a
uniform coverage. Horizontal surfaces shall be completely flooded. The sealer shall
not be applied when wind conditions may cause overspray. Sealer shall not be applied
in rain or when rain is expected to occur within 2 h after completing the sealing
30 application.

709.04 Surface Preparation

The surface to be sealed shall be thoroughly cleaned of all foreign materials by
sandblasting if the surface is a bridge deck or older existing concrete, or by air blasting
for all other surfaces, just prior to sealing. The air compressor shall be equipped with
suitable separators, traps, or filters which remove water, oil, grease, or other
substances from the air lines. If rain sufficient to uniformly wet the surface occurs after
the cleaning operations and prior to the sealing, the surface to be sealed shall be re-
sandblasted or re-airblasted.
40
The concrete to be sealed shall be cured as stated on the list of approved Non-
Epoxy Portland Cement Concrete Sealers prior to sealer application.

709.05 Sealer Application

The concrete surface to be sealed shall be completely cleaned and shall be dry and
dust free prior to the application of concrete sealer. The concrete sealer shall be applied
in a crisscross pattern and should any flat or dry spots appear, more sealer shall be
applied. However, there shall be no puddling of material on the surface. The sealed
surface shall be allowed to cure in accordance with the manufacturer’s
50 recommendations. No vehicular traffic will be allowed on the sealed surface during
the curing time.

A qualified technical representative of the manufacturer may be required to be on

the job the first day the sealer is used. It shall be this representative’s responsibility to

636
 709.06

instruct the workers in proper mixing, application technique, and safety precautions.

(a) Non-Epoxy PCC Sealers

The sealer chosen for use shall be applied at the application rate specified on the
list of approved Non-Epoxy Portland Cement Concrete Sealers. The sealer shall be
60 applied without dilution or alteration. Sealers, which are applied by spraying shall be
sprayed onto the concrete surface using low pressure spray equipment with a sufficient
number of passes to achieve the minimum application rate and a uniform coverage.
The low pressure spray apparatus shall have a 15 psi maximum nozzle pressure with
a course fan spray, such as a garden, form oil, horticulture, or other low pressure
sprayer. The spray equipment tanks, and hoses shall be thoroughly clean, free of
foreign matter, oil, residue, and water prior to use. Sealers shall be selected from the
Department’s list of approved Non-Epoxy Portland Cement Concrete Sealers and shall
be spread to achieve uniform coverage. If roller spreading is required, a clean new
roller shall be used for each application sequence. If brooming is specified, a clean,
70 stiff-bristled broom shall be used to spread and work the sealer into the concrete
surface.

(b) Clear Sealers

Clear sealers shall be used on all vertical wall surfaces including, but not limited
to concrete bridge railing, barrier wall and exterior concrete bridge beams when
sealing is specified for these items. Clear sealers will be those identified on the list of
approved Non-Epoxy Portland Cement Concrete Sealers.

(c) Alternate to Concrete Sealers

80 In lieu of concrete surface sealing for concrete barrier wall, bridge decks,
reinforced concrete bridge approaches, pier and bent caps, bridge railing, and bridge
railing transitions, an alternate concrete mix design may be used.

The concrete mix design shall be as specified, except either 3% silica fume by
weight of cementitious material shall be added to the mix design or 30% ground
granulated blast furnace slag substitution based on the required cement content shall
be incorporated into the mix. The substitution of ground granulated blast furnace slag
shall be in accordance with 702.05. A water-reducing admixture or a water-reducing
retarding admixture shall be used in the mix design, and the amount of water added
90 shall be adjusted accordingly. The use of these admixtures shall be in accordance with
702.05.

When one of these alternate concrete mix designs are used in lieu of a concrete
surface sealer, a finish in accordance with 702.21 will be required.

709.06 Safety Precautions

Precautions shall be taken to protect workers from the hazards of these materials.
Solvents in some of the sealers are flammable. All necessary precautions shall be taken
pertaining to the handling and potential overspray of these concrete sealers.
100

637
 709.07

709.07 Method of Measurement

Since payment will be made in a lump sum, only those measurements necessary
to verify application rates will be made.

709.08 Basis of Payment

The accepted quantities of this work will be paid for at the contract lump sum
price for surface seal.

If an alternate concrete mix design in accordance with 709.05(c) is used in lieu of

110 concrete surface sealing or portions thereof, it will be paid for as surface seal.

Payment will be made under:

Pay Item Pay Unit Symbol

Surface Seal ............................................................................... LS

The cost of all materials, labor, equipment, and necessary incidentals shall be
included in the cost of this work.
120
If a curing-sealing material in accordance with 702.22(b) is used in lieu of sealing
concrete surfaces or portions thereof, it will be paid for as surface seal.

SECTION 710 – PATCHING CONCRETE STRUCTURES AND

REPOINTING MASONRY IN STRUCTURES

710.01 Description
This work consists of patching concrete piers, end bents, abutments, wingwalls,
retaining walls, concrete structure surfaces other than bridge decks, and patching
concrete drainage structures, and repointing rubble, dressed stone, or brick masonry
structures in accordance with 105.03.

10 Bridge deck patching shall be in accordance with 722.

710.02 Materials
Materials shall be in accordance with the following:

Coarse Aggregate, Class A or Higher,

Size No. 11 ........................................................... 904
Concrete, Class A ........................................................ 702.02
Curing Compound ....................................................... 912.01
Epoxy-Resin-Base System .......................................... 909.11
20 Fine Aggregate ............................................................ 904.02
Hydrated Lime ............................................................. 913.04
Masonry Cement ......................................................... 901.01(c)

638
 710.03

Packaged Patching Products ........................................ 901.08

Portland Cement, Type I.............................................. 901.01(b)
Reinforcing Bars.......................................................... 910.01

Mortar shall consist of 1 part cement to 2 parts No. 23 fine aggregate, by volume.

Packaged patching products containing magnesium phosphate or calcium

30 aluminate cement shall not be used.

The Contractor shall provide product-specific documentation for proportioning,

mixing, placement, curing, clean up and disposal of excess patching materials.

Approval of packaged patching products will be based on a Type B certification

in accordance with 916. The certification shall be submitted to the Department’s
Concrete Engineer at least 14 calendar days prior to application of the materials.

CONSTRUCTION REQUIREMENTS
40
710.03 Patching Concrete Structures

(a) Concrete Removal

Areas of unsound concrete to be removed will be marked by the Engineer.

A saw cut shall be made perpendicular to the existing concrete surface a minimum
of 1 in. outside marked areas. The cut shall be a minimum 1 in. deep or to the top of
the reinforcement, whichever is less.

50 Removal of unsound concrete shall not exceed 6 in. in depth and shall be
performed by means of handchipping. Handchipping tools may be hand or
mechanically driven. Jackhammers shall not be heavier than nominal 45 lb class and
chipping hammers shall not be heavier than nominal 15 lb class. Only chipping
hammers shall be used when removing concrete within 1 in. of the reinforcement.
Mechanically driven tools shall be operated at a maximum angle of 45° to concrete
surfaces.

Where the bond between the existing concrete and the reinforcement has been
destroyed, concrete adjacent to the reinforcement shall be removed to a minimum
60 clearance of 1 in. around the entire periphery of the exposed reinforcement. Exposed
reinforcement shall not be damaged due to the removal operations. Reinforcement
damaged by the Contractor shall be replaced.

Regardless of the method of removal, removal operations shall cease if sound

concrete is being removed beyond the limits approved by the Engineer. Removal
methods shall be adjusted to prevent unnecessary removal of sound concrete prior to
resuming removal operations.

639
 710.04

(b) Replacement of Reinforcement

70 Existing reinforcement that has lost 50% or more of its original cross sectional
area shall be removed and replaced with new reinforcement of the diameter of the
original reinforcement. Replacement reinforcement shall be lapped a minimum of 3 in.
along the existing reinforcement.

(c) Patching
After concrete removal operations are completed and just prior to placing patches,
all patch areas shall be sandblasted to expose aggregates in concrete surfaces and to
remove rust, residual concrete and laitance layers from the surface of the
reinforcement. All surfaces shall be free of dust, chips, water, and foreign material to
80 produce a firm, solid surface for adherence of patching concrete. Cleaning shall
precede application of the patching material by not more than 24 h when packaged
patching products are used. Air lines for sandblasting and air cleaning shall be
equipped with oil and water traps.

Cavities of 1/2 in. depth or greater shall be filled with concrete or a packaged
patching product. Cavities of less than 1/2 in. depth shall be filled with mortar or a
packaged patching product. When using concrete or mortar patching materials, the
surfaces of prepared cavities and all exposed reinforcement within the cavities shall
be coated with an epoxy resin adhesive in accordance with 722.07(a)1. When
90 packaged patching products are to be applied, all surface preparation and the use of
bonding agents shall be as directed by the manufacturer. The surface shall be in
saturated surface damp condition with no standing water on the surface unless
otherwise directed by the manufacturer.

The packaged patching product shall be applied only to specific surface locations
recommended by the manufacturer: horizontal, vertical or overhead. Lifts of packaged
patching products shall not be thicker than recommended by the manufacturer. Curing
compound shall not be used between lifts. Packaged patching products may be
extended with aggregate in accordance with the manufacturer’s recommendations.
100
Concrete patches shall be finished to match the texture and finish of abutting
existing concrete.

(d) Curing
For patched areas that require forms, forms may be removed after 24 h and
surfaces cured in accordance with 702.22 or the forms may be left in place for 72 h
and no additional curing will be required. Patched areas that do not require forms shall
be cured in accordance with 702.22.

110 Patches filled with packaged patching products shall be cured in accordance with
the manufacturer’s recommendations.

710.04 Repointing Rubble Masonry

Joints in rubble masonry shall be cleaned of all loose mortar and foreign material.

640
 710.07

All spaces around the rubble aggregate, after being cleaned, shall be filled with mortar
and trowel finished. All loose rubble shall be settled into place before the mortar has
set.

710.05 Repointing Dressed Stone and Brick Masonry

120 Joints in masonry shall be cleaned of all loose mortar and foreign material for a
depth of at least twice the width of the joint. Joints shall be filled with mortar and
trowel finished.

710.06 Method of Measurement

Patching concrete structures and repointing rubble, dressed stone and brick
masonry in structures will be measured by the square foot of actual surface area of
patching or repointing. Individual areas of less than 1 sq ft in area will be considered
as 1 sq ft. Areas greater than 1 sq ft will be recorded as the actual measurement of the
repaired area to the nearest 0.1 sq ft.
130
710.07 Basis of Payment
The accepted quantities of patching concrete structures will be paid for at the
contract unit price per square foot complete in place. Repointing rubble, dressed stone,
and brick masonry in structures will be paid for at the contract unit price per square
foot of repointing masonry complete in place.

Payment will be made under:

Pay Item Pay Unit Symbol

140
Patching Concrete Structures..................................................... SFT
Repointing Masonry in Structures ............................................. SFT

Areas where patching concrete structures or repointing rubble, dressed stone, or

brick masonry in structures exceeds an average of 4 in. in depth will be paid for at a
price calculated by means of multiplying the contract unit price for the respective item
by the following factors:

(a) for portions thereof whose average depth is greater than 4 in.
150 but less than 6 in. ................................................................ 1.25

(b) for portions thereof whose average depth is greater than or equal
to 6 in. but less than 8 in. .................................................... 1.50

(c) for portions thereof whose average depth is greater than or equal
to 8 in. but less than 10 in. .................................................. 1.75

(d) for portions thereof whose average depth is greater than or equal
to 10 in. but less than 12 in. ................................................ 2.00
160

641
 711.01

(e) for all portions thereof whose average depth is greater than or
equal to 12 in., the work shall be done as extra work. Payment
will be made in accordance with 104.03.

The cost of removing the existing concrete or masonry cement, furnishing,

hauling, and placing all materials, preparing the surface, and all necessary incidentals
shall be included in the pay items in this section.

The cost of replacing damaged reinforcement shall be included in the cost of

170 patching concrete structures.

SECTION 711 – STEEL STRUCTURES

711.01 Description
This work shall consist of furnishing, fabricating, erecting, and painting steel
structures and parts of structures, except steel piling, in accordance with 105.03.

711.02 Materials
Materials shall be in accordance with the following:

10 Bronze and Copper-Alloy............................................ 910.06

Castings ....................................................................... 910.05
Elastomeric Bearings ................................................... 915.04
Steel Forgings and Steel Shafting ................................ 910.04
Structural Steel ............................................................ 910.02

Where grade HPS 70W or grade HPS 50W steel is shown on the plans, the high
performance steel shall be in accordance with 910.02(d).

Where grade 50W steel is shown on the plans, the weathering steel shall be in
20 accordance with 910.02(b).

Material specifications shall be shown on the working drawings if the materials

are different than those shown on the plans. Materials which do not require mill test
reports may be changed from those shown on the plans subject to approval.

Sheared plates or universal mill plates shall be used for girder webs. Such plates
shall be ordered with sufficient additional width to allow for trimming of edges to
provide built-in camber for dead load deflection and vertical curve. Sheared plates
thicker than 1/2 in. shall be planed in accordance with 711.14.
30
FABRICATION

711.03 General Requirements

The fabrication methods used shall be those applicable to and prescribed for the
several parts of fabrication as it progresses and shall be in accordance with the
642
 711.04

requirements thereof and as further set out in this specification. Workmanship and
finish shall be first-class, equal to the best general practice in a modern fabricating
shop, and in strict accordance with these specifications, the plans, and such additional
instructions as may be given.
40
Fabrication of high performance steel shall be in accordance with the Guide
Specification for Highway Bridge Fabrication with HPS 70W Steel except as modified
herein.

The requirements contained herein will not be waived, nor will they be modified
to conform with any set of rules that any shop has adopted as its standard unless so
authorized in writing.

Structural steel, regardless of its source, shall be fabricated within the continental
50 limits of the United States of America.

711.04 Certification of Fabricators

(a) General Information

If the fabrication of secondary structural steel members and other miscellaneous
structural steel components, such as but not limited to diaphragms, bearing assemblies,
and miscellaneous plates does not involve any welding or heating of the steel, the
fabrication facility that is fabricating these components will not be required to be
American Institute of Steel Construction, AISC, certified as described in this section.
60
Prior to approval for fabrication, the results of the latest AISC certification review
shall be made available to the Engineer to determine if items critical to successful
fabrication meet the needs of the specific work.

The fabricator shall be certified from the start of the fabrication process, through
and including the shop assembly in accordance with 711.44. If the certification lapses
during the course of the project, the fabricator shall have plans to maintain certification
or complete the fabrication process before the expiration of his certification. Failure
of the fabricator to maintain his certification during the fabrication shall result in a
70 10% reduction in the bid price for structural steel.

Approval of the fabricator shall be requested in writing prior to ordering structural

steel. A valid certification with annual endorsement shall be submitted with the
request.

(b) Certification Categories

The fabricator of structural steel furnished under this section shall be certified in
accordance with the AISC Certification Program for Steel Bridge Fabricators –
Standard for Steel Bridges, to the certification category commensurate with the work
80 to be fabricated. Fabricators producing fracture-critical members, intermediate
bridges, or advanced bridges, shall also meet the applicable supplemental requirements

643
 711.04

of the certification program. For shop painting the Department will only accept an
AISC-420-10/SSPC-QP 3 certification. It shall be the fabricator’s responsibility to
maintain a valid certification and annual endorsements thereto.

1. Simple Bridges
Fabricators of main load-carrying components for simple span bridges or bridges
that do not have welded or bolted splices shall, as a minimum, be certified under the
simple bridges category.
90
2. Intermediate Bridges
Fabricators of main load-carrying components for the following types of
structures shall, as a minimum, be certified under the intermediate bridges category.

a. rolled beam bridge with field or shop splices, either

straight or with a radius greater than 500 ft,

b. a built-up I-shaped plate girder bridge with constant

web depth, with or without splices, either straight or
100 with a radius greater than 500 ft,

c. a built-up I-shaped plate girder with variable web

depth, either straight or with a radius greater than
1,000 ft,

d. a truss with a length of 200 ft or less that is entirely or

substantially pre-assembled at the certified facility and
shipped in no more than three subassemblies.

110 3. Advanced Bridges

Fabricators of main load-carrying components for the following types of
structures shall be certified under the advanced bridges category.

a. tub or trapezoidal box girders,

b. closed box girders,

c. large or non-preassembled trusses,

120 d. arches,

e. bascule bridges,

f. cable-supported bridges,

g. moveable bridges, and

h. bridges with a curve radius equal or tighter than that

specified for the intermediate bridges category above.

644
 711.08

130
711.05 Working Drawings
Working drawings shall be submitted in accordance with 105.02.

Working drawings shall include a detailed bill of materials showing weights of

materials completed in accordance with 711.73(b) if payment is on a unit weight basis.
The working drawings shall indicate whether reaming is to be done in the shop or in
the field. The working drawings shall indicate which splices are to be eliminated.

If the contract plans include detailed structural steel drawings, they may be used.
140 Such drawings shall be checked. The Contractor shall provide notification in writing
that it is assuming responsibility for their correctness.

711.06 Storage of Materials

Structural material, either plain or fabricated, shall be stored at the bridge shop
above the ground upon platforms, skids, or other supports. It shall be kept reasonably
free from dirt, grease, and other foreign matter and shall be protected as far as
practicable from corrosion.

711.07 Mill Orders and Shipping Statements

150 If requested, one copy of mill orders, change orders, and mill shipping statements
for structural steel shall be furnished. The pertinent order, bill, or statement shall be
furnished far enough in advance so that inspection may be provided.

711.08 Mill Test Reports

A copy of all mill test reports for all steel on hand that is to be used to fabricate
structural steel members shall be furnished prior to the start of fabrication. For steel
not on hand when fabrication is started that arrives during fabrication, a copy of the
mill test reports for that steel shall be provided within 24 h of receipt of the steel. If
copies of mill test reports are not provided within the specified timeframe, the
160 Engineer may suspend the fabrication of all structural steel members until such time
that copies of the missing mill test reports are provided. Delays due to suspension of
fabrication will be considered non-excusable. If the manufacturer’s mill test reports
are not available, tests shall be made with no additional payment, and four certified
copies of such tests shall be furnished. Four copies of an affidavit shall be furnished
which shall state that the materials to be used for members not designated for
calculated stress and not to be marked in accordance with ASTM A 6, Article 9, are in
accordance with the requirements of the specifications for the materials as shown on
the plans. The fabricator shall have on file the mill test reports for the material from
which these members were obtained.
170
Those items of structural steel which are considered as being in the category of
members not requiring mill test reports and for which tests may not be required shall
be listed on the working drawings. Approval of working drawings will indicate if it is
satisfactory to waive testing of the items listed.

645
 711.09

Mill test reports, reports from subsequent tests, and affidavits shall be marked in
a manner to clearly identify them with the contract structure and also with the
particular member of the bridge for which these tests were made.

180 711.09 Notice of Beginning Work

Written notification shall be given 10 days in advance of the date on which
fabrication is intended to start. Between the dates of such notification and the start of
fabrication, a surface inspection of the proposed materials will be made. Any such
materials cut or work done prior to this inspection may be rejected.

711.10 Facilities for Inspection

Facilities for the inspection of material and workmanship in the mill and shop
shall be furnished, and the inspectors shall be allowed free access to the necessary
parts of the works.
190
711.11 Straightening Material
Material, before being laid off or worked, must be straight. If straightening is
necessary, it shall be done by methods that do not injure the metal. Sharp kinks and
bends will be cause for rejection of the material.

The straightening of plates, angles, other shapes, and built up members, when
allowed, shall be done by methods that do not produce fracture or other injury.
Distorted members shall be straightened by mechanical means or, if approved, by the
carefully planned and supervised application of a limited amount of localized heat.
200 Heat straightening of ASTM A 709 grade 100 steel members will not be allowed. The
temperatures of the heated area shall not exceed 1,200°F, a dull red, as controlled by
temperature indicating crayons, liquids, or bimetal thermometers. Parts to be heat
straightened shall be substantially free of stress and from external forces, except
stresses resulting from mechanical means used in conjunction with the application of
heat. They shall be allowed to cool very slowly. Water quenching will not be allowed.
Following the straightening of a bend or buckle, the surface of the metal shall be
inspected for evidence of fracture.

Short term application of heat to high performance steel for purposes of heat
210 curving, heat straightening, camber and sweep adjustment, or for other reasons is
limited and shall not exceed 1,100°F. Heat applications shall be in accordance with
Department approved procedures.

711.12 Finish
Portions of the work exposed to view shall be finished neatly. Shearing, flame
cutting, and chipping shall be done carefully and accurately.

All shop butt welds in flange plates shall be ground smooth and flush with the
base metal on all surfaces. This shall apply to parts of equal thickness and parts of
220 unequal thickness. Grinding shall be done in the direction of stress and in such a

646
 711.14

manner that the metal is kept below the blue brittle range. All defects exposed by
grinding shall be cleaned, filled with weld metal, and reground to a uniform finish.

Curved surfaces of shoes shall be machined after weldments have been

completed.

For cambered beams, the camber shall be to a smooth curve. Camber for beams
shall be checked after shop welding is completed and while beams are supported so as
to have no bending moment in the direction of camber. Beams which are not cambered
230 shall be straight within a tolerance of 3/8 in. at center. If camber exists, beams shall be
laid out with camber up. Beams shall be checked for camber while beams are
supported so as to have no bending moment in the direction of camber.

711.13 Flame Cutting

Structural steel in accordance with these specifications may be flame cut,
provided a smooth surface free from cracks and notches is secured and provided that
an accurate profile is secured by the use of a mechanical guide. Hand cutting shall be
done only where approved.

240 In all flame cutting, the cutting flame shall be so adjusted and manipulated as to
avoid cutting inside the prescribed lines. Flame cut surfaces shall meet the ANSI
surface roughness rating value of 1,000 except that flame cut surfaces of members not
subject to calculated stress shall meet the surface roughness value of 2,000. Flame cut
surfaces of members carrying calculated stress shall have their corners rounded to a
1/16 in. radius by grinding after flame cutting.

Re-entrant cuts shall be filleted to a radius of not less than 3/4 in.

Surface roughness exceeding the above values and occasional gouges not more
250 than 3/16 in. deep on otherwise satisfactory flame cut surfaces shall be removed by
machining or grinding. Corrections of the defects must be faired with the surface of
the cut on a bevel of 1:6 or less. Occasional gouges of flame cut edges more than 3/16
in. deep but not more than 7/16 in. deep may be repaired by welding with low hydrogen
electrodes not exceeding 5/32 in. in diameter and with a preheat of 250°F. The
completed weld shall be ground smooth and flush with the adjacent surface.

711.14 Edge Planing

Edge planing will not be required on plates having rolled edges.

260 Sheared edges of plates more than 1/2 in. in thickness and carrying calculated
stress shall be planed to a depth of 1/4 in. Re-entrant cuts shall be filleted before
cutting.

Visually observed defects in sheared or flame cut edges of plates 4 in. or less in
thickness, except ASTM A 709 grade 100 steel plates, shall be investigated or repaired

647
 711.15

in accordance with the following table. Repairs made by welding shall be in

accordance with 711.32.

TABLE
Description of Discontinuity Repair Required
All discontinuity of 1/8 in. max. depth. None-depth shall be explored as directed.
Any discontinuity over 1 in. in length
with depth over 1/8 in. but not greater Remove and weld.
than 1/4 in.
Any discontinuity over 1 in. in length Remove completely and weld. Aggregate
with depth over 1/4 in. but not greater length of welding not over 20% of plate
than 7/16 in. edge length being repaired.
Plate rejected. Defective portion may be
Any discontinuity over 1 in. in length
removed and remainder may be used in
with depth greater than 7/16 in.
7/16 in. depth.

270
711.15 Abutting Joints
Abutting joints in compression members and girder flanges of trusses and arches,
and in tension members where so specified on the plans, shall be faced and brought to
an even bearing. Where joints are not faced, the opening shall not exceed 1/4 in.

711.16 End Connection Angles

Floorbeams, stringers, and girders having end connection angles shall be built to
the exact length shown on the plans measured between the heels of the connection
angles, with an allowable tolerance of +0 to -1/16 in. Where continuity is to be
280 required, end connections shall be faced. The thickness of the connection angles shall
be no less than that shown on the working drawings after facing.

711.17 Blank

711.18 Blank

711.19 Bent Plates

Cold bent, load carrying, rolled steel plates shall be in accordance with the
following:
290
(a) They shall be so taken from the stock plates that the bend line
will be at right angles to the direction of rolling.

(b) The radius of bends shall be such that no cracking of the plate
occurs. Generally accepted minimum radii, measured to the
concave face of the metal, are shown in the following table:

648
 711.21

Thickness, t, Up to Over 1/2 in. Over 1 in. Over 1 1/2 in. Over 2 1/2 in.
in inches 1/2 in. to 1 in. to 1 1/2 in. to 2 1/2 in. to 4 in.
All grades
of structural
2t 2 1/2 t 3t 3 1/2 t 4t
steel in this
specification

If a shorter radius is essential, the plates shall be bent hot at a

300 temperature no greater than 1,200°F. Hot bent plates shall be in
accordance with requirement (a) of 711.19.

(c) Before bending, the corners of the plate shall be rounded to a

radius of 1/16 in. throughout that portion of the plate at which
the bending is to occur.

711.20 Fit of Stiffeners

Bearing stiffeners of girders and stiffeners intended as supports for concentrated
loads shall have full bearing. This bearing shall consist of either milled, ground, or
310 weldable steel in compression areas of flanges, welded as shown on the plans or as
otherwise specified on the flanges to which they transmit load or from which they
receive load. The opposite end of bearing stiffeners may have a gap between the end
of the stiffener and the flange not exceeding six times the web thickness.

Stiffeners not intended to support concentrated loads, including transverse

intermediate stiffeners and full depth diaphragm connection plates, shall be attached
to the compression flange as shown on the plans. These stiffeners may bear on the
tension flange or may have a gap between the end of the stiffener and the near face of
the flange not exceeding six times the web thickness. Regardless of the gap dimension,
320 the distance between the end of the stiffener weld and the near edge of the web-to-
flange fillet weld shall not be less than four and not more than six times the web
thickness.

711.21 Bolt Holes

(a) High Tensile Strength Bolts, and Unfinished Bolts

All holes for bolts shall be punched or drilled. Material forming parts of a member
composed of not more than five thicknesses of metal may be punched 1/16 in. larger
than the nominal diameter of the bolts whenever the thickness of the metal is no greater
330 than 3/4 in. for structural steel or 5/8 in. for high-strength steel. If there are more than
five thicknesses or when the main material is thicker than 3/4 in. for structural steel,
or 5/8 in. for high strength steel, or if required in accordance with 711.24, all holes
shall be subpunched or subdrilled 3/16 in. smaller and, after assembling, reamed 1/16
in. larger or drilled from the solid to 1/16 in. larger than the nominal diameter of the
bolts.

649
 711.22

(b) Ribbed Bolts, Turned Bolts, or other Approved Bearing-Type Bolts

All holes for ribbed bolts, turned bolts, or other approved bearing type bolts shall
be subpunched or subdrilled 3/16 in. smaller than the nominal diameter of the bolt.
340 They shall be reamed assembled, reamed to a steel template, or, after assembling,
drilled from the solid at the option of the fabricator. The finished holes shall always
provide a driving fit as shown on the plans or as specified.

711.22 Punched Holes

The diameter of the die shall not exceed the diameter of the punch by more than
1/16 in. If any holes need to be enlarged to admit the bolts, such holes shall be reamed.
Holes shall be clean cut without torn or ragged edges. Poor matching of holes will be
cause for rejection.

350 711.23 Reamed or Drilled Holes

Reamed or drilled holes shall be cylindrical, perpendicular to the member, and
shall be in accordance with 711.21 as to size. Where practicable, reamers shall be
directed by mechanical means. Drilled holes shall be 1/16 in. larger than the nominal
diameter of the bolt. Diameters of holes in all material connecting top shoes to beam
or girder flanges shall be 1/8 in. larger than the diameters of the bolts. Bolts connecting
the flange to the top shoe shall extend into the top shoe a minimum of 1 in. Open holes
for high strength bolts shall be 15/16 in. in diameter unless otherwise shown on the
plans. Burrs on the outside surfaces shall be removed. Poor matching of holes will be
cause for rejection. Reaming and drilling shall be done with twist drills. If required,
360 assembled parts shall be taken apart for removal of burrs caused by drilling.
Connecting parts requiring reamed or drilled holes shall be assembled and held
securely while being reamed or drilled, and shall be match marked before
disassembling.

If beams or girders are shop reamed or drilled, progressive beam or girder

assembly will be allowed in accordance with 711.44 unless otherwise directed. Beams
or girders spliced over the supports may be shop reamed or drilled with the webs either
in a horizontal or vertical position. If the webs are vertical, they shall be supported
relative to their final erection position. If reamed with the webs horizontal, a minimum
370 of one line of beams or girders shall be shop assembled and inspected for fit in
accordance with the blocking diagram for webs vertical shown on the plans. Beams or
girders spliced at the points of contraflexure shall be shop reamed or drilled while
assembled in accordance with the no-load camber and reaming diagram shown on the
plans. For hinged beams or girders, holes for pins shall be bored or reamed to the
dimensions shown on the plans after the beams or girders are assembled in position in
accordance with the no-load camber diagram shown on the plans. Flange splice bars
shall be subdrilled and reamed or drilled full size while assembled.

When girder sections are fit up in the shop for reaming or drilling of field splices,
380 the centerlines of opposing flanges shall not deviate more than 1/8 in. with the webs
in alignment.

650
 711.28

711.24 Subpunching and Reaming of Field Connections

Holes in all field connections and field splices of main members of trusses, arches,
continuous beam spans, bents, each face of towers, plate girders, and rigid frames shall
be subpunched, or subdrilled if subdrilling is required in accordance with 711.21.
These subsize holes shall subsequently be reamed while assembled, or reamed to a
template, in accordance with 711.44. All holes for floor beams and stringer field end
connections shall be subpunched and reamed to a steel template or reamed while
390 assembled. Reaming or drilling full size of field connection holes through a steel
template shall be done after the template has been located as to position and angle, and
bolted firmly in place. Templates used for reaming matching members, or the opposite
faces of a single member, shall be exact duplicates. Templates used for connections
on like parts or members shall be so accurately located that the parts or members are
duplicates and require no match marking.

711.25 Accuracy of Punched or Subdrilled Holes

Before any reaming is done, the punching, subpunching, or subdrilling shall be so
accurate that after assembling, a cylindrical pin 1/8 in. smaller in diameter than the
400 nominal size of the punched hole may be entered perpendicular to the face of the
member, without drifting, in at least 75% of the contiguous holes in the same plane. If
the requirement is not fulfilled, the badly punched pieces will be rejected. If a hole
does not pass a pin which is 3/16 in. smaller in diameter than the nominal size of the
punched hole, this will be cause for rejection.

711.26 Accuracy of Reamed Holes and Holes Drilled Full Size

When holes are reamed or drilled full size, 85% of the holes in any contiguous
group shall, after reaming or drilling, show no offset greater than 1/32 in. between
adjacent thicknesses of metal. All steel templates shall have hardened steel bushings
410 in holes accurately dimensioned from the centerlines of the connection as inscribed on
the template. The centerlines shall be used in locating accurately the template from the
milled or scribed ends of the members.

711.27 Fitting for Bolting

Mating surfaces of steel shall be cleaned before assembling. The parts of a
member shall be assembled, well pinned, and firmly drawn together with bolts before
reaming is commenced. Assembled pieces shall be taken apart, if necessary, for the
removal of burrs and shavings produced by the reaming operation. The member shall
be free from twists, bends, and other deformation.
420
711.28 Filler Plates
Filler may be required at the connections due to the variation in depth of a given
section or to the use of different sections at a connection point. Where filler plates are
shown on the plans at such connections, the specified thickness is the theoretical
thickness required. During fabrication the thickness of such fillers shall be adjusted to
the actual clearances as determined by measurements of the members involved. The
minimum thickness of any filler plate shall be 1/8 in., unless otherwise approved.

651
 711.29

711.29 Toothed Expansion Plates

430 These plates in the roadway expansion joints shall be cut from a single plate by
burning in such a way that, after the plate is cut and the toothed plates placed in the
same relative position as before burning, no part of the cut shall be wider than 1/4 in.
The cuts shall be straight enough that a 1/8 in. plate passes between the parts on any
designated straightline cut.

711.30 Blank

711.31 Peening Welds by Means of Ultrasonic Impact Treatment, UIT

This work shall consist of removing existing paint, repairing existing cracked
440 welds, peening existing and repaired welds, and painting in accordance with 105.03.

Equipment operators shall be American Society for Nondestructive Testing,

ASNT, Level II technicians, trained in the use of the equipment for peening by
ultrasonic impact methods. Proof of certification shall be furnished two weeks prior to
commencing work.

All welding shall be in accordance with the applicable section of the Bridge
Welding Code. All welding shall be performed by AWS certified welders. Weld repair
shall be in accordance with Bridge Welding Code section 3.7.
450
Paint removal shall be in accordance with 619.08(b) and 619.08(h). However,
pressure washing will not be required. Painting shall be in accordance with 619.09 and
619.10.

Prior to beginning the peening process, all welds shall be inspected with a 10x
magnifying glass and with either ultrasonic or magnetic particle non-destructive
testing equipment. Welds needing repair shall be ground and repaired in accordance
with the Bridge Welding Code. Peening using ultrasonic impact treatment methods
shall be applied to all repaired welds in addition to the welds shown on the plans.
460
UIT shall be performed along the toe of the weld to cause the center of the
treatment groove to be at the weld toe. UIT shall be performed to result in a uniform
groove with a bright, metallic surface. All non-uniform areas shall be retreated.

711.32 Welds
Welding of steel shall be done only as shown on the plans or as specified and only
with specific approval. Welding may be done to remedy minor defects, if approved.
No temporary or permanent welds, if not shown on the plans or otherwise specified,
shall be made without specific written authorization.
470
(a) AWS Requirements
Welding of steel bridges and bridge components shall be performed in accordance
with AASHTO/AWS D1.5 Bridge Welding Code, hereinafter referred to as the Bridge

652
 711.32

Welding Code. Welders, welding operators, and tack welders shall be qualified in
accordance with Bridge Welding Code, Chapter 5 Part B.

When welding steel structural or steel non-structural tubing or steel structural

supports for highway signs, luminaires, or traffic signals, it shall be performed in
accordance with AWS D1.1 Structural Welding Code – Steel, hereinafter referred to
480 as AWS D1.1. Welders, welding operators, and tack welders shall be qualified in
accordance with AWS D1.1, Chapter 4 Part C.

(b) Welding of High Performance Steel

All welding on high performance steel shall be in accordance with the Bridge
Welding Code, except as modified herein and by the Guide Specification for Highway
Bridge Fabrication with HPS 70W Steel, hereinafter referred to as the Guide.

Only submerged arc welding, SAW, and shielded metal arc welding, SMAW,
processes will be allowed. Consumable handling requirements shall be in accordance
490 with the Bridge Welding Code, Sections 12.6.5 and 12.6.6, when using reduced
preheat as described in Table 3 of the Guide, except that SAW consumables for
matching weld metal shall meet the hydrogen control level of H4 in accordance with
Section 12, Article 12.6.2. Consumable handling requirements shall meet the
provisions of the Bridge Welding Code, Section 4, when using the preheat
requirements contained in Section 4, except that the diffusible hydrogen level shall
never exceed H8. SMAW consumables may meet diffusible hydrogen levels of either
H4 or H8 except the higher preheat and interpass temperatures as noted in Table 3 of
the Guide shall apply to H8 conditions.

500 Filler metals used to make single pass fillet welds for web to flange applications
which join HPS 70W steel plates, HPS 70W to grade 50W plates and for attaching
stiffeners and connection plates to grade HPS 70W webs and flanges, shall be in
accordance with the Bridge Welding Code, Table 4.1 for ASTM A 709, grade 50W
base metal. Filler metals for single pass 5/16 in. fillet welds need not meet the
requirements for exposed bare applications.

Filler metals used for all complete penetration groove welds joining grade HPS
70W plate to ASTM A 709, grade HPS 50W or grade 50W plate shall conform to the
requirements for welding grade 50W base metal.
510
Filler metals used for all complete penetration groove welds joining grade HPS
70W plates to grade HPS 70W plates shall conform to the requirements for HPS 70W
base metal as follows:

1. Submerged Arc Welding process:

Wire - LA85 by Lincoln Electric Company

Flux - MIL800HPNi by Lincoln Electric Company

653
 711.32

520 2. Shielded Metal Arc Welding process:

Matching - E9018MR*
Undermatching - E7018MR*

* The designator 'MR', for moisture resistant coating, is required for

all SMAW electrodes used for welding HPS 70W steels.

The Contractor may request approval of alternate consumables for matching weld
strengths in lieu of the above filler metals for SAW. The request for approval shall
530 include documentation of successful welding and shall also include diffusible
hydrogen tests, both in accordance with the Bridge Welding Code.

All welding procedures shall be qualified in accordance with the Bridge Welding
Code Section 5, Qualification. In general, the provisions of Article 5.12 shall apply.
Qualification tests shall measure strength, toughness and ductility, with results
evaluated in accordance with Article 5.19. If specified on the plans, additional tests
shall measure the Charpy V-notch toughness of the coarse grained area of the heat
affected zone, HAZ. The notch in the specimens shall be carefully located in the coarse
grained area of the HAZ, as determined by macro-etching the specimens prior to
540 machining and testing. The toughness requirement for the HAZ shall be the same as
the weld metal.

All procedure qualification tests shall be ultrasonically tested in accordance with

the requirements of the Bridge Welding Code, Section 6, Part C. Evaluation shall be
in accordance with Table 6.3, UT Acceptance – Rejection Criteria – Tensile Stress.
Indications found at the interface of the backing bar may be disregarded regardless of
the defect rating.

A representative of the Department will witness all welding procedure

550 qualification tests.

Results of the welding procedure qualification tests and final welding procedure
specifications shall be submitted to the Engineer for review and approval.

In general, post weld heat treatment will not be required. The use of such post
weld heat treatment will require additional qualification testing.

Wherever magnetic particle testing is done, only the yoke technique will be
allowed, as described in Section 6.7.6.2 of the Bridge Welding Code, modified to use
560 alternating current only.

(c) Field Welding

Field welding shall be by the shielded metal arc welding, SMAW, process and
shall be in accordance with the requirements herein. Magnetic particle testing will not
be required on welded connections that do not carry calculated stresses. All field
welding shall be preheated in accordance with Section 4 of the Bridge Welding Code.
654
 711.36

The Contractor shall provide a copy of the minimum preheat and interpass temperature
table to the Engineer prior to beginning welding. Electrodes with a low hydrogen
classification shall be used.
570
711.33 Stud Shear Connectors
Stud shear connectors shall be in accordance with 711.32 and as shown on the
plans.

711.34 Annealing and Stress Relieving

Structural members which are indicated in the contract to be annealed or
normalized shall have finished machining, boring, and straightening done subsequent
to heat treatment. Normalizing and full annealing shall be in accordance with ASTM
A 941. The temperatures shall be maintained uniformly throughout the furnace during
580 the heating and cooling so that the temperatures at two points on the member differ by
no more than 100°F at any one time.

A record of each furnace charge shall identify the pieces in the charge and show
the temperatures and schedule actually used. Proper instruments, including recording
pyrometers, shall be provided for determining the temperature of members in the
furnace. The records of the treatment operation shall be available and meet approval.
Members, such as bridge shoes, pedestals, or other parts which are built up by welding
sections of plate together shall be stress relieved in accordance with the procedure of
the AWS when required by the plans or as otherwise specified.
590
711.35 Eyebars
Pin holes may be flame cut at least 2 in. smaller in diameter than the finished pin
diameter. All eyebars that are to be placed side by side in the structure shall be securely
fastened together in the order that they are placed on the pin and bored at both ends
while so clamped. Eyebars shall be packed and match marked for shipment and
erection. All identifying marks shall be stamped with steel stencils on the edge of one
head of each member after fabrication is completed so as to be visible when the bars
are nested in place on the structure. The eyebars shall be straight and free from twists,
and the pin holes shall be located accurately on the centerline of the bar. The
600 inclination of any bar to the plane of the truss shall not exceed 1/16 in. in 1 ft.

The edges of eyebars that lie between the transverse centerline of their pin holes
shall be cut simultaneously with two mechanically operated torches abreast of each
other, guided by a substantial template, in such a manner as to prevent distortion of
the plates.

711.36 Facing of Bearing Surfaces

The top and bottom surfaces of steel slabs, base plates, and cap plates of columns
and pedestals shall be planed, or the plates hot-straightened. Parts in contact with them
610 shall be faced.

Sole plates of beams and girders shall have full contact with flanges. Sole plates
and masonry plates shall be planed or heat straightened.
655
 711.37

Cast pedestals shall be planed on surfaces to be in contact with steel and shall
have surfaces to be in contact with masonry, rough finished.

Surfaces of bronze bearing plates intended for sliding contact shall be finished.

620 The surface finish of bearing plates, base plates, and other bearing surfaces that
are to come in contact with each other or with concrete shall meet the following ANSI
surface roughness requirements as defined in ANSI B 46.1:

Bridge rollers and rockers ........................................... ANSI 250

Heavy plates in contact with shoes to be welded......... ANSI 1000
Milled ends of compression members, milled or
ground ends of stiffeners and fillers ..................... ANSI 500
Pins and pin holes ........................................................ ANSI 125
Sliding bearings ........................................................... ANSI 125
630 Steel slabs .................................................................... ANSI 2000

711.37 Pins and Rollers

Pins and rollers shall be turned to the dimensions shown on the working drawings
and shall be straight, smooth, and free from flaws. Pins and rollers more than 9 in. in
diameter shall be forged. Pins and rollers 9 in. or less in diameter may be forged or
cold finished, carbon steel shafting. In pins larger than 9 in. in diameter, a hole no less
than 2 in. in diameter shall be bored full length along the axis after the forging has
been allowed to cool to a temperature below the critical range under suitable
conditions to prevent injury by too rapid cooling.
640
711.38 Boring Pin Holes
Pin holes shall be bored true to the specified diameter, smooth and straight, at
right angles with the axis of the member, and parallel with each other unless otherwise
required. The final surface shall be produced by a finishing cut. The distance outside
to outside of end holes in tension members, and inside to inside of end holes in
compression members shall not vary from that specified more than 1/32 in. Boring of
holes in built-up members shall be done after the bolting is completed.

711.39 Pin Clearances

650 The diameter of the pin hole shall not exceed that of the pin by more than 1/50 in.
for pins 5 in. or less in diameter, or 1/32 in. for larger pins.

711.40 Threads for Bolts and Pins

Threads for all bolts and pins for structural steel construction shall be in
accordance with the United Standard Series UNC-ANSI B 1.1, Class 2A for external
threads and Class 2B for internal threads, except that pin ends having a diameter of 1
3/8 in. or more shall be threaded six threads per 1 in.

656
 711.44

711.41 Pilot and Driving Nuts

660 Two pilot nuts and two driving nuts for each size of pin shall be furnished, unless
otherwise specified.

711.42 Finishing Cast Steel

The surface shall be finished as called for on the detail plans. Surfaces marked
“finish” shall be made to exact size and shape and in such manner that removes all tool
marks. If marked “rough finish” the tool marks need not be removed. However, there
shall be no irregularities greater than 1/32 in. in height on rough finished surfaces.

711.43 Finished Members

670 The several pieces forming a built-up member shall fit together closely and
accurately, and the finished member shall be true to line and free from twists, bends,
and open joints.

Cover plates on trusses, beams, and girders shall be so nearly straight that
variations do not exceed 1/16 in. in 5 ft, with a maximum variation not to exceed 3/16
in. at the center of the plates.

711.44 Shop Assembling

The field connections of main members of trusses, arches, continuous beam spans,
680 bents, tower faces, plate girders, and rigid frames shall be assembled in the shop with
milled ends of compression members in full bearing and then shall have their sub-size
holes reamed to specified size while the connections are assembled. Assembly shall
be full truss or girder assembly unless progressive beam or girder assembly, full chord
assembly, progressive chord assembly, or special complete structure assembly is
shown on the plans or otherwise specified.

Each assembly including camber, alignment, accuracy of holes, and fit of milled
joints will be approved before reaming is commenced.

690 A camber diagram shall be furnished by the fabricator showing the camber at each
panel point of each truss, arch rib, continuous beam line, plate girder, or rigid frame.
When the shop assembly is full truss or girder assembly or special complete structure
assembly, the camber diagram shall show the camber measured in assembly. When
any of the other methods of shop assembly is used, the camber diagram shall show
calculated camber.

(a) Full Truss or Girder Assembly

Full truss or girder assembly shall consist of assembling all members of each truss,
arch rib, bent, tower face, continuous beam line, plate girder, or rigid frame at one
700 time.

657
 711.44

(b) Progressive Beam or Girder Assembly

Progressive beam or girder assembly shall be accomplished by one of the
following methods. In case the structure is on a horizontal curve, other assembly
methods may be approved on the working drawings.

1. This method shall consist of the assembly of at least three

contiguous members, and no less than 150 ft. At least one
beam or girder shall be added at the advancing end of the
710 assembly before any member is removed from the rearward
end so that the assembly portion of the structure is never
shorter than that specified above. Each successive laydown
assembly shall always include a previously reamed splice
and the main member on each side of this splice.

2. The alternate method shall consist of placing the required

number of contiguous shop members so that two complete
spans are assembled for the first laydown. Each successive
laydown shall consist of the required number of contiguous
720 members to complete the next two spans while retaining in
the new laydown the last bearing member from the
previous laydown. On laydowns for structures comprised
of an odd number of spans, a laydown of one span will be
allowed to complete the structure. This laydown shall be
the last span unless otherwise approved on the working
drawings. Each retained bearing member shall be
reassembled in its second laydown with the same relative
orientation to a common base line as it was in the first
laydown.
730
(c) Full Chord Assembly
Full chord assembly shall consist of assembling, with geometric angles at the
joints, the full length of each chord of each truss or open spandrel arch or each leg of
each bent or tower, then reaming their field connection holes while the members are
assembled and reaming the web member connections to steel templates set at
geometric, not cambered, angular relation to the chord lines.

Field connection holes in web members shall be reamed to steel templates. At

least one end of each web member shall be milled or shall be scribed normal to the
740 longitudinal axis of the member. The templates at both ends of the member shall be
located accurately from one of the milled ends or scribed lines.

(d) Progressive Chord Assembly

Progressive chord assembly shall consist of assembling contiguous chord
members in the manner specified for full chord assembly and in the number and length
specified for progressive truss or girder assembly.

658
 711.49

(e) Special Complete Structure Assembly

Special complete structure assembly shall consist of assembling the entire
750 structure, including the floor system. This procedure is ordinarily needed only for
complicated structures such as those having curved girders or extreme skew in
combination with severe grade or camber.

711.45 Drifting of Holes

Except where drifting is specifically prohibited by this specification, the drifting
done during assembly shall be only to bring the parts into position and not sufficient
to enlarge the holes or distort the metal. If a hole needs to be enlarged to admit the
bolt, it shall be reamed.

760 711.46 Match Marking

Connecting parts assembled in the shop for the purpose of reaming holes in field
connections shall be match marked and a diagram showing such marks shall be
furnished.

711.47 Shop Cleaning and Painting

Shop cleaning and painting shall be in accordance with applicable requirements
of 619.

711.48 Shop Cleaning and Storage of Weathering Steel

770 The fabricator shall protect bare steel sections and sub-assemblies so as not to
damage or stain them. The use of paints, crayons, or other materials used for
identification purposes shall be avoided on bare steel sections. Storage shall be such
to enable free drainage to avoid moisture pockets.

A sound uniform surface for the formation of a protective oxide coating on all
surfaces shall be prepared as follows.

(a) Hot Rolled Products

The entire length and perimeter of each fascia beam or girder shall be cleaned in
780 accordance with 619.08(c). The entire length and perimeter of each interior beam or
girder shall be cleaned in accordance with 619.08(d). Unless otherwise specified, all
components such as, but not limited to, diaphragms, cross frames, stiffeners, bearing
assemblies, and sway bracing that are permanently incorporated into the structure shall
be cleaned in accordance with 619.08(d). Contamination from grease, oil, or shop
marking shall be avoided. If such contamination is unavoidable, such surfaces shall be
cleaned in accordance with 619.08(b).

(b) Welded Area

All exposed welds on fascia surfaces shall be prepared by means of power
790 grinding in accordance with 619.08(h) or blast cleaning in accordance with 619.08(c)
to remove welding flux, slag, scale, or spatter.

711.49 Furnishing Bolts

Sufficient field bolts shall be furnished to complete the entire structure.
659
 711.50

711.50 Weighing of Members

If it is specified that part of the material is to be paid for by actual weight, finished
work shall be weighed in the presence of the inspector, if practicable. Satisfactory
scales shall be supplied, and all work involved in handling and weighing the various
800 parts shall be performed.

711.51 Full Size Tests

When full size tests of fabricated structural members or eyebars are required by
the contract, the plans or specifications shall state the number and nature of the tests,
the results to be attained, and the measurements of strength, deformation, or other
performance that are to be made. Suitable facilities, material, supervision, and labor
necessary for making and recording the tests shall be provided. The cost of testing
including equipment, handling, supervision, labor, and incidentals for making the tests
shall be included in the contract price for structural steel, unless otherwise specified.
810
711.52 Acceptance
Acceptance of any material or finished member shall not preclude its rejection if
found to be defective, either during fabrication or erection. Rejected material shall be
replaced and poor workmanship corrected promptly.

711.53 Shipping
Structural members shall be loaded on trucks or cars in such manner that they can
be transported to and unloaded at their destination without being excessively stressed,
deformed, or otherwise damaged.
820
If required, pins, nuts, bolts, and other small details shall be boxed or crated, and
the weight of each piece or box marked on it in plain figures.

Written permission shall be obtained prior to shipping plate girders with the webs
horizontal.

Splice plates shall not extend beyond the ends of beams or girders after bolting
for shipment.

830 Member lengths shall be subject to the provisions of the current edition of the
Oversize-Overweight Vehicular Permit Handbook.

The Contractor shall be responsible for obtaining all required transportation

permits.

ERECTION

711.54 General Requirements

The erection methods shall be those prescribed for the several parts which
840 constitute the finished structure and shall be in accordance with the requirements set
forth herein. Workmanship and finish shall be first-class and all work done in a
660
 711.58

substantial and workmanlike manner in accordance with these specifications and in

reasonable close conformance with the lines, grades, dimensions, and details shown
on the plans, or as directed.

No erection shall be done without the approval of the Engineer. Before starting
erection, information shall be fully given as to the erection methods and the amount
and character of the equipment proposed to be used, which shall be subject to approval.
Approval, if given, shall not be considered as relieving the Contractor of its
850 responsibility for the safety of its methods or equipment or from carrying out the work
in full accordance with the plans and specifications.

711.55 Delivery of Materials

If the contract is for erection only, the materials entering into the finished structure
will be provided free of charge at the place designated and loaded or unloaded as
specified. Material, which is required to be unloaded, shall be unloaded promptly on
delivery to the place designated. Otherwise, the Contractor shall be responsible for
demurrage charges.

860 711.56 Handling and Storing

Material to be stored shall be placed on skids above the ground. It shall be kept
clean and properly drained. Girders and beams shall be placed upright and shored.
Long members, such as columns and chords, shall be supported on skids placed near
enough together to prevent injury from deflection. If the contract is for erection only,
the material shall be checked against the shipping lists and all shortages or injuries
discovered shall promptly be reported in writing. The Contractor shall be responsible
for the loss or damage of material after receipt.

711.57 Falsework
870 The falsework shall be properly designed and substantially constructed and
maintained for the loads which come upon it. Plans for falsework or for changes in an
existing structure necessary for maintaining traffic shall be prepared and submitted for
approval. Approval of these plans shall not be considered as relieving the Contractor
of any responsibility.

711.58 Bearings and Anchorages

Masonry bearing plates shall not be placed upon bridge seat bearing areas which
are improperly finished, deformed, or irregular. Bearing plates shall be set level in
exact position and shall have a full and even bearing on the masonry.
880
The holes shall be drilled and the anchor bolts, except where the bolts or anchor
plates are built into the masonry, shall be set. The bolts shall be set accurately and
fixed with portland cement grout completely filling the holes. The location of the
anchor bolts in relation to the slotted holes in the expansion shoes shall correspond
with the temperature at the time of the erection. The nuts on anchor bolts at the
expansion ends of spans shall be adjusted to enable the free movement of the span.

661
 711.59

711.59 Field Straightening Material

If it is necessary to straighten beams, plate girders, plates, angles, and other shapes
890 in the field, it shall be done in accordance with the applicable requirements of 711.11.

Before straightening a carrying member, a proposed method of straightening shall

be submitted in writing. Approval shall be received prior to commencing the work.

711.60 Field Assembly of Steel

Parts assembled in the field shall be assembled accurately as shown on the plans.
Matchmarks shall be followed. The materials shall be handled carefully so that no part
is bent, broken, or otherwise damaged. Hammering which would injure or distort the
members shall not be done. Bearing surfaces and surfaces to be in permanent contact
900 shall be cleaned thoroughly before assembling.

Unless erected by the cantilever method, truss spans shall be erected on blocking
so placed to give the trusses the required camber. Truss spans shall be completely
bolted on the blocking except for stringers and bottom lateral connections which shall
be bolted after the span is swung. In emergencies or special cases and with specific
approval, truss spans may be swung with main joints fully filled with bolts and drift
pins.

Structural steel shall be erected using sufficient full size drift pins to enable
910 placement of bolts without damage thereto and to facilitate setting splices to grade.

At the time of erection, no less than 50% of the holes in all connections shall be
filled with bolts. The bolts shall not be tightened more than snug tight at this stage.

Any drifting required shall be only such that draws the parts into position but not
sufficient to enlarge the holes or distort the metal. Unfair holes shall be reamed or
drilled.

All field splices are optional, except as shown on the plans. Splice elevations have
920 been calculated to include structural steel dead load only, with falsework removed.
The tops of beam or girder splice plates shall be adjusted to the splice elevations shown
on the plans before bolting field splices.

Splices shall be set to grade with the steel unsupported by falsework and prior to
final bolting. After bolting is complete, these elevations will be checked. Adjustment
shall be made as directed, if steel elevations are not within allowable tolerances.

711.61 Misfits
The correction of minor misfits involving harmless amounts of reaming, cutting,
930 and chipping will be considered a legitimate part of the erection. However, any error
in the shop fabrication or deformation resulting from handling and transportation
which prevents the proper assembling and fitting up of parts by the moderate use of
drift pins or by a moderate amount of reaming and slight chipping or cutting shall be

662
 711.65

reported immediately and approval of the method of correction shall be obtained. The
correction shall be made in the presence of the inspector. If the contract provides for
complete fabrication and erection, the Contractor shall be responsible for all misfits,
errors, and injuries and shall make the necessary corrections and replacements. If the
contract is for erection only, the inspector, with the cooperation of the Contractor, shall
keep a correct record of labor and materials used. Within 30 days, an itemized bill
940 shall be presented for approval.

711.62 Pin Connections

Pilot and driving nuts shall be used in driving pins. They shall be furnished
without charge. Pins shall be driven so that the members take full bearing on them. Pin
nuts shall be screwed up tight and the threads burred at the face of the nut with a
pointed tool.

711.63 Blank

950 711.64 Diaphragm Connections

Diaphragm connections other than those shown on the plans may be allowed. If
other connections are proposed, details shall be submitted for approval. The Contractor
shall assume full responsibility for layout of all diaphragm connections and for the
accuracy of all fitted parts. Connections will not be allowed which require welding to
the web, except at supports.

711.65 Bolted Connections Using High Strength Bolts

(a) General
960 This subsection covers the assembly of structural joints using ASTM F 3125,
grade A 325 high strength carbon steel bolts, or equivalent fasteners, tightened to a
high tension. The bolts are to be used in holes provided in accordance with 711.21,
711.22, and 711.23.

High strength bolts shall be 7/8 in. in diameter unless noted.

(b) Bolts, Nuts, and Washers

Bolts, nuts, and washers shall be in accordance with 910.02(g). All galvanized
nuts shall be lubricated with lubricant containing a visible dye. Black bolts shall be
970 oily to the touch when installed. Weathered or rusted bolts shall be cleaned and
lubricated prior to installation.

(c) Bolted Parts

The slope of surfaces of bolted parts in contact with the bolt head and nut shall
not exceed 1:20 with respect to a plane normal to the bolt axis. Bolted parts shall fit
together solidly when assembled and shall not be separated by gaskets or any other
interposed compressible material. When assembled, all joint surfaces, including those
adjacent to the bolt heads, nuts, or washers, shall be free of scale, except tight mill
scale, and shall also be free of dirt, loose scale, burrs, other foreign material, and other

663
 711.65

980 defects that would prevent solid seating of the parts. Contact surfaces within slip-
critical joints shall be free of oil, grease, and any other material that reduces friction
between the contact surfaces.

(d) Installation

1. Bolt Tension
Each fastener shall be tightened to provide, when all fasteners in the joint are tight,
at least the minimum bolt tension shown in Table A for the size and grade of fastener
used.
990
TABLE A
Bolt Tension for ASTM F 3125, Grade A 325 Bolts
Bolt Size, in. Minimum Bolt Tension,* lbs
1/2 12,050
5/8 19,200
3/4 28,400
7/8 39,250
1 51,500
1 1/8 64,900
1 1/4 82,400
1 3/8 98,200
1 1/2 119,500
* Equal to the proof load given in ASTM F 3125

Threaded bolts shall be tightened with properly calibrated wrenches or by the

turn-of-nut method. If required because of bolt entering and wrench operation
clearances, tightening by either procedure may be done by turning the bolt while the
nut is prevented from rotating. Impact wrenches, if used, shall be of adequate capacity
and sufficiently supplied with air to perform the required tightening of each bolt in
approximately 10 s.

1000 Installation of all high strength bolts shall be in accordance with AASHTO LRFD
Bridge Construction Specifications. The snug tight condition as defined in AASHTO
LRFD Bridge Construction Specifications shall be obtained for all final tightening.

A Skidmore-Wilhelm calibrator or other acceptable bolt tension indicating

devices will be required on the project site for use during bolt installation. Periodic
tests shall be performed to ensure the installed bolt, nut, and washer assembly meets
the above requirements. Such tests shall be performed each work day when calibrated
wrench tightening is used. For short grip bolts, direct tension indicators with solid
plates may be used to perform these tests. Direct tension indicators shall first be
1010 checked with a longer grip bolt in the Skidmore-Wilhelm calibrator.

2. Washers
All fasteners shall have a hardened washer under the nut or bolt head turned in

664
 711.65

tightening. Where an outer face of the bolted parts has a slope of more than 1:20 with
respect to a plane normal to the bolt axis, a smooth beveled washer shall be used to
compensate for the lack of parallelism.

3. Calibrated Wrench Tightening

If calibrated wrenches are used to provide the bolt tension specified in 711.65(d)1,
1020 the settings shall be such as to induce a bolt tension of 5% to 10% in excess of this
value. These wrenches shall be calibrated at least once each working day by tightening,
in a device capable of indicating actual bolt tension, no less than three typical bolts of
each diameter from the bolts to be installed. Power wrenches shall be adjusted to stall
or cut-out at the selected tension. If manual torque wrenches are used, the torque
indication corresponding to the calibrating tension shall be noted and used in the
installation of all bolts of the tested lot. Nuts shall be in tightening motion when torque
is measured. When using calibrated wrenches to install several bolts in a single joint,
the wrench shall be turned to touch up bolts previously tightened which may have been
loosened by the tightening of subsequent bolts. This shall be continued until all are
1030 tightened to the required amount.

4. Turn-of-Nut Tightening
When the turn-of-nut method is used to provide the bolt tension specified in
711.65(d)1, there shall first be enough bolts brought to a snug tight condition to ensure
that the parts of the joint are brought into full contact with each other. Snug tight is
defined as the tightness attained by a few impacts of an impact wrench or the full effort
of a man using an ordinary spud wrench. Following this initial operation, bolts shall
be placed in all remaining holes in the connection and brought to snug tightness. All
bolts in the joint shall then be tightened additionally by the applicable amount of nut
1040 rotation specified in Table B with tightening progressing systematically from the most
rigid part of the joint to its free edges. During this operation there shall be no rotation
of the part not turned by the wrench.

TABLE B
Nut Rotation from Snug Tight Condition
(1) (2)

Disposition of Outer Faces of Bolted Parts

Both faces sloped(3)
Both faces normal to bolt axis, or 1 face normal to axis
from normal to bolt axis
and other face sloped(3) (bevel washer not used)
(bevel washers not used)
Bolt length(4) not exceeding Bolt length(4) exceeding
For all lengths of bolts
8 diameters or 8 in. 8 diameters or 8 in.
1/2 turn 2/3 turn 3/4 turn
(1) For coarse thread heavy hexagon structural bolts of all sizes and lengths and heavy hexagon
semi-finished nuts.
(2) Nut rotation is rotation relative to bolt regardless of the element (nut or bolt) being turned.
Tolerance on rotation: 1/6 of a turn over and nothing under.
(3) Slope 1:20 maximum.
(4) Bolt length is measured from underside of head to extreme, end of point.

665
 711.65

(e) Inspection

1. It will be determined that requirements 2 and 3 of 711.65(e)

are met in the work. When the calibrated wrench method
1050 of tightening is used, the Engineer shall be given full
opportunity to witness the calibration tests prescribed in
711.65(d)3.

2. The installation and tightening of bolts will be observed to

determine that the selected tightening procedure is properly
used and that all bolts are tightened.

3. The following inspection shall be used unless a more

extensive or different inspection procedure is specified.
1060
a. An inspection wrench which may be either a torque
wrench or a power wrench that can be adjusted
accurately in accordance with 711.65(d)3 shall be used.

b. Three bolts of the same grade, size and condition as

those under inspection shall be placed individually in a
calibration device capable of indicating bolt tension.
Length may be any length representative of bolts used
in the structure. There shall be a washer under the part
1070 turned in tightening each bolt.

c. When the inspecting wrench is a torque wrench, each

bolt specified in requirement 3b of 711.65(e) shall be
tightened in the calibration device by any convenient
means to the minimum tension specified for its size in
711.65(d)1. The inspecting wrench shall then be
applied to the tightened bolt. The torque necessary to
turn the nut or head 5°, or approximately 1 in. at a 12
in. radius, in the tightening direction shall be
1080 determined. The average torque measured in the tests
of three bolts shall be taken as the job inspecting torque
to be used in the manner specified in requirement 3e of
711.65(e).

d. When the inspecting wrench is a power wrench, it shall

be adjusted so that it shall tighten each bolt specified in
requirement 3b of 711.65(e) to a tension at least 5% but
no more than 10% greater than the minimum tension
specified for its size in 711.65(d)1. This setting of
1090 wrench shall be taken as the job inspecting torque to be

666
 711.70

used in the manner specified in requirement 3e of

711.65(e).

e. Bolts represented by the sample prescribed in

requirement 3b of 711.65(e) which have been tightened
in the structure shall be inspected by applying, in the
tightening direction, the inspection wrench and its job
inspecting torque to 10% of the bolts, but no less than
two bolts, selected at random in each connection. If no
1100 nut or bolt head is turned by this application of the job
inspecting torque, the connection shall be accepted as
properly tightened. If a nut or bolt head is turned by the
application of the job inspecting torque, this torque
shall be applied to all bolts in the connection. All bolts
whose nut or head is turned by the job inspection torque
shall be tightened and reinspected, or alternatively, the
fabricator or erector, at his option, may retighten all of
the bolts in the connection and then resubmit the
connection for the specified inspection.
1110
711.66 Bolted Connections Using Other Than High Strength Bolts
Bolts for these connections shall be in accordance with 910.02(h).

711.67 Final Clean-Up

Final clean-up shall be conducted in accordance with 104.07.

711.68 Structural Steel Cutting, Rivet and Bolt Removal, and Drilled Bolt
Holes in Repair Projects
Field cutting of structural steel shall be done as shown on the plans or as directed.
1120
Rivets or bolts connecting steel at locations shown on the plans or as directed shall
be removed. This work shall be done in a manner that does not damage the surrounding
steel. If necessary, such work shall be done by drilling.

Bolt holes shall be drilled as directed in the field. A bolt hole is a hole required
for one bolt drilled through any number and thicknesses of metal plates.

711.69 Jacking and Supporting Beams

When jacking and supporting a beam is required on a bridge repair project, the
1130 proposed method for jacking and supporting shall be submitted for approval. This
work shall not be performed until a method is approved.

711.70 Field Cleaning and Storage of Weathering Steel

Cleaning of structural steel specified to be left unpainted shall be in accordance
with 619.08(b) or 619.08(f) or as determined by the Engineer, depending on the
severity of the soilage. Foreign matter which adheres to the steel after it has been

667
 711.71

blasted, and which inhibits formation of the oxide film shall be removed as soon as
practical. The use of acids to remove scale and stains will not be allowed.

1140 Storage shall be such to enable free drainage to avoid moisture pockets.

711.71 Painting
After erection is complete, the structure shall be painted unless otherwise
provided. Painting shall be in accordance with the applicable requirements of 619.

711.72 Method of Measurement

Structural steel shapes, fabricated steel, steel castings, iron castings, bolts, pins,
rollers, rockers, anchor bolts, and threaded rods will be measured by the pound. If the
Schedule of Pay Items includes a lump sum item for structural steel, all of the materials
1150 listed above shall be included in such pay item. No measurement will be made.

Stud shear connectors placed on new structural steel will not be measured. Stud
shear connectors placed on existing structural steel will be measured by the number
installed.

Bronze plates will be measured by the pound. Pay weight will be based on a
theoretical density of 536 lbs/cu ft. Volume will be computed based on finished
dimensions. No deductions will be made for drilled holes.

1160 Field cutting of structural steel will be measured by the square inch as determined
by the multiplication of the length times the depth of the cut. Removal of rivets and
removal of bolts will be measured by the number of each removed. Drilled holes for
bolts on repair work will be measured by the number of drilled holes.

Jacking and supporting structural members will not be measured for payment.

Peening will be measured by the linear inch of peened weld. The length of weld
peened will be measured once per weld regardless of the number of passes necessary
to complete the work as specified.
1170
Repair welds will be measured by the linear inch of repaired weld.

711.73 Basis of Payment

The accepted quantities of structural steel shapes, fabricated steel, steel castings,
iron castings, bolts, pins, rollers, rockers, anchor bolts, and threaded rods will be paid
for at a contract lump sum price if the Schedule of Pay Items includes a lump sum pay
item for structural steel. Changes from the estimated quantities shall be in accordance
with 711.73(a). If the Schedule of Pay Items does not include a lump sum pay item for
structural steel, the accepted quantities of structural steel will be paid for at the contract
1180 unit price per pound for structural steel. Such pay item will include all work listed
above, complete in place. Payment will be in accordance with 711.73(b).

668
 711.73

Stud shear connectors placed on existing structural steel will be paid for at the
contract unit price per each, complete in place and accepted.

The accepted quantities of bronze plates will be paid for at the contract unit price
per pound. The accepted quantities of field structural steel cutting will be paid for at
the contract unit price per square inch for structural steel, field cut. The accepted
quantities of rivet removal, bolt removal, and drilled holes will be paid for at the
1190 contract unit price per each for rivet, remove; per each for bolt, remove; and per each
for drilled hole.

Jacking and supporting structural members, if specified as a pay item, will be paid
for at the contract lump sum price for jacking and supporting the types of structural
members shown in the Schedule of Pay Items.

The accepted quantities of peened weld will be paid for at the contract unit price
per inch. The accepted quantities of repaired weld will paid for at the contract unit
price per inch.
1200
Bolts, including anchor bolts and threaded rods, will be paid for as the full weight
computed on the basis of 490 lbs/cu ft, including nuts and washers, for the actual
number of bolts in the structure.

If welding is shown on the plans, the weights of the structural steel parts will be
computed as described above.

The weight of castings will be computed on the basis of 490 lbs/cu ft for cast steel,
and 450 lbs/cu ft for cast iron, based on the net volume of the finished castings as
1210 shown on the plans, including fillets at angles. No deductions will be made for holes
required to be drilled in castings or for rounding the corners of castings.

(a) Lump Sum Basis

An estimated weight of structural steel will be shown on the plans. Such weight
will be computed by the same method as that used when computing the estimated
weight when paid for on a unit price per pound basis from semi-detailed plans. This
weight will include all structural steel and miscellaneous metals unless otherwise
included in specific pay items.

1220 The weight of structural steel shown on the plans is approximate only. For a lump
sum pay unit, the Contractor shall determine the weight on which the bid is based.

If there is a discrepancy between the plan weight and the actual weight, no
decrease or increase in the payment for the work will be made on account of such
discrepancy.

If a change in the plans is made which will affect the weight of material to be
furnished, payment for the addition or reduction of structural steel quantities required

669
 711.73

as a result of such change in plans will be made at a unit price per pound obtained by
1230 dividing the lump sum amount for structural steel by the total estimated weight of
structural steel shown on the plans. Such unit price may be adjusted in consideration
of the fabricating and connection cost. Changes in the plans involving classifications
of structural steel may increase the pay quantities. Such additional quantities will be
paid for on comparison of evidence of invoice prices.

(b) Unit Weight Basis

The weight of materials will be shown in the bill of materials on the plans when
this information is included in such plans, or as computed from the fabricator’s
approved working drawings when this information is not included in the plans. In
1240 either case, such weight shall include all changes ordered.

For rolled sections, the gross weight of the steel will be considered. The weight
will be figured on the basis of 490 lbs/cu ft. The weight of each piece will be the weight
of the smallest regular shape from which the detail piece can be cut, not deducting cuts
or holes. When so shown on the contract plans or on the approved working drawings,
the weight of groups of two or more pieces shall be the weight of the smallest regular
shape from which the given group of detail pieces may be cut by properly arranging
the cuts.

1250 Payment will be made under:

Pay Item Pay Unit Symbol

Bolt, Remove ............................................................................. EACH

Bronze Plates ............................................................................. LBS
Drilled Hole ............................................................................... EACH
Jacking and Supporting ________ ............................................ LS
structural member type
Peening Weld, UIT .................................................................... INCH
1260 Repair Weld............................................................................... INCH
Rivet, Remove ........................................................................... EACH
Structural Steel .......................................................................... LS
LBS
Structural Steel, Field Cut ......................................................... SIN
Stud Shear Connectors .............................................................. EACH

The cost of paint removal, painting, non-destructive testing, equipment, labor,

materials, access, permits, and necessary incidentals shall be included in the cost of
peening weld, UIT.
1270
The cost of drilling holes for anchor bolts, elastomeric bearings, bridge bearing
pads, fabrication, painting, erecting falsework, welding material, Charpy V-Notch
toughness tests, and necessary incidentals shall be included in the cost of the pay items
in this section.

670
 712.02

The cost of stud shear connectors placed on new structural steel will be included
in the cost of structural steel.

No increase in pay weight will be considered if diaphragm connections other than

1280 those shown on the plans are approved and used.

Shims between beams and top shoes of the thicknesses necessary to adjust the
steel to planned elevations shall be furnished using either the plan datum or another
datum as established. No adjustment will be made to the pay quantities as long as the
total weight of shims required does not exceed that planned. No shim shall be less than
1/8 in. in thickness.

No allowance in weight will be made for work which is done at the option of the
Contractor. No payment will be made for material used at the convenience of the
1290 Contractor in excess of the quantities shown on the plans.

SECTION 712 – TIMBER STRUCTURES

712.01 Description
This work shall consist of furnishing the materials for and the construction of
timber structures, such parts of other structures which are of timber, and wood plank
floors for structures in accordance with 105.03.

712.02 Materials
Materials shall be in accordance with the following:
10
Iron Castings................................................................ 910.05(b)
Lumber and Timber (Treated) ..................................... 911.02
Lumber and Timber (Untreated).................................. 911.01
Malleable Iron Castings ............................................... 910.05(d)
Preservatives ................................................................ 911.02(h)
Steel Castings .............................................................. 910.05(a)
Structural Steel ............................................................ 910.02
Waterborne Finish Paint .............................................. 909.02(d)

20 Machine bolts, drift bolts, and dowels shall be medium steel. Machine bolts shall
have square heads and nuts, unless otherwise specified. Nails shall be full-barbed,
heavy, bright, flat-head, car nails. Lumber and timber shall be treated or untreated.
Rods, plates, bars, and shapes shall be structural steel. Castings shall be steel or iron.
Washers may be cast O. G. or malleable castings or they may be cut from medium
steel plates. Spikes shall be cut, wire, or boat spikes. Spikes, bolts, dowels, washers,
and lag screws shall be black or galvanized.

671
 712.03

CONSTRUCTION REQUIREMENTS

30 712.03 General Requirements

The ground underneath and in the immediate vicinity of all stored material shall
be cleaned of weeds and rubbish and kept well drained. Lumber and timber at the site
of the work shall be stored in piles. Untreated lumber shall be open stacked at least 12
in. above the ground surface, arranged to shed water and prevent warping, and
protected by a weatherproof covering when so required. Creosoted timber and piling
shall be closed-stacked so that warping is prevented and the tops of the stacks are
covered. Treated timber shall be handled carefully without sudden dropping, breaking
of outer fibers, bruising, or penetrating surfaces with tools. It shall be handled with
rope slings. Canthooks, peaveys, spikes, or hooks shall not be used. Creosoted piling
40 may be handled with chains.

Workmanship shall be first-class throughout. Competent bridge carpenters shall

be employed. All framing shall be true and exact. Nails and spikes shall be driven with
just sufficient force to set the heads flush with the surface of the wood. Deep hammer
marks in wood surfaces will be considered evidence of poor workmanship and
sufficient cause for the dismissal of a worker causing them.

In structures of untreated timber the ends, tops, and all contact surfaces of sills,
caps, floor beams, stringers, end joints, contact surfaces of bracing, the back faces of
50 bulkheads, and all timber which is to be in contact with earth, road material, or other
timber shall be coated with two coats of hot creosote oil before being assembled.
Countersinking shall be done where smooth faces are required. The recesses formed
by countersinking shall be painted with hot creosote oil and filled with hot pitch after
the bolt or screw is in place.

All cuts in treated piles or timber and all abrasions, after having been trimmed,
shall be covered with two applications of a mixture of 60% creosote oil and 40%
roofing pitch, or brush coated with at least two applications of hot creosote oil and
covered with hot roofing pitch. Insofar as practicable, cutting, framing, and boring of
60 timber to be treated, except pile cut-offs, shall be done before treatment.

All lumber and timber shall be cut accurately and framed to a close fit in such
manner that joints will have even bearing over the entire contact surfaces. Mortises
shall be true and even for their full depth and tenons shall fit snugly. Shimming will
not be allowed in making joints nor will open joints be accepted. Timbers requiring an
exact fit shall be matchmarked.

Holes for bolts, dowels, rods, and lag screws shall be bored as follows:

70 (a) machine bolts shall be the same diameter as the bolt;

(b) round drift bolts and dowels shall be 1/16 in. less in diameter
than that of the bolt or dowel to be used;

672
 712.05

(c) square drift bolts or dowels shall be equal to the least dimension
of the bolt or dowel;

(d) rods shall be 1/16 in. larger than the rod; and

80 (e) lag screws shall be the screw diameter to the base of thread, and
1/2 the screw diameter to the point of the screw.

Before driving bolts, hot creosote oil shall be poured into all bolt holes so that the
entire surface of the hole is coated. Any unfilled holes, after being treated with creosote
oil, shall be plugged with creosoted plugs.

A washer of the size and type specified shall be used under each bolt head and
under each nut which would otherwise come in contact with wood. Any portion of a
bolt projecting more than 1/4 in. beyond the nut shall be cut off. The threads of each
90 bolt shall be checked at the face of the nut after the nut has been finally tightened. The
ends of bracing shall be bolted through the pile, post, or cap with bolts of no less than
5/8 in. in diameter. Intermediate intersections shall be bolted or spiked with wire or
boat spikes as shown on the plans.

712.04 Caps
Timber caps shall have an even and uniform bearing over the tops of supporting
posts or piles and shall have their ends evenly aligned. All caps shall be secured by
drift bolts of no less than 3/4 in. in diameter extending at least 9 in. into the
approximate center of posts or piles. Pile heads, after being cut to receive the caps and
100 prior to placing the caps, shall be treated to prevent decay. The sawed surfaces of
creosoted piles shall be covered with three applications of a mixture of 60% creosote
oil and 40% roofing pitch or brush coated with three applications of hot creosote oil
and covered with hot roofing pitch. A covering of medium weight roofing felt or
galvanized iron shall be placed on this treatment, bent over the sides of the pile, and
fastened securely. Edges shall be trimmed to present a satisfactory appearance. The
sawed surfaces of untreated piles shall be brush coated with two applications of hot
creosote oil.

712.05 Stringers
110 Stringers shall be sized at bearings and so placed in position that any knots at or
near edges are in the top portion. Outside stringers may have butt joints with the ends
cut on a taper. Interior stringers shall be lapped to take bearing over the full width of
the floor beam or cap at each end. The lapped ends of untreated stringers shall be
separated at least 1/2 in. for the circulation of air and shall be securely fastened to the
cap by drift bolting where specified. Where stringers are two panels in length, the
joints shall be staggered. Cross-bridging between stringers shall be neatly and
accurately framed and securely toenailed with at least two nails in each end.

673
 712.06

712.06 Bents
120 Untreated timber, if used for mudsills shall be heart cedar, heart cypress, redwood,
or other approved durable timber. Mudsills shall be embedded firmly and evenly to
solid bearing and tamped in place. Concrete pedestals for the support of framed bents
shall be carefully finished so that the posts or sills take even bearing on them. The sills
or posts shall be anchored to pedestals with dowels and the dowels set when the
pedestals are poured. They shall be no less than 3/4 in. in diameter and shall project at
least 6 in. above the top of each pedestal. Sills shall have true and even bearing on
mudsills, grillages, piles, or pedestals. They shall be drift-bolted to mudsills or piles
with bolts no less than 3/4 in. in diameter and extend into the mudsills or piles at least
6 in. When feasible, all earth shall be removed from contact with sills to enable free
130 circulation of air around them.

Posts shall be fastened to pedestals with dowels of no less than 3/4 in. in diameter
extending at least 6 in. into the posts. Posts shall be fastened to sills, as shown on the
plans, by means of drift bolts of not less than 3/4 in. in diameter driven diagonally
through the base of the post, and extending at least 9 in. into the sill, or by means of
dowels of no less than 3/4 in. in diameter extending at least 6 in. into posts and sills.
Pile bents shall be driven in accordance with 701.

712.07 Wheel Guards and Railings

140 These shall be framed and erected true to line and grade. Wheel guards and rails
shall be surfaced as shown on the plans. Wheel guards shall be laid in sections of no
less than 12 ft in length.

712.08 Painting
Paint shall be applied to untreated lumber and timber as shown on the plans or as
otherwise specified. Lumber or timber treated with preservative shall not be painted,
unless otherwise specified. The color shall be as specified.

Surface preparation shall be the removal of all contamination such as oil, grease,
150 dirt, foreign matter, rust, mold, mildew, and sealers. Knots and pitch streaks shall be
scraped or burned, and sanded. All nail holes or small openings shall be caulked with
a general purpose caulking compound.

The surfaces shall be painted with one coat of waterborne finish paint. The paint
shall be applied by brush or roller only and at the rate recommended by the
manufacturer. All finishes shall be uniform in texture and color. If a painted surface is
unsatisfactory, the paint shall be removed and the surface shall be cleaned and
repainted or corrected as may be directed.

160 At the end of each work day, paint stains and splatters shall be removed from all
surfaces not intended to receive the paint applied for that day.

674
 712.12

712.09 Single-Ply Plank Floors

These floors shall consist of a single thickness of plank supported by stringers or
joists. The planks shall be laid heartside down with 1/4 in. openings for seasoned
material and with tight joints for unseasoned material. Each plank shall be fastened
securely to each joist or stringer. The planks shall be carefully selected for thickness
and laid so that a smooth riding surface is obtained.

170 712.10 Two-Ply Plank Floors

These floors shall consist of two layers of wood planks supported by stringers or
joists. Both courses shall have been pressure treated with creosote oil. The top course
shall be laid parallel to the roadway centerline with each piece fastened securely to the
lower course. The lower course shall be fastened as provided above for single-ply.
Joints shall be staggered at least 3 ft. Ends shall be fastened securely. If required, the
outer ends of the top planks shall be beveled at each end of the bridge.

712.11 Method of Measurement

Structural timber and lumber, both treated and untreated, will be measured by the
180 1,000 board foot measure. Planks for floors will be measured by the square foot.
Computation of the amount of lumber and timber will be based on full size for rough
lumber and nominal size for dressed lumber on the shortest commercial lengths which
may be used.

Metal parts, other than hardware, will be measured by the pound computed in
accordance with 711.73(b). Bolts, dowels, washers, nails, spikes, and lag screws will
be classed as hardware.

712.12 Basis of Payment

190 The accepted quantities of lumber and timber will be paid for at the contract unit
price per 1,000 board foot measure for lumber and timber, either treated or untreated
as specified. Plank floors will be paid for at the contract unit price per square foot for
plank floors of the ply specified. Metal parts will be paid for at the contract unit price
per pound.

Payment will be made under:

Pay Item Pay Unit Symbol

200 Lumber and Timber, Treated ..................................................... MFBM

Lumber and Timber, Untreated ................................................. MFBM
Metal Parts................................................................................. LBS
Plank Floors, ____ Ply .............................................................. SFT

The cost of preservative treatment, hardware, painting, and necessary incidentals

shall be included in the cost of the pay items.

675
 713.01

SECTION 713 – TEMPORARY BRIDGES AND APPROACHES

713.01 Description
This work shall consist of the construction and maintenance of temporary pile or
timber trestle bridges and approaches in accordance with 105.03.

713.02 Materials
Materials shall be in accordance with the following:

10 Delineators................................................................... 926.02
Delineator Posts ........................................................... 910.15
Fence ........................................................................... 910.18
Piling ........................................................................... 701

CONSTRUCTION REQUIREMENTS

713.03 General Requirements

Unless otherwise provided, the right-of-way will be furnished for temporary
bridges and approaches.
20
Information indicating the details of the temporary bridge proposed to be built
shall be submitted for approval. If this information is not in accordance with the plans,
details of the proposed temporary bridge signed by and bearing the seal of a registered
professional engineer shall be submitted. These details shall be supplied in triplicate
or in such form that may be reproduced readily. Information or details, or both if
required, regarding temporary bridges shall be submitted and approved before work is
started.

Where it is necessary to remove existing fence, a temporary fence shall be erected

30 along the temporary right-of-way line, if so directed. This fence shall be substantially
as good as the existing fence. It shall be built and maintained satisfactorily.

713.04 Temporary Bridge

Unless otherwise provided, the temporary bridge shall have a clear roadway of no
less than 28 ft and be designed to carry an HS20 truck loading. The bridge shall be
provided with substantial railings which shall be kept painted white. Backwalls shall
be built at each end bent to hold the approach fills. Each bent shall have at least four
piles or four substantial posts on an adequate mudsill. The temporary bridge shall be
built to an elevation of not less than that shown on the plans. It shall have a clear length
40 opening no less than shown or otherwise designated. Unless otherwise specified, all
timber and piles may be treated or untreated.

713.05 Temporary Pipe

The minimum thickness required for the temporary pipe or pipe-arch shall be as
follows:

676
 713.07

(a) Corrugated Steel Circular Pipe

Thickness, in. Pipe Diameter, in.

0.064 48 or less
0.079 54 or less
0.109 72 or less
0.138 78 or less
0.168 84 or less

50 (b) Corrugated Steel Pipe-Arch, 3 in. by 1 in. Corrugations

Thickness, in. Pipe-Arch Area, sq ft

0.109 40 or less
0.138 58 or less

(c) Structural Plate Pipe-Arch 6 in. by 2 in. Corrugations

Thickness, in. Pipe-Arch Area, sq ft

0.111 38 or less
0.140 71 or less
0.170 122 or less
0.188 131 or less

For thicknesses, diameters, or areas not listed above, the Engineer shall be
contacted for approval.

713.06 Temporary Approaches

60 Temporary approaches shall be constructed to a line and grade which will provide
a reasonably convenient and safe connection between the temporary bridge and the
existing road. The grade and crown elevation shall be as shown on the plans. The
roadway and slopes shall be as shown on the plans. All necessary drainage shall be
provided. Embankment shall be compacted in accordance with 203. If it becomes
necessary to reconstruct the connection of the approaches with the existing roadway,
either because of the operations or other cause, such adjustment shall be made as
directed. HMA pavement for temporary approaches shall be in accordance with 402.
Temporary pavement markings in accordance with 801.12 shall be placed as shown
on the plans. Delineators in accordance with 804 shall be placed as shown on the plans.
70
Guardrail and guardrail end treatment shall be provided at each corner of the
temporary bridge as shown on the plans or as directed. The furnishing of materials and
installation shall be provided in accordance with 601. After removal, the guardrail and
guardrail end treatment will remain the property of the Contractor.

713.07 Maintenance
Unless otherwise provided, where a temporary bridge is required, traffic over the
existing bridge shall not be prohibited until the temporary bridge and approaches are

677
 713.08

satisfactorily completed and opened to traffic. They shall be so maintained until the
80 new structure is opened to traffic. The necessary material and labor shall be furnished
to repair or replace any portion of the temporary bridge and approaches which may
have deteriorated under traffic. During the winter months, salt or other equivalent
materials shall be used as directed to prevent slippery conditions.

713.08 Removal
When the new work which made the temporary bridge and approaches necessary
is opened to traffic, all the temporary work shall be removed and the temporary right-
of-way shall be restored as nearly as possible to its original or satisfactorily altered
state. All bents in the stream shall be removed entirely or down to the bed of the stream
90 and all other bents either removed entirely or to 2 ft below the ground surface, unless
the property owner of the temporary right-of-way consents in writing to have them cut
at the ground line. Temporary bituminous HMA pavement, when no longer required
for maintenance of traffic, shall be removed and shall be disposed of in accordance
with 203.10.

713.09 Method of Measurement

Temporary bridges, temporary pipes, and approaches will not be measured for
payment unless otherwise specified. HMA mixtures for temporary pavement will be
measured by the ton. Guardrail of the type specified will be measured by the linear
100 foot along the top of rail. Guardrail end treatments will be measured per each of the
type specified. Temporary pavement markings will be measured in accordance with
801.17. Seeding and sodding will be measured in accordance with 621.13. The
removal and disposal of temporary HMA pavement will not be measured for payment.

713.10 Basis of Payment

The accepted quantities of temporary bridge and approaches, or temporary pipe
and approaches will be paid for at the contract lump sum price for the work, complete
in place and later removed as specified. HMA mixtures for temporary pavement will
be paid for as the type of mixture specified, in accordance with 610.06, complete in
110 place. Guardrail installed along approaches will be paid for at the contract unit price
per linear foot. Guardrail end treatment will be paid for at the contract unit price per
each for the type specified. Temporary pavement markings will be paid for in
accordance with 801.18.

Seeding and sodding will be paid for in accordance with 621.14.

If adjustment of approach embankments is necessary, the additional excavation

and borrow will be paid for in accordance with 203.28.

120 Payment will be made under:

678
 714.02

Pay Item Pay Unit Symbol

Guardrail End Treatment, _____,

type
Temporary Bridge Approaches........................................... EACH
Guardrail, W-Beam, ____ ft.-____ in. Spacing,
Temporary Bridge Approaches........................................... LFT
Temporary Bridge and Approaches ........................................... LS
130 Temporary Bridge ..................................................................... LS
Temporary Pipe and Approaches .............................................. LS
Temporary Pipe ......................................................................... LS

The cost of excavation, embankment, backfill, removal and disposal of temporary

HMA pavement, delineators, and temporary fence, shall be included in the cost of the
pay items.

The cost of furnishing, installation, and removal of guardrail and guardrail end
treatment shall be included in the cost of the pay items.
140
If the Contractor elects to build a longer bridge or approaches than specified, such
work shall be done with no additional payment. If such work requires additional right-
of-way, it shall be provided with no additional payment.

SECTION 714 – REINFORCED CONCRETE BOX STRUCTURES

714.01 Description
This work shall consist of the construction of a cast-in-place or precast reinforced
concrete box structure and such parts of similar structures composed of concrete in
accordance with these specifications and 105.03.

The Contractor will be allowed to substitute a three-sided structure in accordance

with 723. The three-sided structure shall be of equivalent hydraulic capacity to that of
10 the box structure shown on the plans. The structure shall be sumped as shown on the
plans.

714.02 Materials
Materials shall be in accordance with the following:

Chemical Anchor System ............................................ 901.05

Coarse Aggregates, Class A or Higher,
Size No. 91 ........................................................... 904
Concrete ...................................................................... 702
20 Epoxy Coated Reinforcing Bars .................................. 910.01
Flowable Backfill ........................................................ 213
Geotextile .................................................................... 918.02(b)

679
 714.02

Hydrated Lime ............................................................. 913.04(a)

Joint Membrane System for Precast Reinforced
Concrete Box Structure Sections .......................... 907.07
Masonry Cement ......................................................... 901.01(c)
Mortar Sand ................................................................. 904.02(e)
Natural Sand ................................................................ 904.02(a)
Non-Epoxy PCC Sealer ............................................... 909.10
30 Pipe Joint Sealant ........................................................ 907.11
Portland Cement .......................................................... 901.01(b)
Precast Reinforced Concrete Headwalls, Wingwalls,
Footings, and Spandrel Walls ............................... 907.06
Precast Reinforced Concrete Structure Sections ......... 907.05
Reinforcing Bars.......................................................... 910.01
Riprap .......................................................................... 904
WWR, Smooth and Deformed..................................... 910.01
Structure Backfill ........................................................ 904.05

40 Cast-in-place concrete for a reinforced concrete box structure, or splices between

an existing culvert structure and a precast reinforced concrete box structure section
extension shall be class A or higher in accordance with 707.04(c). It shall have a 28-
day minimum concrete compressive strength of 5,000 psi. Cast-in-place concrete for
headwalls or wingwalls shall be class A or higher in accordance with 707.04(c). It
shall have a 28-day minimum concrete compressive strength of 4,000 psi.

When the Contractor elects to provide a cast-in-place structure, acceptance of the

structure will be based on tests for relative yield, air content, slump,
water/cementitious ratio, and compressive strength. Relative yield and air content shall
50 be in accordance with 702.05. The slump and concrete temperature shall be in
accordance with 707.04(c). The amount of time from the introduction of mixing water
to the cement and aggregates to the completion of the discharge of the concrete shall
not exceed 90 minutes. The water/cementitious ratio shall be in accordance with
707.04(d). The 28-day compressive strength shall be equal to or greater than the
specified concrete compressive strength and otherwise shall be in accordance with
707.04(c)3. The Contractor shall provide the necessary 6 in. diameter by 12 in.
cylinder molds for the Department’s use.

For plastic concrete sampling, acceptance testing procedures and casting cylinders
60 will be in accordance with 505.01. Except for footings, concrete flexural strength or
results from beam breaks will not be accepted in lieu of concrete compression cylinder
test results.

Cast-in-place concrete used to seal existing culverts shall be class A. Cast-in-place

concrete for footings shall be class B.

Unless otherwise specified herein, reinforcement may consist of either reinforcing

bars or WWR. If specified to be coated, WWR shall be coated with either galvanized

680
 714.04

coating or epoxy coating, and reinforcing bars shall be coated with epoxy coating. For
70 WWR, material with minimum yield strength of 65 ksi shall be used.

CONSTRUCTION REQUIREMENTS

714.03 General Requirements

Unless otherwise specified, the applicable requirements of 702 and 703 shall
apply to the construction of box structures, structure extensions, and concrete parts of
similar structures. Excavation and disposal shall be in accordance with the applicable
requirements of 206. Areas designated for waterproofing shall be waterproofed in
accordance with 702.23. All underground drains encountered during excavation for
80 the structure shall be perpetuated as dictated by field conditions. Drainage openings
through masonry shall be in accordance with 702.16. Handling of box structures shall
be in accordance with 907.05. Handling of wingwalls shall be in accordance with
907.06.

When riprap is specified, geotextile shall first be placed on the in-situ soil in
accordance with 616.11. Riprap shall then be placed in accordance with 616.

714.04 Design Requirements

Where reinforcing bars are used, reinforcing bar splicing and spacing shall be in
90 accordance with the AASHTO LRFD Bridge Design Specifications, except as
modified herein.

(a) Box Structure

A box structure may be designed in accordance with ASTM C 1577 if the box
section is listed therein. A box structure section not listed therein shall be designed in
accordance with the AASHTO LRFD Bridge Design Specifications with the following
exceptions.

The box structure shall be designed in accordance with the soil parameters shown
100 in the contract documents.

Minimum structural reinforcement area shall be at least 0.002 of the gross

concrete area Ag or 0.125 sq in./ft, whichever is greater. The allowable variation in
diameter of reinforcement shall be in accordance with the tolerances prescribed in the
AASHTO specification for that type of reinforcement.

If coated reinforcement is specified, reinforcement, including support devices, in

that structure shall be coated. In lieu of coating, the support device may be
manufactured of a non-corrosive material.
110
(b) Concrete Headwalls, Wingwalls, and Footings
Headwalls, wingwalls, and footings may be precast or cast-in-place. Headwalls
and wingwalls shall be designed based on a minimum equivalent fluid pressure of 40
lbs/cu ft. If flowable backfill is to be used, the Contractor shall consider the effects of

681
 714.04

hydrostatic pressure on the wingwalls. Weep holes shall be provided in all wingwalls.
Horizontal pressures shall be increased for sloping backfill surfaces and live-load
surcharge. Headwall connections and wingwall footings shall be checked for sliding
and for overturning.

120 Wingwalls and wingwall footings shall be designed in accordance with the soil
parameters shown in the contract documents.

A headwall with guardrail mounted on top, the anchorage of the headwall to the
box structure section, or a moment slab with bridge railing shall be designed for the
bridge railing test level shown on the plans.

Reinforcement in headwalls shall consist of reinforcing bars and shall be epoxy

coated. Tension splices in circumferential reinforcement shall be made by means of
lapping. Where reinforcing bars are used in wingwalls, the maximum spacing for
130 wingwall reinforcing bars shall be 18 in. for horizontal bars and 12 in. for vertical bars.

Concrete cover for headwall and wingwall reinforcement shall be a minimum of

2 in. Concrete cover for footing reinforcement shall be 3 in. for the top and sides, and
4 in. for the bottom.

(c) Working Drawings

Working drawings shall be submitted in accordance with 105.02 for fabrication
of a precast reinforced concrete box structure greater than 12 ft span, a box structure
of a size not described in ASTM C 1577, headwalls, wingwalls, and footings. Design
140 calculations shall be submitted with the working drawings. Detailed plans for
falsework and centering will not be required. Working drawings shall include all
details, dimensions, and quantities necessary to construct the structure, headwalls,
wingwalls, or footings and shall include, but not be limited to, the following
information.

1. Structure span and rise.

2. Structure section details showing all concrete dimensions

and reinforcement requirements.
150
3. Headwall details, showing all concrete dimensions,
elevations, reinforcing bar sizes, reinforcing bar bending
diagrams, lengths, spacings, and anchorage details.
Headwall elevation and section views shall be provided.

4. Wingwall design calculations and details showing all

concrete dimensions, elevations, reinforcement sizes,
bending diagrams, lengths, spacings, and anchorage
details. Wingwall plan, elevation, and section views shall
160 be provided.

682
 714.05

5. Wingwall backfill type and limits.

6. Footing details showing all concrete dimensions,

elevations, reinforcing bar sizes, reinforcing bar bending
diagrams, lengths, and spacings indicated. Footing plan
and section views shall be provided. The actual soil bearing
pressure shall be shown on the footing detail sheets.

170 7. Structure backfill type and limits for the structure and
wingwalls.

8. Minimum concrete strength for all concrete portions of the

structure.

9. Bridge load rating calculations and load rating summary

shall be submitted with the working drawings where the
structure span length measured along the roadway
centerline is greater than 20 ft, except where the height of
180 cover is greater than 8 ft and exceeds the perpendicular
span length. The structure shall load rate greater than 1.0
for the loading described herein or as shown on plans. The
load rating methodology shall be in accordance with the
AASHTO Manual of Bridge Evaluation using the LRFR
methodology.

714.05 Erection Requirements

The soils in the bottom of the excavation shall be compacted in accordance with
203.23.
190
An 8 in. layer of coarse aggregate No. 8 in accordance with 301 shall be placed
under the full width of the footing. All cast-in-place footings shall be given a smooth
float finish. The footing concrete shall reach a compressive strength of 2,000 psi or
flexural strength in accordance with 702.24(c) before placement of the wingwalls. The
surface shall not vary more than 1/4 in. in 10 ft if tested with a 10 ft straightedge.

Structure backfill shall be placed and compacted in accordance with 211.

Structure backfill shall be placed and compacted on each side of the structure to the
fill line shown on the plans. During the backfill operation, the difference in elevations
200 of the fill on each side of the structure shall not exceed 24 in.

Unless otherwise specified by the manufacturer on the working drawings, once

the level of structure backfill reaches the top of the structure, two lifts shall be spread
and hand compacted over the structure without traversing the structure with heavy
equipment. Compaction with heavy equipment will not be allowed until a minimum
of two lifts have been placed, hand compacted, and accepted.

683
 714.06

The operation of equipment over a structure shall be in accordance with the

structure manufacturer’s recommendations.
210
714.06 Precast Concrete Headwalls, Wingwalls, and Footings

(a) Headwall Reinforcement Placement Relative to Top of Structure

The headwall shall be a single precast piece which spans from sidewall to sidewall
of a span. The vertical headwall reinforcement shall be attached to the top of the
structure by either drilling holes or precasting holes. A chemical anchoring material,
if used, shall be from the Department’s List of Approved Chemical Anchoring
Materials.

220 (b) Wingwall Placement

Each wingwall that is not precast as one unit with the footing shall be set on
masonite or steel shims. A minimum gap of 1/2 in. shall be provided between the
footing and the bottom of each wingwall. Once the wingwalls are placed, the space
underneath the wingwall section to the top of the keyway sides shall be filled with
prepackaged grout in accordance with ASTM C 1107, or conventional or self-
consolidating fine grout in accordance with ASTM C 476, except as modified herein.
If conventional fine grout is used, it shall be troweled into the keyway and mounded
on one side of the wingwall. The mound of conventional fine grout shall be vibrated
until it passes through to the other side of the wingwall. After completing this process
230 on one side, if the conventional fine grout has not passed through to the other side, the
process shall be repeated on the other side. Conventional or self-consolidating fine
grout shall be from a prepackaged source or composed of one of the following
mixtures.

1. 930 lbs/cu yd Type I portland cement with No. 23 natural

sand or mortar sand.

2. 930 lbs/cu yd Type M masonry cement with No. 23 natural

sand or mortar sand.
240
3. 828 lbs/cu yd Type I portland cement and 75 lbs/cu yd
hydrated lime with No. 23 natural sand or mortar sand.

The maximum water/cement ratio shall be 0.446 for both conventional and self-
consolidating fine grout. An air entraining agent from the Department’s list of
approved PCC admixtures may be used. A type F or G chemical admixture from the
Department’s list of approved PCC admixtures shall be used in self-consolidating fine
grout in order to achieve the slump flow and visual stability index requirements. Filling
procedure B of ASTM C 1611 will be used for measuring slump flow. Appendix X1
250 of ASTM C 1611 will be used for determining the visual stability index value.

684
 714.09

Acceptance of conventional fine grout will be based on an air content of 12%

±4%. Acceptance of self-consolidating fine grout will be based on tests for air content,
slump flow, and visual stability index. Air content shall be 12% ±4%. Slump flow
shall be 27 in. ±3 in. Visual stability index value shall not exceed 1.

Where prepackaged grout is used, a type C certification in accordance with 916

shall be provided.

260 Wingwalls shall be connected to the outside box structure sections with bolted
steel plates.

714.07 Rejection
Structure sections, headwalls, wingwalls, or footings will be rejected due to the
following conditions:

(a) fractures or cracks passing through the section or wall, except

for a single end crack which does not exceed one-half the
thickness of the section or wall;
270
(b) defects which indicate proportioning, mixing, or molding which
are not in accordance with this specification;

(c) honeycombed or open texture; or

(d) damaged section ends, where such damage prevents making a

satisfactory joint.

714.08 Repairs
280 Structure sections, headwalls, wingwalls, and footings shall be repaired, if
necessary, due to imperfections in manufacture, or damage caused by handling or
construction. Repairs will be acceptable if it is determined that the repairs are sound,
properly finished and cured, and if the repaired structure section, headwall, wingwall,
or footing is in accordance with the requirements herein.

714.09 Extension of Existing Structure

All applicable requirements of this specification shall apply to the extension of an
existing box structure, slab-top structure, or arch structure. Such portions of the
existing structure designated for removal shall be removed. All portions of the existing
290 structure which are to remain in place and are damaged shall be repaired or replaced
as directed. Those portions left in place which are wholly or partially filled with debris
shall be cleaned out. Material removed shall be disposed of in accordance with the
applicable requirements of 202.02.

Before removing concrete from an existing structure with wingwalls, the

Contractor shall saw around the perimeter of the removal area on the interior and
exterior of the existing structure a depth of 1 in. All existing reinforcement in the top

685
 714.10

slab, bottom slab, and sidewalls exposed after concrete removal shall be cleaned and
straightened in preparation for lapping with reinforcement from adjacent new work.
300 Where existing reinforcement has deteriorated or been damaged during the removal
operation, holes shall be drilled into the face of the existing structure to provide
embedment for replacement reinforcing bars. The holes shall be of the diameter and
depth required by the manufacturer of the approved chemical anchor system. The holes
shall be cleaned prior to placing the approved chemical anchor system and the
reinforcing bars.

No concrete shall be removed from an existing structure that has a headwall but
no wingwalls. Reinforcing bars to tie the existing structure to the new structure section
shall be installed by drilling holes into the face of the existing structure to provide
310 embedment for reinforcing bars. The diameter and depth of the holes shall be
according to the recommendations of the manufacturer of the approved chemical
anchor system. The holes shall be cleaned prior to placing the approved chemical
anchor system and the reinforcing bars.

An existing structure shall be extended by one of the following methods.

(a) Precast Reinforced Concrete Box Structure Extension

A cast-in-place concrete splice shall be constructed as a transition between the
existing structure and the precast structure extension. The splice reinforcement in the
320 precast structure extension section that will abut the existing structure shall be exposed
18 in. on the tongue end of the precast structure extension section. It shall be lapped
18 in. with either exposed existing structure reinforcement, in the case of an existing
structure with wingwalls, or newly installed reinforcing bars in the existing structure,
in the case of an existing structure with a headwall only as shown on the plans. Existing
exposed structure reinforcement from an existing structure with wingwalls shall be cut
off 1 in. from the face of the new precast extension.

If the existing tongue or groove joint end is acceptable and matches the mating
joint on the new precast reinforced concrete box structure extension, the new extension
330 may be installed using the mating joint of the existing box structure. No cutting of the
box structure or splicing of reinforcement is then required. The joint between the new
precast box structure extension and the existing structure shall be sealed as directed
below.

(b) Cast-In-Place Concrete Structure Extension

The reinforcement for the structure extension shall be lapped with the exposed
reinforcement of the existing structure as shown on the plans.

714.10 Precast Reinforced-Concrete Box Structure Section Joints

340 Precast reinforced concrete box structure section joints shall be sealed as shown
on the plans. Pipe joint sealant shall be applied once the concrete surface temperature
is above 40°F or above the minimum application temperature recommended by the
pipe joint sealant manufacturer. The concrete surfaces shall be clean and dry prior to

686
 714.12

application of the pipe joint sealant. Heat may be applied to the concrete surfaces until
they are in accordance with the temperature and dryness requirements. The pipe joint
sealant shall be centered on both sides of the joint as it is being applied. After
application, the geotextile or membrane material shall be rolled to avoid wrinkling. If
the roll of geotextile or membrane material does not cover the full length of the joint,
an overlap of at least 2 1/2 in. will be required to start the next roll of material. The
350 manufacturer’s application instructions shall apply in addition to the above
requirements.

714.11 Method of Measurement

Precast reinforced concrete box structures or structure extensions, precast coated
reinforced concrete box structures or structure extensions, precast headwalls, precast
wingwalls, cast-in-place reinforced concrete box structures or structure extensions,
cast-in-place coated reinforced concrete box structures or structure extensions, cast-
in-place headwalls, and cast-in-place wingwalls will not be measured. The accepted
quantities for payment will be the quantities shown on the plans.
360
Geotextile and riprap will be measured in accordance with 616.12. Structure
backfill will be measured in accordance with 211.09. Flowable backfill will be
measured in accordance with 213.08. Field drilled holes will be measured in
accordance with 702.27.

Plain or coated reinforcement or WWR used in precast reinforced concrete box

structures or structure extensions, precast headwalls, precast wingwalls, cast-in-place
reinforced concrete box structures or structure extensions, cast-in-place headwalls, or
cast-in-place wingwalls will not be measured for payment.
370
If the Contractor elects to provide a three-sided structure in lieu of the box
structure shown on the plans, it will be measured in accordance with 723.17.

714.12 Basis of Payment

The accepted quantities of precast reinforced concrete box structures or structure
extensions, precast coated reinforced concrete box structures or structure extensions,
cast-in-place reinforced concrete box structures or structure extensions, and cast-in-
place coated reinforced concrete box structures or structure extensions of the size
specified will be paid for at the contract unit price per linear foot.
380
Geotextile or riprap will be paid for in accordance with 616.13. Structure backfill
will be paid for in accordance with 211.10. Flowable backfill will be paid for in
accordance with 213.09. Field drilled holes will be paid for in accordance with 702.28.

If the Contractor elects to provide a three-sided structure in lieu of the box

structure shown on the plans, it will be paid for in accordance with 723.18. The
Department will not incur additional cost for allowing the Contractor to substitute a
three-sided structure for the box structure shown on the plans.

687
 714.12

390 Payment will be made under:

Pay Item Pay Unit Symbol

Structure Extension, Coated Reinforced Concrete,

Box Sections, ____ ft x ____ ft .......................................... LFT
span rise
Structure Extension, Reinforced Concrete,
Box Sections, ____ ft x ____ ft .......................................... LFT
span rise
400 Structure, Coated Reinforced Concrete,
Box Sections, ____ ft x ____ ft .......................................... LFT
span rise
Structure, Reinforced Concrete,
Box Sections, ____ ft x ____ ft .......................................... LFT
span rise

The cost of excavation except as provided in 206.11(a), expansion joint material,

perpetuation of existing drains shown on the plans, removal of portions of existing
structures, cleaning out old channels or structures, approved chemical anchor system,
410 precast reinforced concrete structure joints, and necessary incidentals shall be included
in the cost of the structure or structure extension.

The cost of precast concrete headwalls, precast concrete wingwalls, cast-in-place

headwalls, or cast-in-place wingwalls shall be included in the cost of the structure or
structure extension.

The cost of plain or coated reinforcement or WWR used in precast reinforced

concrete box structures or structure extensions, precast headwalls, precast wingwalls,
cast-in-place reinforced concrete box structures or structure extensions, cast-in-place
420 headwalls, or cast-in-place wingwalls shall be included in the cost of the structure or
structure extension.

The cost of concrete used in a cast-in-place splice shall be included in the cost of
the structure extension.

The cost of designing a box structure, box structure extension, headwalls, and
wingwalls shall be included in the cost of the structure or structure extension.

The costs of coring, testing, excavation, repairs, plugging core and handling holes,
430 mortar, grout, sealer, cylinder molds, and necessary incidentals shall be included in
the cost of the structure. The cost of wingwall footing and the aggregate base shall be
included in the cost of the structure or structure extension.

No additional payment will be made for carrying an underground drain through a

structure or structure extension. However, no deduction will be made for the volume

688
 715.02

of concrete occupied by the drain pipe in a cast-in-place structure or structure

extension.

No additional payment will be made for the repair or replacement of existing

440 concrete damaged by Contractor operations.

SECTION 715 – PIPE CULVERTS, AND STORM AND SANITARY SEWERS

715.01 Description
This work shall consist of the construction or reconstruction of pipe culverts,
storm or sanitary sewers, slotted drain pipe, or slotted vane drain pipe in accordance
with 105.03.

MATERIALS

10 715.02 Materials
Pipe materials, minimum thickness or strength classification, and protective
treatments for pipes except underdrains and drain tile will be determined based on
height of cover, required service life, site abrasiveness, and structure pH criteria shown
on the plans. Pipe with material thickness, strength classification, or protective
coatings in excess of the minimum required by the above noted criteria may be used.
When metal pipe is selected, the same base metal and coating shall be used for the
structure or a pipe extension.

Concrete used for anchors, collars, grated box end sections, encasements, and
20 sealing existing pipes shall be class A. Corrugated polyethylene pipe, type S has a
smooth interior liner with a corrugated outer wall. Type SP pipe is a type S pipe with
perforations.

Materials shall be in accordance with the following:

B Borrow ..................................................................... 211

Concrete ...................................................................... 702
Flowable Backfill ........................................................ 213
Geotextiles ................................................................... 918.02
30 Pipe Joint Sealant ........................................................ 907.11
Reinforcing Bars.......................................................... 910.01
Rubber Type Gaskets .................................................. 907.13
Straps, Hook Bolts, and Nuts....................................... 908.12
Structure Backfill ........................................................ 904

The maximum particle size of backfill material for corrugated pipe shall be less
than 1/2 the corrugation depth.

689
 715.02

(a) Type 1 Pipe

40 Type 1 pipe shall be used for culverts under mainline pavement and public road
approaches and shall be in accordance with the following:

Clay Pipe, Extra Strength ............................................ 907.08

Corrugated Aluminum Alloy Pipe and Pipe-Arches ... 908.04
Corrugated Polyethylene Pipe, Type S ........................ *
Corrugated Polypropylene Pipe ................................... *
Corrugated Steel Pipe and Pipe-Arches ....................... 908.02
Non-Reinforced Concrete Pipe, Class 3 ...................... 907.01
Polymer Precoated Galvanized Corrugated Steel
50 Pipe and Pipe-Arches............................................ 908.08
Profile Wall Polyethylene Pipe, Closed....................... *
Profile Wall Polyethylene Pipe, Ribbed ...................... *
Profile Wall PVC Pipe................................................. *
Reinforced Concrete Horizontal Elliptical Pipe .......... 907.03
Reinforced Concrete Pipe ............................................ 907.02
Smooth Wall Polyethylene Pipe .................................. *
Smooth Wall PVC Pipe ............................................... *
Spiral Rib Steel Pipe.................................................... 908.02
Structural Plate Pipe and Pipe-Arches ......................... 908.09
60 * All thermoplastic pipes shall be from the Department’s list of approved
thermoplastic pipe and liner pipe in accordance with 907.16.

(b) Type 2 Pipe

Type 2 pipe shall be used for storm sewers and shall be in accordance with the
following:

Clay Pipe, Extra Strength ............................................ 907.08

Corrugated Polyethylene Pipe, Type S ........................ *
Corrugated Polypropylene Pipe ................................... *
70 Fully Bituminous Coated and Lined Corrugated Steel
Pipe and Pipe-Arches............................................ 908.07
Non-Reinforced Concrete Pipe, Class 3 ...................... 907.01
Polymer Precoated Galvanized Corrugated Steel
Pipe and Pipe-Arches Type IA and Type IIA ....... 908.08
Profile Wall Polyethylene Pipe, Closed ...................... *
Profile Wall Polyethylene Pipe, Ribbed ...................... *
Profile Wall PVC Pipe................................................. *
Reinforced Concrete Horizontal Elliptical Pipe .......... 907.03
Reinforced Concrete Pipe ............................................ 907.02
80 Smooth Wall Polyethylene Pipe .................................. *
Smooth Wall PVC Pipe ............................................... *
* All thermoplastic pipes shall be from the Department’s list of approved
thermoplastic pipe and liner pipe in accordance with 907.16.

690
 715.02

(c) Type 3 Pipe

Type 3 pipe shall be used for culverts under all drives and field entrances. All
Type 1 pipe materials are acceptable.

(d) Type 4 Pipe

90 Type 4 pipe shall be used for drain tile and longitudinal underdrains and shall be
in accordance with the following:

Clay Pipe** ................................................................. 907.08

Corrugated Polyethylene Drainage Tubing ................. *
Corrugated Polyethylene Pipe, Type S** .................... *
Corrugated Polyethylene Pipe, Type SP ...................... *
Drain Tile** ................................................................ 907.10
Non-Reinforced Concrete Pipe .................................... 907.01
Perforated Clay Pipe** ................................................ 907.09
100 Perforated PVC Semicircular Pipe .............................. *
Profile Wall PVC Pipe................................................. *
* All thermoplastic pipes shall be from the Department’s list of
approved thermoplastic pipe and liner pipe in accordance with 907.16.
** These materials shall be used for drain tiles only.

(e) Type 5 Pipe

Type 5 pipe shall be used for broken-back pipe runs where coupled or jointed pipe
is desirable and shall be in accordance with the following:

110 Corrugated Aluminum Alloy Pipe and Pipe-Arches ... 908.04

Corrugated Polyethylene Pipe, Type S ........................ *
Corrugated Polypropylene Pipe ................................... *
Corrugated Steel Pipe and Pipe-Arches ....................... 908.02
Fully Bituminous Coated and Lined Corrugated
Steel Pipe and Pipe-Arches ................................... 908.07
Polymer Precoated Galvanized Corrugated Steel
Pipe and Pipe-Arches............................................ 908.08
Profile Wall Polyethylene Pipe, Closed....................... *
Profile Wall Polyethylene Pipe, Ribbed ...................... *
120 Profile Wall PVC Pipe................................................. *
Smooth Wall Polyethylene Pipe .................................. *
Smooth Wall PVC Pipe ............................................... *
Spiral Rib Steel Pipe.................................................... 908.02
* All thermoplastic pipes shall be from the Department’s list of approved
thermoplastic pipe and liner pipe in accordance with 907.16.

(f) Slotted Drain Pipe

Slotted drain pipe shall be used to drain paved median and concrete gutter areas.
Slotted drain pipe shall be in accordance with 908.14.
130

691
 715.02

(g) Slotted Vane Drain Pipe

Slotted vane drain pipe shall be used to drain driveway areas. Slotted vane drain
pipe shall be in accordance with 908.14.

(h) End Bent Drain Pipe

End bent drain pipe shall be perforated profile wall PVC pipe, perforated smooth
wall PVC pipe, or corrugated polyethylene drainage tubing Type SP from the
Department’s list of approved thermoplastic liner pipe in accordance with 907.16.

140 (i) Underdrain Outlet Pipe

Pipe shall be profile wall PVC pipe or smooth wall pipe for outlets from the
Department’s list of approved thermoplastic pipe and liner pipe in accordance with
907.16.

(j) Grated Box End Sections

Grating for box end sections shall be in accordance with 910.22. Threaded inserts
for type II grated box end sections shall have a minimum pull-out capacity of 6,000
lbs. The 1/2 in. round bolts shall have hex heads, cut washers, and where necessary,
shall be furnished with the grating. The aggregate leveling bed required for precast
150 units shall be coarse aggregate No. 8 in accordance with 904.03. The hardware cloth
used to cover the weep holes, may be plastic with 1/4 in. mesh or galvanized steel wire
No. 4 mesh with a minimum wire diameter of 1/32 in. It shall be firmly anchored to
the outside of the structure and shall be centered on the holes.

Unless otherwise specified, materials furnished as described herein shall be

covered by a type C certification in accordance with 916.

(k) Pipe End Sections

Metal pipe end sections shall be in accordance with 908.06. Precast concrete pipe
160 end sections shall be in accordance with 905.06.

(l) Roadway Drain Casting Extensions

Pipe used for extending roadway drain castings located in a bridge deck shall be
in accordance with 907.23, 907.28, or 908.10. Pipe support brackets and all hardware
shall be galvanized in accordance with ASTM A 153, class D or ASTM B 695, class
40, type I. A type C certification in accordance with 916 shall be provided for the pipe
brackets.

(m) Drainage Pipe through Concrete Masonry

170 Pipe used as drainage pipe through concrete masonry as described in 702.16 shall
be either profile wall or smooth wall PVC from the Department’s list of approved
thermoplastic pipe and liner pipe in accordance with 907.16, or steel in accordance
with 908.11.

692
 715.04

(n) Bridge Deck Drain System

Pipe and fittings used in an enclosed bridge deck drainage system shall be cast
iron soil pipe in accordance with 908.10 or reinforced thermosetting resin pipe in
accordance with 907.28. All mounting hardware shall be installed in accordance with
the pipe manufacturer’s recommendations. All mounting hardware shall be galvanized
180 in accordance with ASTM B 695, class 40, type I. A type C certification in accordance
with 916 shall be provided for the pipe brackets.

CONSTRUCTION REQUIREMENTS

715.03 General Requirements

The construction requirements, method of measurement, basis of payment, and
pay items described herein shall apply, except for the following, which are described
in their respective sections.

190 Drain Tile .................................................................... 719

Structural Plate Pipe and Pipe-Arches ......................... 717
Underdrains ................................................................. 718

A pipe order shall be prepared and submitted prior to delivery of pipe to the
project site. The order shall include the following:

(a) structure number and location;

(b) manhole, inlet, or catch basin type, if applicable;

200
(c) pipe length, as determined by construction engineering;

(d) pipe size, as shown on the plans;

(e) pipe material including all information required to verify

conformance with cover and service life criteria; and

(f) number and type of end sections or quantity of concrete, A,

structures.
210
When riprap is specified, geotextile shall first be placed on the in-situ soil in
accordance with 616.11. Riprap shall then be placed in accordance with 616.

715.04 Excavation
Unless otherwise directed, the trench cross sectional dimensions shall be as shown
on the plans. The trench bottom shall give full support to the pipe as shown on the
plans. Recesses shall be cut to receive any projecting hubs or bells.

Where pipe is to be placed in fill sections, a portion of the fill shall be constructed
220 prior to installation of the pipe as shown on the plans.

693
 715.05

Where rock or boulder formation is encountered at or above the proposed trench

bottom elevation, the trench shall be excavated at least 8 in. below the proposed grade,
backfilled with structure backfill, and compacted in accordance with 211.04.

In case a firm foundation is not encountered at the required grade, the unstable
material shall be removed to such depth that when replaced with suitable material,
usually B borrow, compacted, and properly shaped, it will produce a uniform and
stable foundation along the entire length of the pipe. A timber mat shall be placed to
230 hold the pipe to line and grade if it is necessary.

All trenches shall be kept free from water until any joint filling material has
hardened sufficiently not to be harmed.

715.05 Laying Pipe

Each section of pipe shall have a full firm bearing throughout its length, true to
the line and grade given. All pipes which settle or which are not in alignment shall be
taken up and re-laid. Pipe shall not be laid on a frozen trench bottom. Fully bituminous
coated and lined pipe and pipe-arches shall only be placed when the ambient
240 temperature is 35°F or above.

Concrete and clay pipe shall be laid with hub upgrade, with the spigot end fully
extended into the adjacent hub, and with all ends fitted together tightly.

Concrete pipe shall not be laid in muck or sulphate soils.

Except for circular concrete pipe, pipe joints designed to accommodate seals or
pipe joints requiring seals shall be sealed with approved rubber type gaskets, caulking,
pipe joint sealant, elastomeric material, or sealing compound. Circular concrete pipe
250 joints shall utilize rubber type gaskets.

If the infiltration of water is a factor, each joint, regardless of the type used, shall
be sealed with an approved compression type joint sealer in accordance with ASTM
C 425 or ASTM C 443, whichever is applicable.

Joints and stub-tee connections for plastic pipe shall be in accordance with the
requirements of the respective material specifications for each type of pipe.

Connections of plastic pipe to manholes, catch basins, and inlets shall be in

260 accordance with the manufacturer’s recommendations.

Prior to being lowered into the trench, corrugated metal pipe sections shall be
examined closely and so fitted that they will form a true line of pipe when in place.
Sections which do not fit together properly shall not be used.

At the time of acceptance, all pipe shall have been cleaned and be free from silt
and other foreign matter.
694
 715.07

Prior to constructing a pipe extension, the existing structure shall be cleaned of all
270 foreign materials. Existing anchors, end sections, or headwalls shall be removed as
shown on the plans or as directed. All existing pipes which are damaged by the
removal operation shall be replaced. Removed materials shall be disposed of in
accordance with 202.

715.06 Joining Pipe

Band couplers for AASHTO M 36 type I and type II corrugated steel pipe and
pipe-arches shall have corrugations that mesh with the corrugations of the pipe
sections being joined or the annular rerolled ends of those pipe sections. Band couplers
with projections or dimples may be used with pipe having either annular or helical
280 corrugations only when corrugated band couplers will not provide a matching
connection to both pipes. Band couplers for AASHTO M 36 type IA and IIA
corrugated steel pipe and pipe-arches shall have corrugations that mesh with the
corrugations of the pipe or shall be gasketed flat bands. Couplers for AASHTO M 36
type IR ribbed steel pipe shall be in accordance with AASHTO M 36 and the
manufacturer’s recommendations.

At the connection of a pipe extension to an existing structure where the joint

system of the pipe extension differs from that in place, or if a satisfactory joint cannot
be obtained between the two structures, a concrete collar shall be constructed. Portions
290 of the existing structure shall be removed as shown on the plans, or as necessary, to
ensure proper fit of the extension to the existing pipe. If not shown on the plans, the
collar shall have a width of at least 18 in. and a thickness of at least 6 in. around the
entire joint.

If rigid pipe connections are of lesser strength than that of the main barrel of a
pipe structure, these connections shall be encased with concrete at least 6 in. thick.

Any pipe which is damaged during installation shall be repaired or replaced as

directed.
300
Slotted drain pipe or slotted vane drain pipe shall be constructed in 20 ft sections
with shop fabricated elbows. The upgrade end of slotted drain pipe shall be plugged
with a metal cap before backfilling. The upgrade end of slotted vane drain pipe shall
be plugged with class A concrete. Such concrete shall extend 6 in. inside the upgrade
end of the pipe.

715.07 Tee and Stub-Tee Connections

At locations shown on the plans, or where directed, a stub-tee connection of the
size specified shall be furnished and placed as a tee connection to corrugated metal
310 pipe, corrugated metal pipe-arch, concrete pipe, reinforced concrete pipe, or reinforced
concrete horizontal elliptical pipe.

The stub-tee connection to a corrugated metal pipe, ribbed metal pipe, or

695
 715.08

corrugated metal pipe-arch shall be constructed of corrugated or ribbed metal and the
length of the stub shall be no less than that which readily accommodates the connecting
band. It shall be made by shop welding a stub of corrugated or ribbed metal pipe to
the respective corrugated metal pipe or pipe-arch or ribbed metal pipe at the time of
fabrication. Where field conditions warrant, stub-tee or other connections may be field
connected by using shop fabricated saddle connectors. Welds, flame cut edges, and
320 damaged spelter coating shall be regalvanized or painted with zinc dust-zinc oxide
paint in accordance with Federal Specification TT-P-641, type II or MIL-P-21035.
Where applicable, damaged bituminous coating shall be repaired with asphalt mastic
in accordance with AASHTO M 243. The pipe connection to the stub shall be made
by means of connecting bands of required size or by means of concrete collars as
directed.

The stub-tee connection to concrete pipe, reinforced concrete pipe, or reinforced

concrete horizontal elliptical pipe may be field constructed or factory constructed. The
concrete used in the stub shall be of the same proportions as that used in the
330 construction of such pipe. The length of the concrete stub shall be no less than 6 in.
and no more than 12 in. The pipe connection to the concrete stub shall be made by
means of a cement mortar bead or concrete collar or as directed.

715.08 Blank

715.09 Backfilling
All pipe trenches shall be backfilled with structure backfill or flowable backfill.
Structure backfill shall be placed in accordance with 211. Flowable backfill shall be
placed in accordance with 213.07 as shown on the plans or as directed.
340
Prior to placing flowable backfill, all standing water shall be removed from the
trench. If the water cannot be removed from the trench, structure backfill shall be used
in lieu of flowable backfill to an elevation 2 ft above the groundwater. The remainder
of the trench shall be backfilled as shown on the plans.

All pipes, except underdrains, will be visually inspected for acceptance a

minimum of 30 days after the completion of backfill operations. Pipes that cannot be
visually inspected shall be video inspected for acceptance using equipment in
accordance with 718.07. The Engineer will determine the sections of pipe to be video
350 inspected.

For pipes that were video inspected, a copy of the video inspection shall be
provided in a format acceptable to the Engineer. The video inspection shall be
provided prior to performing the mandrel testing or if mandrel testing is not required,
prior to acceptance of the pipe.

For pipe not requiring mandrel testing that is determined to be unacceptable by

the Engineer, the unacceptable pipe shall be replaced between the nearest pipe joints

696
 715.09

or to the nearest structure, or a remediation plan shall be prepared by a professional

360 engineer and submitted to the Engineer for final determination.

After the visual or video inspection, the Contractor shall check pipe deflection by
performing a mandrel test as directed on pipes manufactured from materials listed in
the following table. The Engineer will determine the runs of pipe installations to be
mandrel tested with a minimum of 10% of the total length of each material to be
inspected.

Pipes Required to Be Mandrel Tested

Pipe Material Standard Specifications
Corrugated Polyethylene Pipe 907.17(b)
Corrugated Polypropylene Pipe 907.19
Profile Wall Polyethylene Pipe 907.20
Smooth Wall Polyethylene Pipe 907.21
Profile Wall PVC Pipe 907.22
Smooth Wall PVC Pipe 907.23

The mandrel shall have a minimum of nine arms or prongs and a diameter that is
370 95% of the nominal pipe diameter. The Contractor shall provide a proving ring that is
95% of the nominal pipe diameter for each mandrel.

The Contractor shall pull the mandrel through the pipe by hand. If the mandrel
does not pass through the pipe, the Contractor shall measure and report the minimum
diameter of the deficient pipe to the Engineer.

If the minimum diameter of the deficient pipe is between 92.5% and 95.0% of the
nominal pipe diameter, the Contractor shall provide an evaluation of the deficient pipe
prepared by a professional engineer. The evaluation shall consider the severity of the
380 deflection and its effects on structural integrity, environmental conditions, and the
design service life of the pipe. A report summarizing the evaluation and including the
professional engineer’s recommendation for acceptance, remediation, or replacement
of the pipe shall be submitted to the Engineer for final determination.

If the minimum diameter of the deficient pipe is equal to or less than 92.5% of the
nominal pipe diameter, the deficient pipe shall either be replaced or a remediation plan
shall be prepared by a professional engineer and submitted to the Engineer for final
determination.

390 The deficient pipe shall be replaced if the professional engineer’s remediation
plan recommends replacement of the pipe or if the pipe has been damaged.

Deficient pipe shall at a minimum be replaced between the nearest pipe joints or
to the nearest structure. Replaced or remediated pipe sections shall be mandrel tested
a minimum of 30 days after the completion of backfill operations.

697
 715.10

Commercial and private drive pipes are excluded from the mandrel testing and
video inspection requirements.

400 Where material other than structure backfill or flowable backfill is allowed and
used for backfilling, it shall be of such nature that compacts readily. That portion
around and for 6 in. above the top of the pipe shall be free from large stones. This
material shall be placed in layers not to exceed 6 in., loose measurement, and each
layer compacted thoroughly by means of mechanical tamps. Where coarse aggregate
is used for structure backfill, geotextile shall be installed.

An adequate earth cover, as shown on the plans, shall be placed over the structure
before heavy equipment is operated over it.

410 Backfill for slotted drain pipe and slotted vane drain pipe shall consist of class A
concrete on both sides of the pipe. During the backfilling and paving operations, the
slot shall be covered to prevent infiltration of material into the pipe.

715.10 Pipe End Sections, Anchors, Grated Box End Sections, and Safety
Metal End Sections
Pipe end sections, anchors, grated box end sections, and safety metal end sections
shall be constructed as shown on the plans or as directed.

Straps or hook bolts required for anchors shall be as shown on the plans. Anchor
420 straps shall be placed at both the upstream and downstream end of each corrugated
aluminum alloy, corrugated steel, or structural plate pipe or pipe-arch with a diameter
or span of 42 in. or greater. Hook bolts and anchor straps shall be placed at both the
upstream and downstream end of each corrugated aluminum alloy, corrugated steel,
or structural plate pipe or pipe-arch with a diameter or span of 84 in. or greater.

A dimpled connection band shall be used for connecting pipe end sections and
safety metal end sections to ends of corrugated metal pipe whose end corrugations are
not perpendicular to the centerline of the pipe.

430 Grated box end sections shall be constructed according to the required pipe size
and surface slope of the grated box end section specified at each location. Precast units
shall be cast as a single complete unit except for the toewall which shall be cast in
place. They shall be set and leveled on a 6 in. thick bed of coarse aggregate. If precast
units are used and the adjoining pipe is to be field connected directly to the precast
unit, the connection shall be made using a class A concrete collar of 6 in. minimum
longitudinal and radial thickness. Inserts for approved lifting devices may be cast in
the bottom slab of the precast sections. The number and location of lifting devices
needed for handling shall be determined by the fabricator. All reinforcement shall have
a minimum cover of 1 1/2 in. and shall have a minimum lap of 21 in. The type A
440 construction joint between the floor and the wall is optional for cast in place units.

698
 715.13

715.11 Re-Laid Pipe

Where shown on the plans or as directed, existing pipe shall be taken up, re-laid,
and if necessary, extended. Removal of the pipe shall be in accordance with 202.04
and the operations involved in its relaying shall be in accordance with similar
operations contained herein for laying new pipe.

715.12 Pavement Replacement

Where a structure is to be placed under an existing pavement, the pavement
450 removal and replacement shall be as shown on the plans.

The pavement replacement areas in asphalt pavements shall be filled with HMA
for Structure Installation of the mixture type specified in the pay item in accordance
with 402 except OG mixtures shall be in accordance with 401.05. A MAF in
accordance with 402.05 will not apply. Mixtures will be accepted in accordance with
402.09. Each course shall be compacted by approved mechanical equipment in
accordance with 409.03(d).

The pavement replacement areas in Portland Cement Concrete pavements shall

460 be filled with PCCP in accordance with 502 except utilization of the Department
provided spreadsheet is not required for the CMDS.

Partial loads of HMA or PCCP left over from structure installation processes shall
not be incorporated into other work.

715.13 Method of Measurement

The accepted quantities of circular pipe, deformed pipe, slotted drain pipe, slotted
vane drain pipe, end bent drain pipe, sanitary sewer pipe, and pipe extensions will be
measured by the linear foot, complete in place. The length of pipe to be measured for
470 payment will be based on the net length of pipe used, which will be obtained by
multiplying the nominal length of each pipe section by the number of sections used. If
the pipe connects to manholes, inlets, or catch basins, the terminal sections will be
field measured to the outside face of the structure. The length of beveled or skewed
terminal sections of circular corrugated or ribbed metal pipe to be measured for
payment will be the average of the top and bottom centerline lengths for beveled ends
or of the sides for skewed ends. Measurement of deformed pipe will be made along
the bottom centerline of the pipe.

Where used other than as a roadway drain extension pipe or as a bridge deck drain
480 system, cast iron soil pipe will be measured by the pound based on the theoretical
weight shown on the plans.

Roadway drain extension pipe will be measured per each drain extended.

Pipe used as drainage pipe through concrete masonry or pipe used for bridge deck
drainage system will not be measured for payment.

699
 715.13

Reinforcing bars, straps, and hook bolts used in anchors will not be measured for
payment. Concrete used for backfill of slotted drain pipe and slotted vane drain pipe
490 will not be measured for payment.

Excavation above the trench bottom elevation shown on the plans will not be
measured for payment. Additional excavation below the proposed trench bottom
elevation required to install the pipe at a lower elevation or to remove rock or
unsuitable material will be measured in accordance with 203.27(b).

Pipe end sections, concrete anchors, and safety metal end sections will be
measured by the number of units of each size installed. The size of the end section,
concrete anchor, and safety metal end section will be considered as the nominal
500 diameter of the pipe to which they are attached. A concrete anchor attached at one end
of twin pipes will be measured as two concrete anchors. A concrete anchor attached at
one end of triple pipes will be measured as three concrete anchors.

Tee, stub-tee, and wye branch connections will be measured along the centerline
of the barrel. An additional 5 lft of the smaller diameter pipe will be included for
making such connection.

Elbow connections will be measured along the centerline of such connection. An

additional 2 lft of pipe of the same diameter as that of the elbow will be included for
510 each such connection.

If increaser or reducer connections are made, measurement will be made on the

basis of the larger diameter pipe for the full length of the section forming such
connections.

Structure backfill will be measured in accordance with 211.09. Flowable backfill

will be measured in accordance with 213.08.

Pavement replacement and subbase necessary due to structure placement under

520 an existing pavement will be measured to the neat lines shown on the plans.

For structures for which the plans show pipes of differing sizes for either smooth,
semi-smooth or corrugated interiors, and either the semi-smooth corrugated interior
alternate is installed, measurement of structure backfill or flowable backfill will be
based on the neat line dimensions shown on the plans for the smooth interior alternate.

Grated box end sections will be measured per each for the specified type, surface
slope, and pipe size.

530 Video inspection for pipe will be measured by the linear foot as determined by
the electronic equipment.

Geotextile used to wrap backfill material will not be measured for payment.

700
 715.14

715.14 Basis of Payment

The accepted quantities of pipe and pipe extensions will be paid for at the contract
unit price per linear foot for pipe of the type, shape, and size specified, complete in
place. Where used other than as a roadway drain casting extension pipe or as a bridge
deck drain system, cast iron soil pipe will be paid for at the contract unit price per
540 pound for the diameter specified.

Pipe end sections, concrete anchors, and safety metal end sections will be paid for
at the contract unit price per each for the size specified, complete in place. A concrete
anchor attached at one end of twin pipes will be paid for as two concrete anchors. A
concrete anchor attached at one end of triple pipes will be paid for as three concrete
anchors. Roadway drain casting extension pipe will be paid for at the contract unit
price per each.

Pavement replacement necessary due to structure installation under an existing

550 pavement will be paid for at the contract unit price per ton of HMA for structure
installation of the type specified and per square yard for PCCP for structure
installation. Subbase will be paid for in accordance with 302.09.

Structure backfill will be paid for in accordance with 211.10. Where used as a
substitute for structure backfill, flowable backfill will be paid for as structure backfill.
When specified for pipe backfill, flowable backfill will be paid for in accordance with
213.09.

If a pipe structure is lowered, relocated, or if unsuitable material is encountered

560 so that additional excavation is necessary over and above that shown on the plans at
the original location, such additional excavation will be paid for at three times the
contract unit price for the class of excavation involved. If the contract does not include
rock excavation or unclassified excavation, rock removal below the proposed trench
bottom elevation will be paid for at three times the contract unit cost for common
excavation. However, in each of the above cases, such excavation will not be paid for
if the additional amount involved at such structure is 10 cu yd or less.

For structures for which the plans show pipes of differing sizes for smooth, semi-
smooth or corrugated interiors, and either the semi-smooth or the corrugated interior
570 alternate is installed, payment for pipe backfill will be made based on the neat line
dimensions shown on the plans for the smooth interior alternate.

Grated box end sections will be paid for at the contract unit price per each for the
specified type, surface slope, and pipe size.

Video inspections for pipe will be paid for at the contract unit price per linear foot
completed.

Payment will be made under:

580

701
 715.14

Pay Item Pay Unit Symbol

Concrete Anchor, ________ in. ................................................. EACH

diameter
Concrete Anchor, Min. Area ____ sq ft .................................... EACH
Grated Box End Section, ____, ____, ________ in. ................. EACH
type slope diameter
Grated Box End Section, ____, ____, Min. Area ____ sq ft ..... EACH
type slope
590 HMA for Structure Installation, Type ............................. TON
mixture type
PCCP for Structure Installation ................................................. SYS
Pipe End Section, ________ in.................................................. EACH
diameter
Pipe End Section, Min. Area ____ sq ft .................................... EACH
Pipe Extension, Circular, ________ in., ________ ................... LFT
diameter material
Pipe Extension, Deformed, Min. Area ____ sq ft, ________ .... LFT
material
600 Pipe, Bridge Deck Drain System ............................................... LS
Pipe, Drainage through Concrete Masonry ............................... LS
Pipe, End Bent Drain, ________ in. .......................................... LFT
diameter
Pipe, Relaid, ____ in. x ____ in. ............................................... LFT
span rise
Pipe, Relaid, ________ in. ........................................................ LFT
diameter
Pipe, Roadway Drain Casting Extension ................................... EACH
Pipe, Sanitary Sewer, ________ in. ........................................... LFT
610 diameter
Pipe, Slotted Drain, ________ in., ________ in........................ LFT
diameter thickness
Pipe, Slotted Vane Drain, ________ in. .................................... LFT
diameter
Pipe, Type ____, Circular, ________ in. ................................... LFT
diameter
Pipe, Type ____, Deformed, Min. Area ____ sq ft ................... LFT
Pipe, Underdrain Outlet, ________ in. ...................................... LFT
diameter
620 Safety Metal End Section, ____, ________ in. ......................... EACH
slope diameter
Safety Metal End Section, ____, Min. Area ____ sq ft ............. EACH
slope
Soil Pipe, Cast Iron, _______ in. ............................................... LBS
diameter
Video Inspection for Pipe .......................................................... LFT

702
 715.14

The cost of reinforcing bars, straps, and hook bolts used in anchors shall be
included in the cost of the concrete anchor. The cost of the toe plate anchor and
630 galvanized bolts required for pipe end sections and safety metal end sections shall be
included in the cost of the pay items. The cost of pipe support brackets and all hardware
used to attach the roadway drain casting extension pipe to the drain casting and the
pipe support bracket to the structural member and to the drain extension pipe shall be
included in the cost of the pay items. The cost of the pipe, all necessary fittings, all
mounting hardware, design costs, and all other costs to provide the bridge deck drain
system shown on the plans shall be included in the lump sum cost of the bridge deck
drain system. The cost of concrete backfill for slotted drain pipe and slotted vane drain
pipe shall be included in the cost of the pay items.

640 B borrow obtained from planned excavation may be used to backfill culverts. No
deduction will be made from the excavation or borrow quantities.

If existing concrete building foundations, concrete walls, concrete columns, or

concrete steps not visible and not shown on the plans are encountered within the limits
of the trench, the removal of such items, as required, will be paid for in accordance
with 203.28.

The cost of sawing of pavement, excavation above the trench bottom elevation
shown on plans, backfilling with material other than structure backfill or flowable
650 backfill, dewatering, shoring, timber mats, class A concrete required for collar
construction or sealing existing pipe, joint materials, replacing pipe which is damaged
during installation or re-laying operations, sanitary sewer testing required by the local
utility, and all other necessary incidentals shall be included in the cost of the pay items
in this section. The cost of removal of pavement, existing pipe, end sections, anchors,
or headwalls, concrete collars, encasements, and the disposal of surplus materials shall
be included in the cost of the pay items.

The cost of concrete, grating, pipe tubing, reinforcing bars, aggregate leveling
bed, hardware cloth, and necessary incidentals, for construction of grated box end
660 sections will be included in the cost of the grated box end section.

Geotextile required for coarse aggregate structure backfill material will not be
paid for separately. The cost of the geotextile shall be included in the cost of the
structure backfill.

The cost of providing video inspection equipment, technician, and a copy of the
video inspection shall be included in the cost of video inspection for pipe.

No additional payment will be made for repair, remediation, or replacement of

670 pipes, backfill, video inspection of the repaired, remediated, or replaced pipe, and all
other work associated with the repair, remediation, or replacement of unacceptable
pipes.

The cost of mandrel testing shall be included in the cost of the pipe.
703
 716.01

SECTION 716 – TRENCHLESS PIPE INSTALLATION

716.01 Description
This work shall consist of installing pipes underground using construction
techniques that eliminate open cutting of the pavement or of the ground in accordance
with 105.03. This specification addresses auger boring, guided boring, horizontal
directional drilling using a reamer diameter up to and including 24 in., pipe jacking,
and pipe ramming, as defined below.

10 Installations by means of directional drilling which require a reamer larger than

24 in., microtunneling, or other tunneling methods, may be utilized if approved by the
Engineer. The Contractor shall submit a detailed proposal prepared by a professional
engineer for installations other than auger boring, guided boring, horizontal directional
drilling using a reamer diameter less than 24 in., pipe jacking, and pipe ramming.

The following definitions apply to trenchless pipe installation.

(a) Auger Boring

Technique for forming a bore from a drive shaft to a reception shaft, by means of
20 a rotating cutting head. Spoil is removed back to the drive shaft by helically wound
auger flights rotating in a steel casing.

(b) Carrier Pipe

The tube which carries the product being transported and which may pass through
casings at highway or railroad crossings. It may be made of steel, concrete, clay,
plastic, ductile iron, or other materials.

(c) Casing Pipe

A pipe installed as external protection to a carrier pipe.
30
(d) Drive Shaft
Excavation from which trenchless technology equipment is launched. It may
incorporate a thrust wall to spread reaction loads to the soil.

(e) Guided Boring

A trenchless tunneling method that utilizes small diameter pilot tubes that are
installed and steered through the ground utilizing a slanted face at the cutting head
containing a target with light emitting diodes, LEDs, and a camera mounted theodolite
located in the shaft to achieve high accuracy in line and grade. The hole is enlarged to
40 the same outside diameter of the final product pipe after the installation of the pilot
tubes, which is then jacked into place.

(f) Horizontal Directional Drilling

A steerable system for the installation of pipes, conduits, or cables in a shallow
arc using a surface launched drilling rig.

704
 716.02

(g) Microtunneling
A remote controlled trenchless construction method that simultaneously installs
pipes as the soil is excavated. This method provides continuous support of the
50 excavation face with slurry pressure to balance groundwater and earth pressures.

(h) Pipe Jacking

A system of directly installing pipes behind a shield machine by means of
hydraulic jacking from a drive shaft such that the pipes form a continuous string in the
ground.

(i) Pipe Ramming

A non-steerable system of forming a bore by driving an open ended steel casing
using a percussive hammer from a drive shaft. The soil may be removed from the
60 casing by augering, jetting, or compressed air.

(j) Reception Shaft

Excavation into which trenchless technology equipment is driven and recovered
following the installation of the pipe.

(k) Response Levels

Pre-established levels of instrument readings of settlement or of other monitored
behavior such as lateral movement or vibrations, which trigger the implementation of
mitigative measures. Response levels consist of the initial review level, at which
70 mitigative measures must be implemented, and the alert level, at which construction
must be halted and actions taken to ensure the alert level will not be exceeded in
subsequent construction.

(l) Spoils
Earth, rock, or other materials displaced by a tunnel or casing, and removed as the
tunnel or casing is installed.

MATERIALS

80 716.02 Materials
Materials shall be in accordance with the following:

Cellular Grout .............................................................. 725

Clay Pipe, Extra Strength ............................................ 907.08
PVC Pipe ..................................................................... *
Reinforced Concrete Pipe ............................................ 907.02
Smooth Wall Polyethylene Pipe .................................. *
Steel Pipe ..................................................................... 908.11
Water ........................................................................... 913.01
90 * All thermoplastic pipes shall be from the Department’s list of approved
thermoplastic pipe and liner pipe in accordance with 907.16.

705
 716.03

Concrete pipe shall be from the Department’s Approved List for Certified Precast
Concrete Producers.

Concrete pipe installed by means of pipe jacking shall be designed with sufficient
concrete strength and steel reinforcement to resist jacking forces and shall have tongue
and groove joints. All reinforced concrete pipes shall have steel reinforcement
concentric with the pipe wall.
100
Steel pipe used as a carrier pipe shall have the following minimum wall thickness.
Steel pipe used as a casing pipe, but not used as a carrier pipe, shall be selected by the
Contractor to have minimum wall thickness sufficient to resist jacking forces. For
installations where the casing is not used as a carrier but only as a casing for a carrier
pipe, the thickness of the casing shall be determined by the Contractor.

Outside Diameter, in. Wall Thickness, in.

18 or less 1/4
19 – 20 5/16
21 – 26 3/8
27 – 30 1/2
31 – 42 1/2
43 – 48 9/16

CONSTRUCTION REQUIREMENTS

110 716.03 General Requirements

The Contractor shall submit a Quality Control Plan, QCP, in accordance with ITM
803. The QCP shall be submitted to the Engineer for review and acceptance, at least
15 days prior to the start of trenchless pipe installation operations.

Where ground water is known or anticipated, and where the technique selected
for trenchless pipe installation does not provide positive support at the trenchless
excavation face, such as by slurry support in microtunneling, then trenchless pipe
installation shall not proceed without dewatering in advance of trenchless pipe
installation. A dewatering system of sufficient capacity to handle the flow shall be
120 maintained at the site until its operation can be safely halted. The dewatering system
shall be equipped with screens or filter media sufficient to prevent the displacement of
fines.

Where the use of explosives is necessary for performing the work, their use shall
be in accordance with 107.13.

Bentonite or other suitable lubricants may be applied to the outside surface of the
pipe to reduce frictional forces.

130 Joints in steel pipe shall be watertight. Where welded joints are utilized, they shall
be welded in accordance with 711.32. Joints in concrete pipe or other jacking pipe

706
 716.03

materials including clay pipe shall be designed to withstand the additional forces that
are created in the joints during the installation process. The joints in concrete pipe or
other pipe jacking materials shall be protected with a resilient material around the
circumference of the pipe. Resilient material shall also be used between the pipe and
the thrust ring.

Pavement or ground surface heave or settlement resulting in damage to pavement,

existing utilities, or structures above the installation will not be allowed. To confirm
140 if heave or settlement is occurring, the Contractor shall undertake surface monitoring.

Installations shall have a bored hole essentially the same diameter as the outside
of the installed pipe. If voids develop or if the bored diameter is greater than the outside
diameter of the pipe by more than 1 in., grouting shall be used to fill such voids.

When the installation is 4 in. or larger and the casing is used as the carrier pipe, a
visual or a video inspection shall be performed using a high resolution, high sensitivity
color video camera and recording equipment. The pipe shall be cleaned of debris prior
to the inspection. Cleaning shall be accomplished by means of water jetting or other
150 approved methods.

The camera and recording equipment shall be specifically designed for continuous
viewing and recording of detailed images of the interior wall of pipes and transitions
of the specified sizes. The equipment shall include sufficient lighting to view the entire
periphery of the pipe. The equipment shall have appropriate attachments to maintain
a position in the center of the pipe and an electronic counter to continuously record the
location of the equipment in the pipe. A copy of the video inspection shall be submitted
to the Engineer.

160 All sections of pipe found to be damaged or where joint failure is evident shall be
repaired or replaced as approved by the Engineer.

If an obstruction is encountered during installation which stops the forward

progress of the pipe, and it becomes evident that it is impossible to advance the pipe,
the Engineer shall be notified. For installations utilizing tunnel shields or tunnel-boring
machines or other methods that allow access to the face, the obstruction shall be
removed in accordance with the QCP. For installations utilizing methods that do not
allow access to the face, at the direction of the Engineer, the pipe shall be abandoned
in place and filled with grout or other approved materials.
170
Where a gravity-flow carrier pipe is placed inside a casing pipe, the gravity-flow
carrier pipe shall be shimmed to proper line, elevation, and grade and then the void
between the two pipes shall be grouted with cellular grout.

Upon completion of the installation of the pipe, all excavated areas not occupied
by the pipe shall be backfilled and compacted with suitable material in accordance
with 203.

707
 716.04

716.04 Method of Measurement

180 Pipe installed by means of trenchless installation methods will be measured by
the linear foot along the center line of the pipe installed.

716.05 Basis of Payment

Pipe installed by means of trenchless installation methods will be paid for by the
linear foot for pipe installation, trenchless, of the size specified, complete and in place
including all incidentals.

Removal of boulders, concrete, or other obstructions will be paid in accordance

with 104.03.
190
Payment will be made under:

Pay Item Pay Unit Symbol

Pipe Installation, Trenchless, _____ .......................................... LFT

size

The cost of the QCP, excavating and backfilling of the drive shaft and reception
shaft, video inspection, camera and recording equipment, bentonite or other lubricant,
200 grout, and the casing if installed shall be included in the cost of pipe installation,
trenchless.

If a partial installation has to be abandoned in place and filled with grout due to
the encountering of an obstruction, the abandoned work will be paid for at 75% of the
contract unit price of the pipe installed.

No payment will be made to repair or replace sections of pipe that have been
damaged or show evidence of joint failure.

SECTION 717 – STRUCTURAL PLATE PIPE, PIPE-ARCHES, AND

ARCHES

717.01 Description
This work shall consist of furnishing and placing structural plate pipe,
pipe-arches, or arches in accordance with 105.03.

717.02 Materials
Materials shall be in accordance with the following:
10
Concrete, Class A ........................................................ 702
Flowable Backfill ........................................................ 213
Pipe Joint Sealant ........................................................ 907.11

708
 717.03

Reinforcing Bars.......................................................... 910.01

Structural Plate Arches ................................................ 908.09
Structural Plate Pipe and Pipe-Arches ......................... 908.09
Structure Backfill ........................................................ 904.05

Structural plate pipe and pipe-arches are part of the pipe classification system
20 described in 715.02. The minimum material thickness and required protective
treatments will be determined in accordance with 715.02. When metal pipe is selected,
the same base metal and coating shall be used for the structure or a pipe extension.

CONSTRUCTION REQUIREMENTS

717.03 General Requirements

Forming, punching, and assembling shall be in accordance with AASHTO LRFD
Bridge Construction Specifications. The radius of the arc joining the top to the bottom
shall be in accordance with 908.09(a)1. Excavation shall be in accordance with the
30 applicable requirements of 715 for pipe and pipe-arches and 206 for arches. Concrete
shall be placed in accordance with 702 and reinforcing bars shall be placed in
accordance with 703.

Each side of an arch shall rest in a groove formed into the masonry or shall rest
on a galvanized angle or channel securely anchored to or embedded in the structure.
Where the span of the arch is greater than 14 ft, or the skew angle is more than 20°, a
metal bearing surface having a width at least equal to the depth of the corrugations
shall be provided.

40 Metal bearings may be either rolled structural or cold-formed galvanized angles

or channels no less than 3/16 in. in thickness with the horizontal leg securely anchored
to the substructure on 24 in. maximum centers. When the metal bearing is not
embedded in a groove in the substructure, one vertical leg shall be punched to allow
bolting to the bottom row of plates.

If it is necessary to make a tee-connection to a structural plate pipe, pipe-arch, or

arch, a stub-tee connection of the size and at the locations shown on the plans shall be
furnished and placed, and its length shall be no less than 12 in. and no more than 24
in. The stub shall be connected in the field and the stub connection bituminous coated.
50 The stub connection to the entering pipe shall be made by means of a connecting band
of the required size or by means of concrete collars, as directed.

Structures on which the spelter coating has been bruised or broken either in the
shop or in shipping, or which shows defective workmanship, shall be rejected unless
it can be repaired satisfactorily. This requirement applies not only to the individual
plates but to the shipment on any contract as a whole. Among others, the following
defects are specified as constituting poor workmanship. The presence of defects in an
individual culvert plate or in a shipment shall constitute sufficient cause for rejection.

709
 717.04

60 (a) uneven laps;

(b) elliptical shaping, unless specified;
(c) variation from a straight centerline;
(d) ragged edges;
(e) loose, unevenly lined, or unevenly spaced bolts;
(f) illegible brand;
(g) bruised, scaled, or broken spelter coating;
(h) dents or bends in the metal itself; and
(i) twisted so that ends do not lay on bedding satisfactorily.

70 717.04 Backfill
All structural plate pipe and pipe arches shall be backfilled with structure backfill
or flowable backfill. Arch backfill shall be structure backfill. The amount of camber
on the invert of the pipe or pipe-arch shall be varied to suit the height of fill and
supporting soil, except the camber grade shall not be above level. Structure backfill
shall be placed in accordance with 211. Flowable backfill shall be placed in accordance
with 213.

An adequate earth cover shall be provided over the structure, as shown on the
plans, before heavy construction equipment is operated over it. This earth cover shall
80 be free of stones.

Where backfilling at arches before headwalls are placed, the material shall first
be placed midway between the ends of the arch, forming as narrow a ramp as possible,
until the top of the arch is reached. The ramp shall be built up evenly on both sides
and the backfilling material compacted as it is placed. After both ramps have been
built to the top of the arch, the remainder of the backfill shall be deposited in both
directions from the center to the ends and evenly on both sides of the arch.

If the headwalls are built before the arch is backfilled, the backfill material shall
90 first be placed adjacent to one headwall until the top of the arch is reached, after which
the fill material shall be placed from the top of the arch towards the other headwall.
The material shall be deposited evenly on both sides of the arch.

In multiple installations the above procedure shall be followed. The backfill shall
be brought up evenly on both sides of each arch so that unequal pressures are avoided.

Compaction by saturation will not be allowed, except below the free water table,
then the provisions of 203.23 do not apply.

100 717.05 Relaid Pipe and Pipe-Arch

When required, any existing structural plate pipe or pipe-arch shall be taken up,
re-laid, and extended. Removal shall be in accordance with 202.04 and the operations
involved in its relaying shall be in accordance with similar operations contained herein
for new structural plate pipe or pipe-arch.

710
 717.09

717.06 Blank

717.07 Concrete Paved Inverts

Structural plate pipe and pipe-arches with concrete field paved inverts shall be
110 constructed in accordance with and at locations shown on the plans or where directed.

The paved inverts for these structures shall be reinforced with WWR and sealed
with pipe joint sealant as shown on the plans. The concrete for paving the invert shall
not be placed until such time as the backfilling and embankment procedures have been
completed satisfactorily.

717.08 Method of Measurement

Structural plate pipe and pipe-arch, new, extended, and re-laid, will be measured
in accordance with 715.13. Structural plate arches will be measured by the linear foot,
120 complete in place. Metal bearings and other hardware required to attach the structural
plate arch to its substructure will not be measured for payment.

Concrete for headwalls and substructures will be measured in accordance with

702.27. Volumes occupied by a structural plate arch extending through the headwall
will be deducted. Reinforcing bars used in substructures will be measured in
accordance with 703.07. Concrete anchors will be measured in accordance with
715.13. Reinforcing bars, straps, and hook bolts used in anchors will not be measured
for payment.

130 Structural backfill will be measured in accordance with 211.09. Flowable backfill
used for backfill will be measured in accordance with 213.08.

717.09 Basis of Payment

The accepted quantities of new, extended, or re-laid structural plate pipe, or
pipe-arch will be paid for in accordance with 715.14. Structural plate arches will be
paid for at the contract unit price for arch, structural plate, of the size specified.
Concrete, A, structures will be paid for in accordance with 702.28. Reinforcing bars
in substructures will be paid for in accordance with 703.08. Concrete anchors will be
paid for in accordance with 715.14.
140
If a pipe or pipe-arch is lowered or relocated, or if rock or unsuitable material is
encountered which requires additional excavation, such excavation will be paid for in
accordance with 715.14. Structure backfill will be paid for in accordance with 211.10.
Where used as a substitute for structure backfill, flowable backfill will be paid for as
structure backfill. Where specified for backfill, flowable backfill will be paid for in
accordance with 213.09.

Stub-tee connections including the connecting bands, concrete collars, or cement

mortar beads will be paid for in accordance with 715.14.
150
Payment will be made under:

711
 718.01

Pay Item Pay Unit Symbol

Arch, Structural Plate, Min. Area ____ sq ft ............................. LFT

The cost of excavation, concrete field paved inverts, disposal of surplus materials,
reinforcing bars, straps, and hook bolts used in anchors, and necessary incidentals shall
be included in the cost of the pay item.
160
The cost of metal bearings and other hardware needed to attach the structural plate
arch to its substructure shall be included in the cost of the arch.

SECTION 718 – UNDERDRAINS

718.01 Description
This work shall consist of constructing underdrains using pipe, granular
aggregates, outlet protectors, or geotextiles in accordance with 105.03.

MATERIALS

718.02 Materials
10 Materials shall be in accordance with the following:

Coarse Aggregate, Class E or Higher,

Size No. 8 or 9 ..................................................... 904
Concrete, Class A ........................................................ 702
Geotextile for Underdrains .......................................... 918.02(b)
Reinforcing Bars.......................................................... 910.01
Sod, including Nursery Sod ......................................... 621
Structure Backfill ........................................................ 904.05
Underdrain Outlet Pipe ................................................ *
20 Underdrain Pipe ........................................................... 715.02(d)
* All thermoplastic pipes shall be from the Department’s list of approved
thermoplastic pipe and liner pipe in accordance with 907.16.

Transition pipes, 45° elbows, elbow connector pipes, and increasers shall be of
the same material as the underdrain outlet pipe.

Rodent screens shall be woven stainless steel wire mesh or galvanized hardware
cloth. Coarse aggregate No. 8 or 9 shall be used for 6 in. underdrain installations and
for underdrains for MSE walls. Coarse aggregate No. 9 shall be used for 4 in.
30 underdrain installations.

The mixture for HMA for underdrains shall be Intermediate OG19.0 mm in

accordance with 401. An ESAL Category 4 in accordance with 401.04 and a PG

712
 718.05

Binder 76-22 shall be used. A MAF in accordance with 401.05 will not apply.
Acceptance of the HMA for underdrains will be in accordance with 402.09.

CONSTRUCTION REQUIREMENTS

718.03 Pipe Installation

40
(a) Locations Outside MSE Wall Ground Reinforcement Limits
Trenches shall be excavated to the dimensions and grade shown on the plans. Each
longitudinal underdrain trench shall be cut continuously across all twin outlet areas
and all single outlet areas. Such pipeless portions of the trench shall be backfilled with
aggregate for underdrains. Pipes shall be secured to ensure that the pipe’s required
grade and horizontal alignment are maintained. Perforated pipe shall be placed with
the perforations down. The pipe sections shall be joined securely with the appropriate
couplings, fittings, or bands. The pipe shall be installed in the underdrain trench such
that a minimum clearance of 2 in. exists between the pipe and the trench walls.
50 Aggregate for underdrains shall be placed in a manner which minimizes
contamination. HMA for underdrains shall be placed and compacted separately from
mainline mixtures. HMA for underdrains may be placed in one lift and shall be
compacted with equipment in accordance with 409.03(d).

If plain end concrete pipe is being laid, the joint width shall not exceed 1/4 in.

(b) Underdrains Within MSE Wall Ground Reinforcement Limits

Underdrains for MSE walls shall be as shown on the plans. Coarse aggregate used
as underdrains for MSE walls shall be compacted in accordance with 706.04.
60
718.04 Geotextile
Storage and handling of geotextiles shall be in accordance with the manufacturer’s
recommendations. Each geotextile roll shall be labeled or tagged. Damaged or
defective geotextile shall be replaced as directed. The geotextile shall be placed
loosely, but with no wrinkles or folds. The ends of subsequent rolls of geotextile shall
be overlapped a minimum of 1 ft. The upstream geotextile shall overlap the
downstream geotextile. Placement of aggregate shall proceed following placement of
the geotextile. HMA for underdrains shall be placed and compacted separately from
mainline mixtures. HMA for underdrains may be placed in one lift and shall be
70 compacted with equipment in accordance with 409.03(d).

718.05 Underdrain Outlets

If the underdrain pipe and the outlet pipe are of different sizes, an increaser of the
same material as the outlet pipe shall be installed 2 ft from the 45° elbow and prior to
the transition pipe. If a single outlet pipe is to be skewed at 45°, a second 45° elbow
and an elbow-connector pipe are not required.

The outlet pipe or pipes shall be located as close as possible to the center of the
outlet protector.
80
713
 718.06

After the outlet pipe installation, the trench shall be backfilled as shown on the
plans. Structure backfill shall not extend into the limits of the underdrain trench. The
trench outside the limits of structure backfill shall be filled with materials suitable for
growing vegetation. Aggregate and stabilized materials removed from an existing
shoulder shall not be used as backfill and shall be disposed of in accordance with
206.07. At the time of installation, a rodent screen shall be placed on the outlet pipe or
the ends of the underdrain pipe when located in inlets or catch basins.

718.06 Underdrain Outlet Protectors

90 Underdrain outlet protectors shall be constructed as shown on the plans.

718.07 Video Inspection

Underdrains and outlets shall be inspected using high resolution, high sensitivity,
waterproof color video camera/recording equipment.

The camera/recording equipment shall be specifically designed for continuous

viewing/recording of detailed images of the interior wall of pipes and transitions of
the specified sizes. The equipment shall have the capability of viewing a minimum of
450 ft into the pipes and shall be designed to include sufficient lighting to view the
100 entire periphery of the pipe. The equipment shall have appropriate attachments to
maintain a position in the center of the pipe and an electronic counter to continuously
record the location of the equipment in the pipe. The recording equipment shall record
video of a quality and in a format acceptable to the Engineer. A color video printer
shall be included in the equipment for printing observations during inspection.

The Engineer will determine the runs of the underdrain installations to be

inspected. Video inspection shall be conducted after guardrail, lighting, sign
installation, and final seeding or sodding operations are completed.

110 Damage discovered by the video inspection shall be repaired. Damage shall
include but is not limited to; crushed or partially crushed pipe that impedes the
progress of the camera, blockages, vertical pipe sags filled with water to a depth of d/2
or greater, 90° connections, connector separations, cracks or splits in the pipes. All
repaired sections shall be video reinspected prior to acceptance. A copy of the video
inspection shall be submitted to the Engineer.

718.08 Patching Underdrains

Underdrains that are disturbed shall be repaired such that the underdrain is
perpetuated. This repair shall include the construction of new outlets where the
120 existing configuration prior to the damage cannot be reinstalled. The repairs shall be
as approved by the Department. Once the repairs are completed, a video inspection
may be required by the Department to verify that the repairs have been successfully
completed.

Geocomposite edge drains that are disturbed shall be outletted as approved and
not perpetuated.

714
 718.10

718.09 Method of Measurement

Underdrain and outlet pipe will be measured by the linear foot, complete in place.
130 If the pipe connects to structures such as manholes, inlets, or catch basins, the pipe
will be field measured to the outside face of the structures. Outlet protectors will be
measured by the number and type of units installed.

Measurement of outlet pipe will be made along the centerline of the pipe from the
point of connection with the underdrain pipe to the downstream end of the outlet pipe
and will include all transitions, elbows, and increaser or decreaser connections.

Structure backfill will be measured in accordance with 211.09. HMA for

underdrains will be measured by the ton.
140
Aggregate for underdrains and underdrains for MSE walls will be measured by
the cubic yard, complete in place. The pay limits will not extend beyond the neat lines
shown on the plans.

Geotextiles for underdrains will be measured by the square yard, for the type
specified, based on the neat line limits shown on the plans.

Video inspections for underdrains will be measured by the linear foot as

determined by the electronic equipment.
150
Patching of underdrains will not be measured.

Rodent screens and other incidentals will not be measured for payment.

Concrete, reinforcing bars, or sod for underdrain outlet protectors will not be
measured for payment.

718.10 Basis of Payment

The accepted quantities of underdrains and underdrain outlet pipe will be paid for
160 in accordance with 715.14. Aggregate for underdrains will be paid for at the contract
unit price per cubic yard. Underdrains for MSE walls will be paid for as aggregate for
underdrains. Geotextile for underdrains will be paid for at the contract unit price per
square yard for the type specified. Outlet protectors will be paid for at the contract unit
price per each of the type of unit installed, complete in place. The accepted quantities
of HMA for underdrains will be paid for at the contract unit price per ton.

Underdrain patching for structure installation will be paid for at the contract unit
price per linear foot of underdrain, patching and shall be equal to the length of the
theoretical pavement replacement as shown on the plans.
170
Structure backfill will be paid for in accordance with 211.10.

The final accepted quantity video inspection for underdrain will be paid for at the
contract unit price per linear foot.
715
 719.01

Payment will be made under:

Pay Item Pay Unit Symbol

180 Aggregate for Underdrains ........................................................ CYS

Geotextile for Underdrains, ______ .......................................... SYS
type
HMA for Underdrains ............................................................... TON
Outlet Protector, ____ ............................................................... EACH
type
Underdrain, Patching ................................................................. LFT
Video Inspection for Underdrain ............................................... LFT

Geotextile for underdrains which has been rejected due to contamination or other
190 reasons shall be replaced with no additional payment.

The cost of excavation, forming, reinforcing bars, concrete, curing materials, and
sod shall be included in the cost of outlet protector.

The cost of providing the video inspection equipment, technician, and a copy of
the video inspection shall be included in the cost of the underdrain video inspection.
The cost of repair of underdrain pipes, aggregates, backfill, outlet protectors,
geotextile fabric, providing video re-inspection of the repairs, and other incidentals
shall be included in the cost of the other pay items in this section.
200
Where underdrain repair for structure installation is required, the cost of
underdrain pipe, aggregate for underdrains, geotextile for underdrains, HMA for
underdrains, outlet protectors if required, video inspection for underdrains, and all
other incidentals for underdrains shall be included in the cost of underdrain, patching.
The cost of repairing underdrains damaged by activities other than for structure
installation, or as defined above, shall be at the Contractor’s expense.

The cost of disposal of unsuitable excavated materials, installation of pipe end

caps, rodent screens, and other incidentals shall be included in the cost of the pay items
210 in this section.

SECTION 719 – TILE DRAINS

719.01 Description
This work shall consist of the installation of drain tile in accordance with 105.03.

MATERIALS

719.02 Materials
Materials shall be in accordance with the following:
10
716
 719.04

Concrete, Class A ........................................................ 702

Drain Tile Terminal Pipe ............................................. 907.24
Flowable Backfill ........................................................ 213
Reinforcing Bars.......................................................... 910.01
Riprap .......................................................................... 616.02
Structure Backfill ........................................................ 904
Rodent Screen.............................................................. 718.02

Drain tile materials shall be in accordance with 715.02(d).

20
CONSTRUCTION REQUIREMENTS

719.03 Trench Excavation

The trench excavation shall begin at the outlet end and proceed towards the upper
end, true to the required line and grade. The trench shall be as shown on the plans. If
no trench details are shown on the pans, the trench shall be of sufficient width to
provide ample working space on each side of the drain tile to enable compaction of
the backfill around the tile. Recesses shall be cut into the trench bottom to
accommodate any projecting hubs or bells.
30
If excavation is made too deep, proper bearing shall be secured by backfilling to
the required elevation with sand, clay, or other approved material which shall be
tamped into place and shaped properly.

If a firm foundation is not encountered at the required trench bottom grade, the
unstable material shall be removed to such depth that provides ample support after
being backfilled, compacted, and shaped to the required elevation or the drain tile shall
be laid on planking which is not less than 1 in. thick, 10 in. wide, and 10 ft long.

40 If rock is encountered at or above the required trench bottom grade, the trench
shall be excavated at least 8 in. below the pipe and backfilled, compacted, and shaped
as described above.

Where excavation is made for installing drain tile across private property, the
topsoil and sod, if present, shall be kept in separate stockpiles. After completion of the
backfill operation, the topsoil and sod shall be placed so that the area is restored as
closely as possible to its original condition.

719.04 Laying Tile

50 Tile shall not be laid on a frozen or muddy trench bottom. It shall be laid true to
line and grade, starting at the outlet end. Each tile shall have a firm bearing for its
entire length and joints left as tight as practicable by turning the individual sections
until the ends fit closely. A joint which does not close to within 1/4 in. shall be covered
with pieces of broken tile. If laid on planking, the joints shall be covered with pieces
of broken tile and then entirely covered with clay and tamped.

717
 719.05

Drain tile installed on private property shall be perforated pipe in accordance with
715.02(d).

60 When an existing tile drain is encountered on permanent right-of-way, it shall be

replaced in the following manner. If the tile is intercepted by a side ditch prior to
crossing proposed pavement, it shall be replaced between the right-of-way line and the
ditch with non-perforated drain tile and a 10-foot long terminal pipe section of drain
tile with a rodent screen. If the tile is to outlet into a storm sewer, it shall be replaced
between the right-of-way line and the storm sewer with pipe in accordance with
715.02(b). If the tile is to outlet at a side ditch after crossing proposed pavement, it
shall be replaced between the right-of-way line and the ditch with pipe in accordance
with 715.02(a) with a rodent screen. If the tile is to be maintained across the right-of-
way, it shall be replaced from right-of-way line to right-of-way line with pipe in
70 accordance with 715.02(a).

719.05 Backfilling
Pipe replacing drain tile shall be backfilled in accordance with 715.09.

719.06 Blank

719.07 Method of Measurement

Drain tile and replacement pipe of the type and size specified will be measured in
accordance with 715.13. Terminating pipe sections of the type and size specified will
80 be measured per linear foot. Structure backfill will be measured in accordance with
211.09. Flowable backfill will be measured in accordance with 213.08. Riprap will be
measured in accordance with 616.12.

Tee or wye branch connections will be measured per each along the centerline of
the barrel. An additional allowance of 5 lft of the smaller diameter pipe will be made
for making such connections.

Elbow connections will be measured along the centerline of such connection. An

additional allowance of 2 lft of pipe of the same diameter as that of the elbow will be
90 made for each such connection.

Increaser and reducer connections will be measured by the linear foot as the larger
diameter pipe over the length of the connection.

719.08 Basis of Payment

The accepted quantities of drain tile and replacement pipe will be paid for in
accordance with 715.14. Terminating pipe sections will be paid for at the contract unit
price per linear foot for pipe, drain tile terminal section, of the size specified, complete
in place. Structure backfill will be paid for in accordance with 211.10. Flowable
100 backfill will be paid for in accordance with 213.09. Riprap will be paid for in
accordance with 616.13.

718
 720.02

Tee and wye connections will be paid for by means of the allowance of an
additional 5 lft of the smaller pipe at the connection. Elbow connections will be paid
for by means of the allowance of an additional 2 lft of the pipe at the connection.

If increaser or reducer connections are made, payment will be made on the basis
of the larger diameter of the connection for the full length of the section forming such
connections.
110
Payment will be made under:

Pay Item Pay Unit Symbol

Pipe, Drain Tile Terminal Section, ______ in. .......................... LFT

diameter

The cost of excavating, backfilling with suitable excavated material, disposal,

planking, removal of existing tile, and necessary incidentals shall be included in the
120 cost of this work.

SECTION 720 – MANHOLES, INLETS, AND CATCH BASINS

720.01 Description
This work shall consist of the construction, reconstruction, or adjustment to grade
of manholes, inlets, and catch basins in accordance with 105.03.

720.02 Materials
Materials shall be in accordance with the following:

10 Castings ....................................................................... 910.05

Clay or Shale Brick ..................................................... 905.01
Clay Pipe ..................................................................... 907.08
Concrete Brick ............................................................. 905.02
Concrete Masonry Blocks ........................................... 905.03
Concrete ...................................................................... 702
Hydrated Lime ............................................................. 913.04
Joint Filler ................................................................... 906.01
Joint Mortar ................................................................. 901.08, 907.12
Non-Reinforced Concrete Pipe .................................... 907.01
20 Precast Concrete Manholes, Inlets,
and Catch Basins ................................................. 907.04
Reinforced Concrete Pipe ............................................ 907.02
Reinforcing Bars.......................................................... 910.01
Water ........................................................................... 913.01

719
 720.03

CONSTRUCTION REQUIREMENTS

720.03 General Requirements

The construction of the items listed in this specification shall be in accordance
30 with 203.14.

Excavation shall be to the established bottom of the foundations. The finished

surface shall be firm and smooth. If soft or yielding spots are encountered at this
elevation, they shall be removed, backfilled with suitable material, and tamped into
place. If rock is encountered at the bottom elevation, the excavation shall be carried
down 6 in. further and backfilled with approved material tamped to the required
elevation.

Concrete construction shall be in accordance with the requirements for structural

40 concrete. Masonry shall be in accordance with the requirements for the respective type.
Exposed corners of concrete shall be rounded to a 1/4 in. radius. Air-entrained concrete
will not be required in the precast portions of concrete manholes or catch basins.

Frames for castings and bearing plates for manholes shall be set in full mortar
beds and secured as shown on the plans or as otherwise approved. The mortar shall be
composed of 1 part cement to 2 parts No. 23 fine aggregate, by volume. Castings shall
be set to the finished pavement elevation so that subsequent adjustments are not
necessary.

50 Iron hood traps in catch basins shall be installed in walls as shown on the plans
and so placed that a 6 in. seal is formed. Joints between hoods and walls shall be made
gas tight.

Mortar for laying brick and masonry units shall be composed of 1 part masonry
cement and 2 parts mortar sand. Mortar for plastering may be the same or it may be
composed of 1 part of a combination of portland cement and hydrated lime and 2 parts
mortar sand. The lime shall not exceed 10% of the cement. In any case, proportioning
shall be by volume. Ingredients, except water, shall be dry mixed, after which water
shall be added to bring the mortar to a stiff paste and mixing continued until a uniform
60 mixture results.

Required plaster coats on the inside and outside shall be at least 1/2 in. thick and
shall be smooth, clean, and watertight.

Inlet and outlet pipes shall extend through walls a sufficient distance to allow for
connections on the outside and the concrete or mortar carefully placed around them to
prevent leakage around their outlet surfaces. Unless otherwise shown, the inside ends
shall be flush with the inside walls. The pipe shall be of the same size and kind as that
with which it connects on the outside.
70

720
 720.03

Where castings are adjacent to or are surrounded by cement concrete construction,

each casting shall be entirely separated from the concrete by a preformed joint filler
not less than 3/8 in. thick. The cost of each joint, including the material, shall be
included in the price for the structure. Grates shall be placed with the maximum
dimension of the rectangular opening parallel to the direction of flow.

The surface of the grate shall be flush with the top edge of the frame, wingwall,
and headwall. The frame shall be galvanized and anchored into concrete. The frame
shall be factory assembled. All joints shall be fully welded.
80
Adjusting slots for curb boxes shall be of the dimensions shown on the plans. One
slot shall be located at each end of the curb box, and one slot shall be located at the
approximate centerline on the back of the curb box. Galvanized or stainless steel 3/8
in. UNC x 3 1/2 in. round head, square shoulder bolts with one flat washer, one lock
washer, and one nut each shall be used in each slot to anchor the curb box to the frame
such that the top of the curb box is flush with the top of the curb. Bolts shall be torqued
to a minimum of 120 ft lbs.

Steel grating type 12 shall be an approved, galvanized grating which shall be of

90 sufficient strength to support a 12,000 lb wheel load with a maximum fiber stress of
20,000 lbs/sq in. The grating shall seat firmly in, but shall not be secured to, the frame.
The length and width of the grating shall be so as to leave not more than 3/8 in.
clearance on each side when in place in the frame. The grating shall be cut such that
all riveted or welded connections are left intact.

If a manhole is constructed within the pavement area or within an area that may
be paved at some future date, the height of the casting used shall be based on the depth
of pavement constructed or proposed and a bearing plate for such casting will also be
required. Adjusting rings or steps of alternate types to those shown on the plans may
100 be used subject to approval.

If a manhole is constructed outside the proposed pavement area and outside an

area that may be paved at some future date, the height of the casting used shall be at
least 7 in. and a bearing plate for such casing will not be required.

The manhole bottom shall be constructed of a precast bottom section, or of class A

concrete formed in place. A precast cover shall be placed on a manhole in which
headroom is limited.

110 Only competent masons shall be employed in laying units. Brick or other masonry
units shall be laid in courses with full and close joints of mortar and finished properly
as the work progresses. No joint shall exceed 3/8 in. in width. All units shall be wetted
thoroughly immediately prior to being laid. Broken or chipped units will not be
allowed in the face of the structure. No spalls or bats shall be used except for shaping
around irregular openings or where necessary to finish out a course. As nearly as
practicable, adjoining courses shall break joints at a 1/2 unit. Courses shall be level

721
 720.04

except where otherwise necessary. If brick is used, at least one course in each seven
shall be composed of headers.

120 The pipe used in pipe catch basins shall be of the bell-and-spigot type.

Reinforced concrete spring boxes shall be constructed of class A concrete to the

dimensions and at locations shown on the plans or as otherwise specified.

If the completed structure is partially or completely under or at its nearest point is

within 5 ft of pavement, sidewalks, curbs, gutters, or similar miscellaneous existing or
proposed structures, the excavated space not occupied by the newly completed
structure shall be filled to the required subgrade elevation with material in accordance
with 211.02. Placement of this material shall be in accordance with 211.04. If the
130 completed structure is not located as set out above, the backfill shall be with approved
material which, when compacted, shall meet the required subgrade density.

Material excavated for the structure shall, if suitable, be utilized as backfill. If, in
excess for that purpose, the excess shall be used in embankment where locations are
available or otherwise disposed of as directed. If the excavated material is unsuitable
or is in excess for use in the work, it shall be disposed of in accordance with 201.03.
When finally accepted, all structures shall be free from any accumulation of silt,
debris, or other foreign matter.

140 The Contractor may precast inlets, catch basins, or manholes, subject to approval.
If precast concrete inlets, catch basins, or manholes are used, a layer of structure
backfill of minimum thickness of 4 in. shall be used under each unit for ease in
positioning. If holes are formed or field cut in precast inlets or catch basins to receive
the pipe structures, the pipes shall be connected directly to the precast unit, by means
of a class A concrete collar of a minimum longitudinal and radial thickness of 6 in.
Holes formed or cut in the wrong place shall be plugged satisfactorily with a class A
concrete mixture.

Horizontal joints may be used in the construction of precast catch basins. A sketch
150 of the type, location, and sealing material planned for each joint shall be submitted for
approval. No joints shall be closer than 3 in. above standing water for those catch
basins requiring hoods.

Grade and location adjustments to precast inlets and catch basins caused by
unforeseen conditions shall be handled as if the units were being cast-in-place. All
additional adjustments required due to precasting will not be paid for directly, but the
cost thereof shall be included in the cost of the inlet or catch basin.

720.04 Grade Adjustment of Existing Structures

160 When grade adjustment of existing structures is specified, the frames, covers, and
gratings shall be removed and the walls reconstructed as required. The cleaned frames
shall be reset at the required elevation. If so specified or if it is determined that the
existing casting and supporting walls are in good condition, an approved device may
722
 720.06

be used to adjust the manhole casting cover to the correct grade without reconstructing
the walls or resetting the frame. Upon completion, each structure shall be cleaned of
any accumulations of silt, debris, or foreign matter of any kind and shall be kept clear
of such accumulation until final acceptance of the work.

Excavation and backfill shall be done in accordance with 720.03.

170
If an existing casting is unfit for further use, a new casting shall be furnished with
payment at the contract unit price per each for castings of the type specified, furnished,
and adjusted to grade. This payment shall include and be full compensation for
furnishing the new casting, placing and adjusting it to grade, including any necessary
removal, construction, or reconstruction of not to exceed 12 in. average height of the
upper portion of the masonry.

When manholes, catch basins and inlets are adjusted to grade and are to abut
existing concrete construction, the castings shall be entirely separated from the
180 adjacent concrete by a preformed expansion joint no less than 3/8 in. in thickness. The
cost of furnishing and placing the preformed expansion joint material will not be paid
for directly, but shall be included in the payment for reconstructed catch basin, or
reconstructed inlet, or castings furnished and adjusted to grade. The preformed
expansion joint material shall be in accordance with 906.01.

On resurface contracts the castings shall, unless otherwise directed, be adjusted to

grade after the last binder course has been laid and before placing the surface course.

720.05 Capping Existing Structures

190 All structures directed to be capped shall be as shown on the plans or by filling
the structure with class A concrete after the existing drainage has been maintained.
The flow of water through pipes or underdrains in structures shall be perpetuated.
Alternate methods for capping shall be submitted for approval before they may be
used.

720.06 Method of Measurement

Manholes, inlets, spring boxes, and catch basins, both new and reconstructed as
applicable, will be measured per each unit, complete in place.

200 Castings adjusted to grade and castings furnished and adjusted to grade will be
measured per each unit complete in place, if the average adjustment height does not
exceed 12 in. If corrections to the structure involve portions exceeding an average
adjustment height of 12 in., the additional work will be measured by the linear foot for
the type of structure involved.

The capping of existing structures will be measured by the number of structures

capped.

723
 720.07

720.07 Basis of Payment

210 The accepted quantities of manholes, inlets, spring boxes, catch basins, castings
adjusted to grade not exceeding 12 in., and castings furnished and adjusted to grade
not exceeding 12 in. will be paid for at the contract unit price per each, complete in
place.

That portion of a reconstructed structure which exceeds 12 in. in average height

will be paid for at the contract unit price per linear foot, for structure, of the type
specified, reconstruct, complete in place.

The capping of inlets and other structures will be paid for at the contract unit price
220 per each for cap inlet.

Payment will be made under:

Pay Item Pay Unit Symbol

Casting, ____, Adjust to Grade ................................................. EACH

type
Casting, ____, Furnish and Adjust to Grade.............................. EACH
type
230 Catch Basin, ____...................................................................... EACH
type
Inlet, ____.................................................................................. EACH
type
Inlet, Cap ................................................................................... EACH
Inlet, type H, with Slotted Drains .............................................. EACH
Inlet, type HA, with Slotted Drains ........................................... EACH
Manhole, ____ ........................................................................... EACH
type
Pipe Catch Basin, ____ in. ........................................................ EACH
240 size
Spring Box................................................................................. EACH
Structure, ____, Reconstructed.................................................. LFT
type

The cost of both inlets, the 12 in. pipe connecting the two inlets, the type 5
castings, the concrete filler between the barrier wall and the inlet, and other
miscellaneous materials shall be included in the cost of the inlet, type H. The cost of
the inlet, the type 5 casting, the concrete filler between the barrier wall and the inlet,
and other miscellaneous materials shall be included in the cost of the inlet, type HA.
250
The cost of both inlets, the 12 in. pipe connecting the two inlets, the type 5
castings, the concrete filler between the barrier wall and the inlets, the slotted drain
pipe, the concrete collar around the slotted drain pipe, and other miscellaneous
materials shall be included in the cost of the inlet, type H, with slotted drains. The cost

724
 721.05

of the inlet, the type 5 casting, the concrete filler between the barrier wall and the inlet,
the slotted drain pipe, the concrete collar around the slotted drain pipe, and other
miscellaneous materials shall be included in the cost of the inlet, type HA, with slotted
drains.

260 The cost of excavation, backfill, reinforcing bars, structure backfill, concrete
collar required for pipe connection to structures, removal, disposal and replacement of
pavement, or surface material, casting removal, installation of concrete cap, HMA
wedge, damage repair to pavement and shoulders, and necessary incidentals shall be
included in the cost of the pay items.

SECTION 721 – AUTOMATIC DRAINAGE GATES

721.01 Description
This work shall consist of furnishing and placing cast-iron, automatic, hinged,
flap-gate valves to the outlet ends of pipe or headwalls in accordance with 105.03.

721.02 Materials
The cast-iron flap and seat shall be machined accurately to ensure watertightness.
They shall be in accordance with the applicable requirements of 910.05(b).
10
721.03 Construction Requirements
The gate shall be constructed to offer minimum resistance to water flowing
through it. When the water elevation in the outlet stream is 1/2 in. or more above or
below the bottom of the valve, the valve shall close or open, as the case may be. The
valve shall be able to resist a head of at least 10 ft.

The end of the pipe, or headwall, to which the flange is attached shall be vertical
and the flange attached thereto either with rivets, bolts, or other approved means.

20 721.04 Method of Measurement

Automatic drainage gates will be measured by the number of units installed.

721.05 Basis of Payment

The accepted quantities of this work will be paid for at the contract unit price per
each for automatic drainage gate, of the size specified, complete in place.

Payment will be made under:

Pay Item Pay Unit Symbol

30
Automatic Drainage Gate, _____ in. x _____ in. ...................... EACH
width height
Automatic Drainage Gate, _____ in. ......................................... EACH
diameter

725
 722.01

If the gate is fastened to the end of a pipe, no additional payment will be allowed
for that portion of pipe extending beyond the outside face of the headwall.

SECTION 722 – CONCRETE BRIDGE DECK OVERLAYS

722.01 Description
This work shall consist of the surface preparation and construction of a bridge
deck overlay consisting of latex modified portland cement concrete, LMC, latex
modified concrete very early strength, LMC-VE, or silica fume modified concrete,
SFMC, on an existing or new bridge deck, or it shall consist of patching an existing
concrete overlay on a bridge deck in accordance with 105.03.

10 722.02 Quality Control

LMC-VE overlays shall be placed in accordance with the QCP, which shall be
prepared and submitted in accordance with ITM 803. The QCP shall include the
Contractor’s experience placing LMC-VE overlays within the last three years. The
QCP shall be submitted to the Engineer at least 14 days prior to commencing overlay
operations. Approval of the QCP by the Department’s Office of Materials
Management is required.

722.03 Materials
Materials shall be in accordance with the following:
20
Admixtures .................................................................. 912.03
Coarse Aggregate, Class A or Higher,
Size No. 11* ......................................................... 904
Epoxy Resin Adhesive ................................................ 909.11
Fine Aggregate ............................................................ 904
Fly Ash ........................................................................ 901.02
Latex Modifier ............................................................. 912.04
PCC Sealer/Healer ....................................................... 901.06
Portland Cement .......................................................... 901.01(b)
30 Rapid Hardening Hydraulic Cement** ....................... ASTM C 1600
Silica Fume .................................................................. 901.04
Water ........................................................................... 913.01
* Crushed stone only.
** Cement shall be calcium sulfoaluminate, CSA, hydraulic cement
type VRH except that the 3 h compressive strength shall be a
minimum of 2,500 psi. Portland cement shall not be used.

Evaporation retardant shall be a product that produces a monomolecular film. A

Type D certification in accordance with 916 shall be furnished to the Engineer prior
40 to use.

Citric acid shall be marked “food grade” on the packaging.

726
 722.05

722.04 Storage and Handling of Materials

Fine and coarse aggregates shall be stored and handled avoiding contamination
and maintaining uniform moisture content. Fine and coarse aggregates which are
stored in piles or bins shall remain separated and shall be covered with a moisture
proof material which prevents variations in moisture content of the aggregates. The
maximum variation of moisture content in successive concrete batches shall be 0.5%.
50
Cement shall be shipped and stored in accordance with 702.04 and 901.01.

The latex modifier, liquid silica fume slurry, and dry condensed silica fume shall
be stored in accordance with the manufacturer’s recommendations. Latex modifier
shall be strained to remove solid particles during transfer of the material from storage
drums to the mobile mixer tank.

722.05 Proportioning

60 (a) Latex Modified Concrete

A mix design shall be submitted a minimum of 14 days prior to use and calibration
of the mobile mixer in accordance with 722.09. The proportioning of the ingredients
for the LMC shall be in accordance with 702.05 except as modified herein.

The amount of fine aggregate shall be 60% ±5% by dry weight of the total
aggregate and shall be considered as the amount of aggregate blend passing the No. 4
(4.75 mm) sieve. The coarse aggregate shall be No. 11, class A crushed stone. The
cement content shall be a minimum of 658 lbs/cu yd of concrete. The same brand of
cement shall be used throughout a bridge structure. The amount of latex modifier shall
70 be 3.5 gal. per 94 lbs of cement. The net water added shall produce a slump of 5 in. ±1
in. at 4 to 5 minutes after discharge from the mixer. The moisture content of the
aggregates shall be controlled such that the slump is within the specified limits. The
maximum water-cement ratio shall be 0.400 including the water in the latex. The air
content shall be a maximum of 6%, by volume, of the plastic mix.

The yield will be checked using the 1/4 cu yd box method as follows. The chute
shall be cleaned and the box shall be positioned to receive the discharged concrete.
The mixer shall be operated until the cement counter indicates that 1/4 cu yd of
concrete has been produced. The contents of the box shall be consolidated and struck
80 off. Where the box is not essentially full, the gates shall be adjusted and the procedure
shall be repeated until the actual and calculated volumes of concrete agree. Yield tests
shall be run on the first load of each truck and every third load per truck thereafter.
The air content shall be tested on the first load of each truck prior to placing concrete
onto the deck. Additional tests will be required after making any adjustments.

Slump and air content tests will be performed after each acceptable yield test. The
slump test shall be in accordance with AASHTO T 119 and will be performed 4 to 5
minutes after the concrete is discharged from the mixer. The water flow meter reading
will be recorded at the time the slump test is taken. The concrete shall not be disturbed

727
 722.05

90 during the waiting period for the slump test. The air content test shall be in accordance
with 505. Any concrete mixture which is not properly proportioned or does not
conform to the specified slump will be rejected.

Class F or class C fly ash may be used in the latex modified portland cement
concrete. The maximum cement reduction shall be 15% and the minimum replacement
ratio by weight of fly ash to cement shall be 1.25:1. Where portland pozzolan cement,
type IP is to be used in the concrete mix design, the cement content shall be increased
by a multiplier of 1.06 times the specified cement content.

100 (b) Latex Modified Concrete, Very Early Strength

Proportioning of ingredients for LMC-VE shall be in accordance with 722.05(a)
except as follows.

Cement shall be a rapid hardening hydraulic cement. Fly ash or other pozzolonic
materials shall not be used. Citric acid may be used as a retardant. The maximum
content of citric acid shall be 1% of the cement weight. The minimum compressive
strength shall be 2,500 psi at 3 h and 3,500 psi at 24 h. The net water added shall
produce a minimum slump of 7 in. and maximum slump of 10 in. at 4 to 5 minutes
after discharge from the mixer. The maximum water-cement ratio shall be 0.440
110 including the water in the latex.

1. Trial Batch Demonstration

A trial batch shall be produced to verify that the mix design complies with the
physical properties specified, as well as, simulating the placement properties unique
to the conditions of the contract such as profile grade, cross slope, delivery time,
discharge rate, slump loss with time, air content and target compressive strength. All
testing of the trial batch concrete shall be performed by an American Concrete
Institute, ACI, certified concrete field testing technician, grade I.

120 The trial batch demonstration shall include a meeting between the Contractor,
material suppliers, and Department to discuss LMC-VE, mixing, delivery, placement,
finishing, curing and compressive testing. Representatives from the rapid hardening
cement manufacturer shall be present for trial batch demonstrations and the start-up
for initial bridge deck placement. The Office of Materials Management may waive the
required attendance for these representatives where the Contractor provides sufficient
evidence of adequate experience with producing and placing LMC-VE. The trial batch
demonstration may be conducted in conjunction with calibration of the mobile mixer
in accordance with 722.13.

130 2. Blank

(c) Silica Fume Modified Concrete

A concrete mix design submittal, CMDS, shall be submitted a minimum of 14
days prior to the trial batch utilizing the Department provided spreadsheet. The
proportioning of ingredients for each batch of SFMC shall be in accordance with

728
 722.05

702.05 except as modified below and shall meet the mix design, trial batch
demonstration, and job-use requirements as specified.

The portland cement content shall be 658 lb/cu yd. Silica fume shall be added at
140 50 lb/cu yd.

The SFMC shall utilize an approved type F or G admixture to be combined with

an air entraining admixture, AEA, a HRWR admixture system or a HRWRR admixture
system shall be selected from the Department’s list of approved PCC Admixtures and
Admixture Systems.

The water/cement ratio shall be no less than 0.370 and shall not exceed 0.400.
Portland cement and silica fume shall be included in the total amount of cementitious
material.
150
The same brand of cement and silica fume shall be used throughout the structure.
The HRWR or HRWRR admixture system shall not be changed during any individual
contiguous pour.

The Contractor shall obtain a written statement from each admixture manufacturer
stating the compatibility of the HRWR admixture system and satisfactory performance
in SFMC.

The SFMC shall have a relative yield and air content in accordance with 702.05.
160 The slump will be tested in accordance with AASHTO T 119 at the time of placement
and shall be at least 4 1/2 in. but shall not exceed 7 1/2 in. The SFMC shall have a
minimum compressive strength of 4,500 psi at 7 days and 5,500 psi at 28 days. The
compressive strength shall be in accordance with 702.24.

1. Trial Batch Demonstration

A trial batch shall be produced to verify that the mix design complies with the
physical properties specified, as well as, simulating the placement properties unique
to the conditions of the contract such as profile grade, cross slope, delivery time,
discharge rate, slump loss with time, air content and target compressive strength. All
170 testing of the trial batch concrete shall be performed by an American Concrete
Institute, ACI, certified concrete field-testing technician, grade I.

The trial batch demonstration shall include a meeting between the Contractor,
material suppliers, and Department to discuss SFMC, batching, mixing, delivery,
placement, finishing, curing and compressive testing. Representatives from the silica
fume and chemical admixture manufacturer shall be present for trial batch
demonstrations and the start-up for initial bridge deck placement. The Office of
Materials Management may waive the required attendance for these representatives
where the Contractor provides sufficient evidence of adequate experience with
180 producing and placing SFMC.

729
 722.06

2. Batching
Batching shall be in accordance with 702.06 except the minimum batch shall be
4 cu yd and the maximum shall not exceed 80% of the truck rated capacity. Dry
condensed silica fume shall be either sacked or bulk and it shall be batched in
accordance with the requirements for cement as specified in 702.06. No partial sack
of dry condensed silica fume shall be used in a batch of SFMC. Dry condensed silica
fume shall be typically added after the initial water and aggregates, with premixing
prior to the addition of cement and fly ash, to facilitate dispersion. An alternate
190 batching sequence will be allowed as recommended by the manufacturer of the silica
fume and as approved by the Engineer. Liquid silica fume slurry shall be batched as
required by the manufacturer and as approved by the Engineer. The AEA shall be
added initially with either the first portion of mix water or the fine aggregate. Where
a type A or D chemical admixture is used as part of the approved HRWR admixture
system, it shall be added separately with a portion of the mix water, after the AEA is
premixed in the concrete. A type F or G chemical admixture shall be added separately
at the end of the batching sequence with some mix water held in reserve to aid
dispersion.

200 A change in the sequence of batching may be approved if it is in accordance with

the chemical admixture and silica fume manufacturer’s recommendations, and is
agreed to in writing prior to any trial batch demonstration.

722.06 Preparation of the Bridge Floor

(a) Removal of Existing Concrete Overlay

When an existing deck overlay is to be removed, the removal shall be performed
with a milling machine. The milling shall include the depth of the existing deck overlay
and an additional depth as shown on the plans. If no additional depth is shown on the
210 plans, the additional depth shall be 1/2 in. Removal in areas that are inaccessible to the
milling machine, shall be performed by chipping hammers or handchipping in
accordance with 722.06(b)3.

(b) Surface Preparation of Existing Concrete Deck

1. Removal of Existing Concrete Deck Surface

When an existing concrete deck without an overlay surface is to be removed, the
removal shall be performed with a milling machine. The milling shall be to a depth
shown on the plans. If no depth is shown on the plans, the milling shall be 1/2 in.
220 depth. The surface removal operation shall be limited to that portion of the bridge deck
that is closed to traffic at any one time. After this initial surface removal, additional
milling may be required as directed.

The milling machine shall uniformly remove the required depth of concrete
surface in a satisfactory manner. Surface removal, which is in areas adjacent to the
curb that are inaccessible to milling, shall be done by handchipping in accordance with

730
 722.06

722.06(b)3. All surface removal residue, including water, dust and concrete, shall be
immediately removed.

230 Where the milling operation results in the snagging of the top mat of steel
reinforcing bars, the milling operation shall cease and the depth of removal adjusted.
Damaged reinforcing bars shall be repaired as directed with no additional payment.

2. Hydrodemolition
When shown on the plans, removal of unsound concrete shall be performed by
hydrodemolition. Following the cleanup from the surface removal operation, areas of
unsound concrete to be removed will be marked. The hydrodemolition equipment shall
consist of a self-propelled computerized machine that utilizes a high pressure water jet
stream capable of removing concrete as specified, as well as, removing rust and
240 concrete particles from exposed reinforcing bars.

Prior to hydrodemolition, the equipment shall be calibrated on an area of sound

original deck concrete as designated by the Engineer.

The initial settings shall be verified on an area of unsound concrete. The initial
settings may need to be adjusted in order to achieve total removal of unsound concrete.
Equipment shall be calibrated each day prior to operation. Where directed, equipment
shall be recalibrated to ensure removal of known areas of unsound concrete and to
guard against removal of sound concrete. The Engineer shall be notified of the final
250 equipment settings resulting from the calibration process.

After calibration of the equipment, concrete removal by hydrodemolition shall be

performed on the bridge deck. The removal will be verified as necessary, every 30 ft
along the cutting path. Handchipping shall be used in areas that are inaccessible to the
hydrodemolition equipment. Handchipping tools may be handheld or mechanically
driven. The removal operation shall cease where it is determined that sound concrete
is being removed. Equipment shall be recalibrated, or approved changes to equipment
and methods shall be performed, prior to resuming the removal operation.

260 The Contractor shall submit a waste water control and disposal plan for approval
seven days prior to commencing hydrodemolition activities. The waste water control
and disposal plan shall detail how all waste water generated by the hydrodemolition
activities shall be contained, tested for pH, stored, and transported to a disposal facility
in accordance with 202.

The Contractor shall provide sufficient shielding to ensure containment of all

dislodged concrete during hydrodemolition operations and to prevent damage to
surrounding property from flying debris, both on and under the work site.

270 Cleaning of the hydrodemolition debris and slurry shall be performed with a
vacuum system equipped with fugitive dust control devices and capable of removing
wet debris and water in the same pass. The vacuum equipment shall be capable of

731
 722.06

washing the deck with pressurized water during the vacuum operation to dislodge all
debris and slurry from the bridge deck surface. Debris and slurry shall not be allowed
to dry prior to vacuuming.

After hydrodemolition has been completed, the deck will undergo sounding to
identify remaining areas of unsound concrete. Ponded or standing water shall be
removed from the deck prior to sounding.
280
Additional concrete removal of remaining unsound concrete, shall be as directed
by the Engineer and shall be performed by handchipping or hydrodemolition.

3. Handchipping
When hydrodemolition is not shown on the plans, all removal of unsound concrete
shall be performed by handchipping. Following the cleanup from the surface removal
operation, areas of unsound concrete to be removed will be marked. Handchipping
tools may be hand or mechanically driven. Jackhammers shall not be heavier than
nominal 45 lb class and chipping hammers shall not be heavier than nominal 15 lb
290 class. Only chipping hammers shall be used when removing concrete within 1 in. of
reinforcing bars. Mechanically driven tools shall be operated at a maximum angle of
45° from the bridge floor surface.

Regardless of the method of removal, the removal operation shall cease where it
is determined that sound concrete is being removed. Agreed upon changes in
equipment and methods shall be performed prior to resuming the removal operation.

4. Additional Surface Preparation around Reinforcing Bars

Where reinforcing bars have been exposed for a length greater than 2.0 ft and the
300 bond between the existing concrete and reinforcing bars has been destroyed, the
concrete adjacent to the bars shall be removed to a minimum clearance of 1 in. around
the entire periphery of the exposed bars.

5. Additional Construction Requirements

Regardless of the method used for unsound concrete removal, where the deck is
unsound for more than 1/2 of its original depth, the concrete shall be removed full
depth, except for limited areas as determined by the Engineer. Forms for areas of up
to 4 sq ft may be suspended from wires attached to the reinforcing bars. For areas
greater than 4 sq ft, the forms shall be supported from the structural members of the
310 superstructure or by shoring from below.

Prepared cavities which are deeper than the level of the adjacent prepared deck
surface, but are not full depth, shall require partial depth patching in accordance with
722.07(b). Prepared partial depth cavities shall be made full depth when directed.
Exposed reinforcing bars shall not be damaged by the removal operation. Any
damaged reinforcing bars shall be repaired as directed with no additional payment.

732
 722.07

The removal areas shall be thoroughly cleaned of all dirt, foreign materials and
loose concrete to the extent necessary to produce a firm solid surface for adherence of
320 the new concrete. A minimum 1 in. vertical surface shall remain, or be cut, 1 in. outside
and around the entire periphery of each removal area after removal of all loose and
unsound concrete. The 1 in. vertical cut may be waived where it is determined that a
cut will damage the reinforcing bars. Where hydrodemolition is utilized on the
adjacent surface, the 1 in. vertical surface will not be required.

(c) Cleaning
After the concrete removal operation is completed and just prior to placing the
patches or the overlay, the entire deck shall be heavily sandblasted to expose fine and
coarse aggregates and to remove unsound concrete or laitance layers from the surface.
330 Exposed reinforcing bars and the concrete under and around the exposed bars shall be
thoroughly cleaned by sandblasting. The surface shall be then cleaned free of all dust,
chips, water, and foreign material to the extent necessary to produce a firm, solid
surface for adherence of the new concrete. The air lines for sandblasting and air
cleaning shall be equipped with oil traps.

When hydrodemolition is utilized, water blasting may be used in lieu of

sandblasting. The sandblasting or water blasting shall be performed using two passes
with the second pass being at a right angle to the first pass or a cross-blasting
technique. The minimum pressure of the water blast shall be 6,000 psi.
340
722.07 Patching of the Bridge Floor
A vacuum device shall be used to remove all water from the prepared cavities.

(a) Full Depth Patching

The material used for full depth patching shall be either bridge deck patching
concrete, overlay concrete, or concrete patching material from the Department's list of
approved Rapid Setting Patch Materials. Full depth patching shall be performed prior
to the overlay operation. The patching material shall be consolidated by internal
vibration at the time of placement. Equipment shall not be operated on the repaired
350 deck areas until the test beams indicate a minimum modulus of rupture of 550 psi.

1. Patching with Bridge Deck Patching Concrete

Epoxy resin adhesive shall be used to coat the surfaces of the prepared cavities
and all the exposed reinforcing bars within the cavities. The epoxy coating shall be
tacky at the time that the patching concrete is placed. Where the epoxy coating has
cured beyond the obvious tacky condition, it shall be re-applied prior to patching. The
coated cavities shall then be filled with the patching concrete to the level of the
adjacent deck surface. Curing of the patching concrete shall be as directed.

360 Bridge deck patching concrete shall be composed of the following:

a. Fine aggregate shall be 35% to 45% of the total weight

of aggregate used.

733
 722.08

b. The cement shall be 564 lbs/cu yd of portland cement

type III or type IIIA, or 846 lbs/cu yd of portland
cement type I or type IA.

c. Air entraining admixture shall be added to produce 5%

370 to 8% entrained air.

d. The net water added shall produce a slump of no more

than 6 in. and a maximum water/cement ratio of 0.450.

2. Patching with Overlay Concrete

The surfaces of the prepared cavities shall be coated with a bond coat in
accordance with 722.10. The cavities shall then be filled with the overlay concrete to
the level of the adjacent deck surface.

380 3. Patching with Rapid Setting Patch Materials

Concrete patching materials shall be as approved by the overlay supplier for
compatibility with the overlay material. Concrete patching materials shall be placed
and cured in accordance with the manufacturer’s recommendations.

(b) Partial Depth Patching

The material used for partial depth patching shall be either bridge deck patching
concrete, overlay concrete, or concrete patching material from the Department’s list
of approved Rapid Setting Patch Materials. The patching material shall be
consolidated by internal vibration at the time of placement.
390
1. Patching with Bridge Deck Patching Concrete
Partial depth patching with bridge deck patching concrete shall be in accordance
with 722.07(a) and 722.07(a)1. Curing of the patching concrete shall be as directed.

2. Patching with Overlay Concrete

The surfaces of the prepared cavities shall be coated with a bond coat in
accordance with 722.10 except where hydrodemolition is utilized. The cavities shall
be filled with the overlay concrete at the time that the overlay is placed. Concrete
overlay material used for patching shall be cured in accordance with 722.12.
400
3. Patching with Rapid Setting Patch Materials
Concrete patching materials shall be as approved by the overlay supplier for
compatibility with the overlay material. Concrete patching materials shall be placed
and cured in accordance with the manufacturer’s recommendations.

722.08 Overlay Dam

An overlay dam shall consist of the removal of existing concrete from the bridge
floor and replacing it with new concrete as shown on the plans or as otherwise directed.
Overlay dam material shall be in accordance with 722.05.

734
 722.09

410
The existing concrete shall be removed as required in accordance with 722.06(b).
Exposed reinforcing bars shall not be cut or otherwise damaged.

Power driven hand tools for removal by handchipping will be allowed. Pneumatic
hammers with a maximum weight of 69 lbs may be used for the tops of mudwalls.
Where, during the removal process, the tools or methods being used appear to cause
damage such as cracks or spalling on the concrete which is to remain, the work shall
cease immediately and agreed upon changes in equipment and methods shall be
performed prior to resuming the removal operation.
420
The surface to be repaired, the reinforcing bars, and the concrete under and around
the bars shall be cleaned in accordance with 722.06(c). The cavity shall be coated with
an epoxy resin adhesive in accordance with 722.07(a)1, then filled with class C
concrete in accordance with 702.

722.09 Mixing

(a) Latex Modified Concrete and Latex Modified Concrete, Very Early
Strength
430 Proportioning and mixing of the latex modified concrete shall be performed in a
self-contained, self-propelled continuous mixer. The mixer shall be calibrated to
accurately proportion the specified mix prior to starting the work. The calibration shall
be in accordance with 722.13. Sufficient mixing capacity or mixers shall be provided
to enable the intended pour to be placed without interruption. The mixer shall carry
sufficient quantities of unmixed ingredients to produce at least 6 cu yd of latex
modified concrete at the site.

The mixer shall measure and control the flow of ingredients being introduced into
the mix and shall record these quantities on an approved visible recording meter
440 equipped with a ticket printer. Water flow shall be readily adjustable to compensate
for minor variations in aggregate moisture content, and shall be displayed by an
approved flow meter. The flow of the latex modifier shall also be displayed by an
approved flow meter. The manufacturer’s inspection plate shall clearly show the serial
number, proper operating revolutions per minute, and the approximate number of
counts on the cement meter to deliver 94 lbs of cement.

The mixer shall automatically proportion and blend simultaneously all the
ingredients of the specified mix on a continuous or intermittent basis as required by
the finishing operation. The latex modified concrete shall be discharged through a
450 conventional chute directly in front of the finishing machine. The surface ahead of the
deposited mixture shall be kept damp by spraying it with water. Where the water is
applied by the mixer, it shall be dispensed ahead of the water flow meter.

735
 722.10

(b) Silica Fume Modified Concrete

Mixing shall be in accordance with 702.09(a), 702.09(b), and 702.09(c), except
mixing time shall be a minimum of 84 s. Retempering SFMC by adding water or by
other means will not be allowed after 30 minutes from initial batching and mixing.
When concrete is delivered in transit mixers, additional water may be allowed to
increase a marginally low slump. Water shall not be added once 10% of the load has
460 been discharged. Additional mixing shall be performed as directed and all operations
completed within the time limits in accordance with 702.09(c). The amount of water
shall be determined accurately and noted on the batch ticket. Such addition of water
will not be allowed as a continuing operation. The total of all water included in the
mix shall not exceed the maximum allowable water/cement ratio.

722.10 Placing and Finishing

Existing expansion joints shall be maintained throughout the overlayment unless
otherwise shown on the plans. A construction dam or bulkhead, equal in thickness to
the joint width, shall be installed to the required grade and profile prior to placing the
470 overlay. Screed rails for the finishing machine shall be placed to the required profile,
and stably anchored vertically and horizontally. Screed rails shall not be treated with
a bond breaking compound.

The overlay shall be placed only when the ambient temperature is 45°F and rising,
unless otherwise approved by the Department in writing. The maximum allowable
ambient temperature during placement is 85°F. The overlay shall not be placed if rain
is expected within 4 h. Adequate precautions shall be taken to protect freshly placed
overlay material from sudden or unexpected rain. Damaged material shall be removed
and replaced with no additional payment. A construction dam or bulkhead shall be
480 installed in case of a delay in placement of 1 h or more. During delays of less than 1 h,
the end of the placed overlay material shall be protected from drying with layers of
wet burlap.

After the surface has been cleaned, and immediately before placing the overlay
material, the surface shall be thoroughly soaked and covered with plastic sheeting for
a period of 1 h. The surface shall not be allowed to dry before placing the overlay
material and there shall be no standing water at the time of placement. The surface
shall then be thoroughly and evenly coated with a brush applied bond coat of overlay
concrete, except a bond coat shall not be applied to surfaces where the removal was
490 performed by hydrodemolition. The progress of the bond coat application shall be
controlled to ensure that the bond coat does not dry before the overlay is placed to the
required grade. Aggregate segregated in the brush application of the bond coat shall
be removed before the overlay is placed. Surface irregularities shall be filled to
approximately three-quarters of their depth sufficiently ahead of the overlay operation
to allow the material to stiffen and resist rolling back during the finishing.

Following the bond coat application and partial filling of any surface
irregularities, the concrete overlay shall be placed to an elevation approximately 1/2
in. above final grade. The mix shall then be consolidated and machine finished to the

736
 722.10

500 required grade. The machine finishing shall be to within 12 in. of the curb line or
coping line unless otherwise directed. Supplemental hand finishing with a wood float
shall be performed as needed to produce the required tight, uniform surface.

The finishing machine shall be self-propelled and capable of positively controlled

forward and reverse motion. The machine shall be equipped with at least two finishing
devices. The first finishing device shall be a vibrating mechanism, such as a vibrating
pan, for consolidating the deposited mix. The vibrating pan shall be metal and of
sufficient dimensions to ensure proper consolidation. The second finishing device
shall be either a rotating cylindrical drum, at least 45 in. in length, or a vibrating
510 oscillating metal faced screed of 4 in. minimum in width. The vertical position of the
finishing devices shall be positively controlled and the devices shall be raised clear of
the finished surface when the machine is operated in the reverse direction. The
vibration frequency of any vibrating finishing device shall be variable, with positive
control between 3,000 and 6,000 vibrations per minute. Alternate finishing machines
may be considered for approval subject to a written request.

Screed rails and construction dams shall be separated from the newly finished
overlay by passing a pointing trowel along the rail-to-overlay and dam-to-overlay
interfaces after the overlay has sufficiently set such that it does not flow back. This
520 trowel cut shall be made for the entire length and depth of the rail or dam. The rails
may be removed any time after the overlay has initially set. Adequate precautions shall
be taken during and subsequent to the rail removal to protect the edge of the new
overlay from damage.

Protection shall be provided to prevent rapid drying of concrete. The rate of water
evaporation shall be determined both prior to placement based on forecasted
conditions and during placement based on actual conditions in accordance with ACI
308, section 5.2.1 or the following equation:

530 E = (Tc2.5 - rTa2.5)(1 + 0.4V) x 10-6

where:

E= Evaporation rate, lb/sq ft/h

Tc = Concrete mix temperature, °F
Ta = Ambient temperature, °F
r= (Percent of Relative Humidity)/100
V= Wind velocity, mph

Measurement of Ta, r, and V shall be obtained from readings made by the local
weather bureau or the Contractor's measurements made on site. Measurement of Tc
shall be determined from the concrete on site at the point of placement. Fog misting
shall be performed after the finishing operation and prior to the wet cure, where the
540 evaporation rate exceeds or is expected to exceed 0.05 lb/sq ft/h. Fog misting shall

737
 722.11

keep the environment above the concrete surface at high humidity to protect against
plastic shrinkage cracks and shall not be used to apply water directly to the surface to
facilitate finishing. Evaporation retardants shall not be substituted for fog misting
where the evaporation rate exceeds 0.05 lb/sq ft/h.

An evaporation retardant shall be applied in a fine mist immediately after the

finishing is complete to ensure that the surface remains wet until covered. The
evaporation retardant shall be used as such and not as a finishing aid. These products
consist primarily of water and excessive amounts of evaporation retardant shall not be
550 applied and the product shall not be worked into the overlay surface. Evaporation
retardant shall only be used on SFMC overlays. Evaporation retardant shall not be
used in any other applications.

722.11 Texturing
The overlay surface shall be textured with a double thickness burlap drag or a
minimum 4 ft wide turf drag immediately following the placement of the overlay
material. Areas where the texture is disturbed by other finishing operations shall be
immediately restored to a burlap drag finish.

560 Grooving or tining in the plastic concrete of the concrete overlay will not be
allowed. Transverse grooving, when specified, shall not commence until the curing
requirements have been met in accordance with 722.12. Grooves shall be cut into the
hardened concrete surfaces perpendicular to the centerline using a mechanical cutting
device. For curved bridges, grooves shall be cut transverse to the curve chord within
the spans. Grooving shall be done before traffic is allowed on the surface except at
follows:

The Contractor shall have the option of cutting the transverse grooves at the end
of each phase of construction or waiting until all phases have been completed. If the
570 Contractor elects to delay the grooving process until completion of all phases, the
concrete overlay surface for any phase opened to traffic shall receive an interim coarse
broom finish during placement.

The completion of the grooving process shall be within 30 days of completion of

the last phase of construction. Any additional maintenance of traffic operations
required for the grooving process shall be included in the cost of Maintaining Traffic.
The interim broom finish shall not be allowed as a surface texture when opened to
traffic over a winter season. If the coarse broom texture is present and the Contractor
is not in a position to finish all phases of the project, transverse grooving shall be
580 placed into the hardened concrete in order to establish an acceptable driving surface
texture for the winter season.

Each groove shall be 1/8 in. ±1/64 in. in width, 3/16 in. ±1/16 in. in depth. The
grooves shall be uniformly spaced at 3/4 in. intervals measured from the center of
groove to center of groove or randomly spaced at intervals between 5/8 in. to 1 1/4 in.
from center of groove to center of groove with an average spacing of 7/8 in. Grooving

738
 722.12

shall not be within the area approximately 2 ft adjacent to the curbs. The grooving
shall terminate approximately 6 in. from any expansion joints with steel nosing. Stair
stepped ends in grooving will be allowed for skewed bridge decks. When a new
590 reinforced concrete approach slab is placed adjacent to the overlay, the grooving shall
extend across the reinforced concrete approach slab. Grooving shall terminate
approximately 6 in. from the interface with the roadway pavement.

The Contractor shall submit a waste water control and disposal plan for approval
seven days prior to commencing grooving activities. The waste water control and
disposal plan shall detail how all waste water generated by the grooving activities shall
be contained, tested for pH, stored and transported to a disposal facility in accordance
with 202.

600 Cleaning of the grooving debris and slurry shall be performed with a vacuum
system equipped with fugitive dust control devices and capable of removing wet debris
and water in the same pass. The vacuum equipment shall be capable of washing the
deck with pressurized water during the vacuum operation to dislodge all debris and
slurry from the bridge deck surface. Debris and slurry shall not be allowed to dry prior
to vacuuming.

722.12 Curing
When fly ash is used, the requirement for additional wet or dry curing time shall
be determined based on the relative initial, and final time of set and a comparison of
610 strength versus age using control concrete strengths at conventional cure period ages
as the reference. The additional curing requirements shall be as approved by the
Engineer.

For LMC overlays the minimum curing period shall be 48 h of wet cure followed
by 48 h of dry cure. An LMC overlaid bridge deck may be opened to traffic during the
dry curing duration when the compressive strength of cylinders is 4,000 psi or greater.

For SFMC overlays the minimum curing period shall be seven calendar days
consisting of 120 h of wet cure followed by 48 h dry cure. The deck shall remain
620 completely covered during the dry cure period. An SFMC overlaid bridge deck may
be opened to traffic after the dry cure period when the compressive strength of
cylinders is 4,500 psi or greater.

For LMC-VE concrete overlays the minimum curing period shall be 3 h of wet
cure. An LMC-VE overlaid bridge deck may be opened to traffic after the wet curing
period when the compressive strength of cylinders is a minimum of 2,500 psi.

The wet cure period for all overlay types is not controlled by strength and shall
not be reduced. Membrane forming curing compound shall not be used to cure the
630 bridge deck overlay. All cylinders shall be 6 in. by 12 in. and compressive strength
shall be determined from the average of a minimum of two cylinders. For LMC and
SFMC, cylinders shall be made and standard cured in accordance with 702.24. For

739
 722.13

LMC-VE cylinders shall be made and field cured at the jobsite under the same
conditions as the LMC-VE overlay.

The plastic film which forms on the surface of the overlay shall be protected from
shrinkage cracking with a single layer of well drained wet burlap. This layer of wet
burlap shall be placed as soon as the overlay surface will support it without
deformation. The entire surface shall be covered with plastic sheeting and maintained
640 in a saturated wet condition during the wet cure period. A network of soaker hoses
shall be used under the plastic sheeting during the wet cure period for LMC and silica
fume overlays.

When the ambient temperature falls below 50°F during either the wet or dry
curing periods, the time that the temperature is below 50°F shall not be considered as
part of the total curing period. When there is sufficient rain to wet the surface of the
overlay for 1 h or more during the dry cure period, this number of hours shall not be
considered as part of the dry cure period.

650 Immediately upon the start of the dry cure period or opening to traffic, the surface
shall be checked for cracks. Upon request, the Contractor shall flood the deck with
water to facilitate inspection for cracks and distress. Where cracks exist, a thorough
investigation will be conducted prior to sealing cracks. Cores may be required to
determine the actual crack depth. Surface cracks not exceeding 3/8 in. in depth shall
be sealed with an approved sealer/healer followed by an application of an approved
sand. Cracks exceeding 3/8 in. in depth shall not be sealed at this time. Corrective
procedures for repairing cracks exceeding 3/8 in. in depth will be determined after
further investigation which may include additional cores. The Office of Materials
Management will be contacted and the Engineer will determine the method of repair
660 including possible removal.

Where the area of shallow cracking exceeds 5% of the deck area, then the method
of repair shall be the same as for cracks exceeding 3/8 in. The shallow crack area will
be calculated by multiplying the total combined linear feet of all cracks less than 3/8
in. deep by a tributary width of 1 lft. The percentage of deck area will be the shallow
crack area divided by the total deck area and multiplied by 100.

Where it is determined by sounding or coring that adequate bonding between the

overlay and the bridge deck has not been attained, the deficient areas shall be removed
670 and replaced as directed.

722.13 Calibration of Continuous Mixers

(a) Frequency
A complete calibration shall be performed for each mixer prior to each pour unless
the initial calibration was made within the previous 10 calendar days. A mixer that has
been calibrated within the previous 10 calendar days may be approved for use
providing that the mixer operator is in possession of the completed, signed, certified

740
 722.13

and dated Department calibration form for that mixer. A complete calibration of a
680 mixer may be required at any time as directed. All mixers which are calibrated within
the 10 day limit but are changing aggregate sources shall have an aggregate blend test
performed.

(b) Equipment
All special equipment required for calibration shall be furnished. It shall include
but not be limited to suitable material containers, buckets, stop watches and a scale
accurate to within 0.1 lbs or 0.3% of the test load, whichever is greater, at any point
within the range of use. The minimum capacity of the scale shall be 150 lbs. The scale
shall be verified annually per ITM 910. The Contractor shall provide paperwork that
690 shows the date the scale was verified by a company with NIST traceable class F
weights. Samples shall be obtained and handled by the Contractor. Normal testing
equipment such as aggregate sieves and containers shall also be furnished.

(c) Pre-calibration
The aggregate bin shall be clean and the bin vibrators shall be in good working
order. The mixer shall be equipped with a grounding strap. The cement meter feeder,
the fins and all pockets shall be clean and free of any accumulated cement. The
aeration system shall be equipped with a gauge or indicator to verify that the system
is operating. The main belts and the latex strainer shall be clean and free of any
700 accumulated material.

(d) Calibration

1. Cement Meter
The mixer manufacturer’s mix setting chart shall determine the specified
operating revolutions per minute and the approximate number of counts required on
the cement meter to deliver 94 lbs of cement. At least 3,760 lbs of cement shall be
placed in the cement bin.

710 The mixing unit shall rest on a level surface. The engine throttle shall be adjusted
to obtain the required revolutions per minute. The unit discharging the cement shall be
operated until the belt has made one complete revolution. The unit shall then be
stopped and the cement meter shall be reset to zero.

A suitable container shall be positioned to catch the cement and at least 90 lbs of
cement shall be discharged. The time required to discharge the cement shall be
measured with a stop watch, the number of counts on the cement meter shall be
recorded, and the weight of the discharged cement shall be determined. This process
shall be repeated a total of three times. The cement counter shall be reset to zero before
720 each repetition.

The following formulas shall be used to calculate the number of counts per 94 lbs
of cement and the time required to discharge 94 lbs of cement.

741
 722.13

A
94 ÷ ― = Counts per 94 lbs of cement
B

A
730 94 ÷ ― = Time in seconds per 94 lbs of cement
C

A = Total weight of cement in pounds for three trials

B = Total number of counts on the cement meter for three trials
C = Total time in seconds for three trials.

2. Water Flow Meter

The accuracy of the water flow meter shall be verified by adjusting the flow to
2 gal. per minute. With the equipment operating at the required revolutions per minute,
740 the water discharged during a one minute interval shall be collected and weighed. The
weight in pounds of the discharged water shall be divided by 8.33 to determine the
number of gallons. This procedure shall be repeated with the flow meter adjusted to 3
gal. per minute.

3. Aggregate Bin Gates

The aggregate gate openings shall be adjusted to provide the required amount of
aggregate to produce a cubic yard of the designated mix. The gate settings for the fine
aggregate and coarse aggregate shall be determined separately. Each aggregate shall
be verified by stopping the cement discharge and collecting the aggregate discharged
750 in a container. Calculations for all aggregates shall be based on saturated surface dried,
SSD, weights taken from the mix design. The calculations shall be adjusted for the
tested moisture content. The final gate setting for each aggregate shall dispense
material within a tolerance of ±2% of the target weights after adjustment for measured
moisture content.

4. Latex Throttling Valve

The latex strainer shall be unobstructed. The latex throttling valve shall be
adjusted to deliver the required amount of latex emulsion admixture for each 94 lbs of
cement. With the unit operating at the required revolutions per minute for the
760 calculated time in seconds per 94 lbs of cement, the latex shall be discharged into a
container. The weight of the latex shall be determined and, if necessary, the valve shall
be adjusted such that the amount of latex discharged is within 1/2 lb of the amount
required for each 94 lbs of cement. One verification shall be performed to check the
accuracy of the valve setting.

5. Admixture Dispensers
This equipment shall be calibrated in accordance with the manufacturer’s
instructions for the specific materials and quantities involved.

742
 722.14

770 722.14 Patching an Existing Bridge Deck Overlay

(a) Materials
Materials shall be in accordance with 722.03.

(b) Storage and Handling of Materials

Storage and handling of materials shall be in accordance with 722.04.

(c) Proportioning
Proportioning shall be in accordance with 722.05.
780
(d) Preparation of the Bridge Floor
Preparation of the bridge floor shall be in accordance with the applicable
provisions of 722.06.

(e) Patching
Patching shall be in accordance with 722.07 except as modified herein. Where no
new overlay is planned, bridge deck patching concrete used in patching the bridge
floor shall be placed to the level of the original deck. The remainder of each cavity
shall be patched with the same material as the existing overlay.
790
(f) Mixing
Mixing shall be in accordance with the applicable provisions of 722.09.

(g) Placing and Finishing

Placing and finishing shall be in accordance with the applicable provisions of
722.10. Machine finishing shall be required when directed.

(h) Texturing
The surface texturing shall match the pattern of the adjacent overlay and shall be
800 in accordance with the following:

Immediately after the finishing is complete and before the surface film has
formed, the surface of the overlay patch shall be textured by grooving in the same
direction as the existing overlay. The grooves may be formed by mechanized
equipment using a vibrating beam roller, a series of discs or other approved device.
Manual tools such as fluted floats, spring steel tined rakes, or finned floats with a
single row of fins may be used. The grooves shall be relatively uniform and smooth
and shall be formed without tearing the surface or bringing coarse aggregate to the top.
The grooves shall be in accordance with 504.03. The grooves shall be terminated the
810 same distance from the vertical faces of railings as the existing grooves in the adjacent
existing overlay surface.

All areas of hardened grooved overlay patch which do not conform to these
requirements due to either a deficiency in the grooving or a rough open textured
surface shall be corrected with no additional payment. Corrections shall be made by

743
 722.15

cutting transverse grooves in the hardened overlay with an approved cutting machine
or by sealing with an approved mixture and retexturing to a satisfactory finish as
directed.

820 (i) Curing

Curing shall be in accordance with 722.12.

(j) Calibration of Continuous Mixers

Calibration shall be in accordance with 722.13.

722.15 Method of Measurement

Removal of the existing overlay and the additional depth into the existing deck
surface will be measured by the square yard of deck area regardless of the number of
passes with the milling machine.
830
Removal of the existing concrete deck surface will be measured by the square
yard for the initial depth shown on the plans. Additional surface removal required
below the initial depth will be measured by the square yard for each required 1/4 in.
depth. The areas of the bridge floor which are shown on the plans to be removed,
except for undefined full depth patching areas, will not be measured for payment.

Hydrodemolition of the bridge deck will be measured by the square yard.

Additional surface preparation will be measured by the linear foot of exposed
reinforcing bar. Reinforcing bar repair will not be measured for payment.
840
When hydrodemolition is not shown on the plans, partial depth patching will be
measured by the square foot.

The measurement of bridge deck patching concrete for partial depth cavities
created by handchipping or hydrodemolition will be based on a theoretical quantity
determined by multiplying the area of the appropriate partial depth cavities by an
assumed average depth of 2 in. and converting the resulting volume into cubic yards.
Overlay material used in a partial depth cavity will be measured by the cubic yard. The
quantities of patching material used in a partial depth cavity will be included in the
850 measurement of additional bridge deck overlay.

Overlay material used to fill surface irregularities will be measured by the cubic
yard and will be included in the measurement of additional bridge deck overlay.

Full depth patching will be measured by the square foot. The patching material
used in full depth patching will not be measured for payment.

Bridge deck overlay will be measured by the square yard for the specified
thickness. Where there is no specified thickness shown on the plans, the specified
860 thickness shall be 2 in.

744
 722.16

Overlay dams and patching an existing overlay will be measured by the square
foot.

Transverse grooving will be measured by the square yard. No deduction in

measurement will be made for areas where grooving is terminated or not required.

Epoxy resin adhesive and bond coat will not be measured for payment. Blasting,
cleaning, finishing, texturing other than the transverse grooving, and curing will not
870 be measured for payment.

722.16 Basis of Payment

Removal of the existing overlay and the additional depth into the existing deck
surface will be paid for at the contract unit price per square yard of bridge deck, remove
existing concrete overlay.

Milling of the initial depth of surface will be paid for at the contract unit price per
square yard of bridge deck, remove existing concrete surface. Additional surface
removal below the initial depth will be paid for at the contract unit price per square
880 yard for bridge deck, remove existing concrete surface for each required 1/4 in. depth.

Hydrodemolition of the bridge deck will be paid for at the contact unit price per
square yard. When hydrodemolition is shown on the plans, additional surface
preparation will be paid for at the established price shown per linear foot for bridge
deck overlay, additional surface prep.

When hydrodemolition is not shown on the plans, partial depth patching will be
paid for at the contract unit price per square foot for bridge deck patching, partial
depth.
890
When partial depth cavities are subsequently directed to be made full depth,
additional payment will be made at 80% of the contract unit price per square foot for
bridge deck patching, full depth.

Full depth patching will be paid for at the contract unit price per square foot for
bridge deck patching, full depth.

Patching material used for partial depth cavities will be paid for at the established
price shown per cubic yard for bridge deck overlay, additional for the type of overlay
900 material placed.

Overlay material used to fill surface irregularities will be paid for at the
established price shown per cubic yard for bridge deck overlay, additional for the type
of overlay material placed.

Bridge deck overlay will be paid for at the contract unit price per square yard, for
the type of overlay material specified.

745
 722.16

Patching an existing bridge deck overlay will be paid for at the contract unit price
910 per square foot for bridge deck overlay patching.

Overlay dam will be paid for at the contract unit price per square foot, complete
in place.

Transverse grooving will be paid for at the contract unit price per square yard.

The Department will include the pay item Bridge Deck Overlay Budget, with an
established dollar amount in the proposal to pay for additional surface preparation
completed after hydrodemolition and bridge deck overlay additional used to fill
920 irregularities and partial depth cavities. This established amount is the Department’s
estimate of the total cost of the work required to be performed for the contract. The
established amount shown in the proposal is included in the total bid amount. The
Department will pay for those items installed and listed with established prices for the
quantities installed as directed by the Engineer. Where the work exceeds the
Department’s estimated amount, the additional quantities will be reviewed for
acceptance in accordance with 104.03 except that the additional surface preparation
and bridge deck overlay additional will be paid at the pre-determined established
prices shown.

930 Payment will be made under:

Pay Item Pay Unit Symbol

Bridge Deck Overlay Budget .................................................... DOL

Bridge Deck Overlay, Latex Modified ...................................... SYS
Bridge Deck Overlay, LMC-VE ................................................ SYS
Bridge Deck Overlay, Patching ................................................. SFT
Bridge Deck Overlay, Silica Fume Modified ............................ SYS
Bridge Deck, Remove Existing Concrete Overlay .................... SYS
940 Bridge Deck, Remove Existing Concrete Surface ..................... SYS
Bridge Deck Patching, Full Depth ............................................. SFT
Bridge Deck Patching, Partial Depth ......................................... SFT
Hydrodemolition ....................................................................... SYS
Transverse Grooving ................................................................. SYS
Overlay Dam ............................................................................. SFT

Items shown with an established price will be paid at the prices shown. Where
any of the following items are shown in the schedule of pay items the bid item and
price will prevail over the established prices shown.
950
Pay Item Pay Unit Established
Symbol Price
Bridge Deck Overlay, Additional LMC .................CYS ............... $550

746
 722.16

Bridge Deck Overlay, Additional LMC-VE ...........CYS ............... $650

Bridge Deck Overlay, Additional
Silica Fume Modified ......................................CYS ............... $200
Bridge Deck Overlay, Additional Surface Prep......LFT ............... $15

The cost of overlay removal by handchipping in areas adjacent to the curb or

960 otherwise inaccessible to the power-operated mechanical milling machine shall be
included in the cost of bridge deck overlay, remove existing overlay. The cost of
disposing of overlay removal residue, including water, dust, concrete and incidentals
shall be included in the cost of bridge deck, remove existing overlay.

The cost of deck surface preparation by handchipping in areas adjacent to the curb
or otherwise inaccessible to the power-operated mechanical milling machine shall be
included in the cost of bridge deck, remove existing concrete surface or bridge deck,
remove existing overlay. The removal of surface milling residue, including water,
dust, concrete and incidentals shall be included in the cost of bridge deck, remove
970 existing concrete surface or bridge deck, remove existing overlay.

The cost of the waste water control and disposal plan, waste water containment,
testing, storing, transporting and disposal, and any incidentals related to the carrying
out of the plan shall be included in the cost of hydrodemolition. If the waste water is
found to have a pH of 12.5 or higher and thereby classified as hazardous, the additional
costs associated with this classification will be paid for in accordance with 109.05.

The initial equipment calibration, any re-calibration, equipment shielding,

handchipping curb areas, handchipping unsound concrete, cleaning of debris and
980 slurry, compressed air cleaning, water blasting, and sandblasting shall be included in
the cost of hydrodemolition.

When hydrodemolition is shown on the plans, the cost of removal of unsound

concrete shall be included in the cost of hydrodemolition. Preparation of cavity
surfaces, furnishing and applying bond coat or epoxy resin adhesive as required in
handchipped locations, furnishing and placing patching material, and necessary
incidentals shall be included in the cost of bridge deck overlay for the type of overlay
material specified. Additional concrete removal required around exposed bars shall be
included in the cost of additional surface preparation.
990
When hydrodemolition is not shown on the plans, the cost of removal of unsound
concrete, preparation of cavity surfaces, furnishing and applying bond coat or epoxy
resin adhesive as required, furnishing and placing patching material, and necessary
incidentals shall be included in the cost of bridge deck patching, full depth, or bridge
deck patching, partial depth.

The cost of patching material used for full depth patching shall be included in the
cost of bridge deck patching, full depth. The cost of texturing patched areas will not
be paid for separately, but shall be included in the cost of the patch.

747
 723.01

1000
The cost of furnishing and placing patching material in partial depth cavities and
necessary incidentals shall be included in the cost of bridge deck overlay, additional.

The cost of removing the existing concrete; furnishing, hauling, and placing all
materials including the epoxy; preparing the surface; and all necessary incidentals
shall be included in the cost of overlay dam.

The cost of deck cleaning shall be included in the cost of other pay items.

1010 The cost of removing and disposing of the slurry created during the transverse
grooving shall be included in the cost of transverse grooving.

Coring of the bridge deck, patching core holes, and all corrective measures
required in accordance with 722.12 shall be performed at no additional cost to the
Department.

SECTION 723 – REINFORCED CONCRETE THREE-SIDED STRUCTURES

723.01 Description
This work shall consist of constructing a reinforced concrete three-sided arch-
topped structure or structure extension with headwalls and wingwalls, a reinforced
concrete three-sided flat-topped structure or structure extension with headwalls and
wingwalls, or a reinforced concrete true arch shape structure or structure extension
with spandrel walls and wingwalls in accordance with 105.03. The reinforced concrete
three-sided structure, structure extension, headwalls, wingwalls, footings, and
10 spandrel walls may be precast or cast-in-place.

The Contractor will be allowed to substitute a box structure in accordance with

714. The box structure shall be of equivalent hydraulic capacity to that of the three-
sided structure shown on the plans. The structure shall be sumped as shown on the
plans.

MATERIALS

723.02 Materials
20 Materials shall be in accordance with the following:

Chemical Anchor System ............................................ 901.05

Coarse Aggregates, Class A or Higher,
Size No. 91 ........................................................... 904
Concrete ...................................................................... 702
Epoxy Coated Reinforcing Bars .................................. 910.01(b)9
Flowable Backfill ........................................................ 213
Geotextile .................................................................... 918.02

748
 723.02

Hydrated Lime ............................................................. 913.04(a)

30 Masonry Cement ......................................................... 901.01(c)
Mortar Sand ................................................................. 904.02(e)
Natural Sand ................................................................ 904.02(a)
Non-Epoxy PCC Sealer ............................................... 909.10
Pipe Joint Sealant ........................................................ 907.11
Portland Cement .......................................................... 901.01(b)
Precast Reinforced Concrete Headwalls,
Wingwalls, Footings, and Spandrel Walls ............ 907.06
Precast Reinforced Concrete Structure Sections ......... 907.05
Reinforcing Bars.......................................................... 910.01
40 Riprap .......................................................................... 904
WWR, Smooth and Deformed..................................... 910.01
Structure Backfill ........................................................ 904

Cast-in-place concrete for a reinforced concrete three-sided structure, or splices

between an existing culvert structure and a precast reinforced concrete three-sided
structure extension shall be class A or higher in accordance with 707.04(c). It shall
have a 28-day minimum concrete compressive strength of 5,000 psi. Cast-in-place
concrete for headwalls, wingwalls, or spandrel walls shall be class A or higher in
accordance with 707.04(c). It shall have a 28-day minimum concrete compressive
50 strength of 4,000 psi.

When the Contractor elects to provide a cast-in-place structure, acceptance of the

structure will be based on tests for relative yield, air content, slump, water cementitious
ratio, and compressive strength. Relative yield and air content shall be in accordance
with 702.05. The slump and concrete temperature shall be in accordance with
707.04(c). The amount of time from the introduction of mixing water to the cement
and aggregates to the completion of the discharge of the concrete shall not exceed 90
minutes. The water cementitious ratio shall be in accordance with 707.04(d). The 28-
day compressive strength shall be equal to or greater than the specified concrete
60 compressive strength and otherwise shall be in accordance with 707.04(c)3. The
Contractor shall provide the necessary 6 in. diameter by 12 in. cylinder molds for the
Department’s use.

For plastic concrete sampling, acceptance testing procedures and casting cylinders
will be in accordance with 505.01. Except for footings, concrete flexural strength or
results from beam breaks will not be accepted in lieu of concrete compression cylinder
test results.

Cast-in-place concrete used to seal existing culverts shall be class A. Cast-in-place

70 concrete for footings and base slabs shall be class B.

Unless otherwise specified herein, reinforcement may consist of either reinforcing

bars or welded wire reinforcement, WWR. If specified to be coated, WWR shall be
coated with either galvanized coating or epoxy coating, and reinforcing bars shall be

749
 723.03

coated with epoxy coating. For WWR, material with minimum yield strength of 65 ksi
shall be used.

Reinforcement in headwalls and pedestals shall consist of reinforcing bars and

shall be epoxy coated. Reinforcement in spandrel walls shall be coated. If the structure
80 is specified as requiring coated reinforcement, reinforcement, including support
devices, in that structure shall be coated. In lieu of coating, the support device may be
manufactured of a non-corrosive material.

Headwalls, wingwalls and spandrel walls shall be connected to the outside

structure sections. Wingwalls shall be connected to the spandrel walls if the structure
is a true arch shape structure. Precast headwalls, precast wingwalls, and precast
spandrel walls shall be connected with bolted steel plates.

CONSTRUCTION REQUIREMENTS
90
723.03 General Requirements
Excavation and disposal shall be in accordance with the applicable requirements
of 206. The areas designated for waterproofing shall be waterproofed in accordance
with 702.23. All underground drains encountered during excavation for the structure
shall be perpetuated as dictated by field conditions. Drainage openings through
masonry shall be in accordance with 702.16. Handling of three-sided structures shall
be in accordance with 907.05. Handling of wingwalls and spandrel walls shall be in
accordance with 907.06.

100 For precast three-sided structures, the manufacturer’s representative shall provide
technical instruction and on-site technical assistance to the Contractor during the
erection of the members.

723.04 Design Requirements

A three-sided structure shall be designed for HL-93 loading in accordance with
AASHTO LRFD Bridge Design Specifications.

The three-sided structure, headwalls, wingwalls, footings, and spandrel walls

shall be designed in accordance with the soil parameters shown in the contract
110 documents.

Headwalls, wingwalls, and spandrel walls shall be designed based on a minimum

equivalent fluid pressure of 40 lbs/cu ft. If flowable backfill is to be used, the
Contractor shall consider the effects of hydrostatic pressure on the structure. Weep
holes shall be provided in all wingwalls. Horizontal pressures shall be increased for
sloping backfill surfaces and live load surcharge. Headwall connections, wingwall
footings, and spandrel walls shall be checked for sliding and for overturning.

A headwall with guardrail mounted on top, the anchorage of the headwall or

120 spandrel wall to the structure section, or a moment slab with bridge railing, shall be

750
 723.04

designed for the bridge railing test level shown on the plans.

Continuity shall be established between the structure footing and the wingwall
footing.

(a) Placement of Reinforcement

For three-sided arch-topped or true arch shape structure sections, the concrete
cover over the outside circumferential reinforcement shall be a minimum of 2 in. The
cover over the inside circumferential reinforcement shall be a minimum of 1 1/2 in.
130 The clear distance of the end circumferential reinforcement shall not be less than 1 in.
and no more than 2 in. from the ends of the structure section. The ends of the
longitudinal distribution reinforcement shall be no more than 3 in. from the ends of
the structure section.

For flat-topped structure sections, the cover dimension over the top mat of
reinforcement shall be a minimum of 2 in. The cover over the lower mat of
reinforcement in the structure top shall be a minimum of 1 1/2 in. The cover in the legs
shall be a minimum of 2 in. The clear distance of the end circumferential reinforcement
shall not be less than 1 in. and no more than 2 in. from the ends of the structure section.
140 The ends of the longitudinal distribution reinforcement shall be no more than 2 in.
from the ends of the structure section.

Cover for headwall, wingwall, spandrel wall, and pedestal reinforcement shall be
a minimum of 2 in. Cover for footing and base slab reinforcement shall be 3 in. for the
top and sides and 4 in. for the bottom.

(b) Splicing and Spacing of Reinforcement

Reinforcement splicing and spacing shall be in accordance with the AASHTO
LRFD Bridge Design Specifications except as indicated herein. Tension splices in
150 circumferential reinforcement shall be made by means of lapping. Where reinforcing
bars are used for longitudinal distribution reinforcement, the reinforcing bars shall
have a center to center spacing not to exceed 12 in. in flat-topped structure sections or
16 in. in arch-topped or true arch shape structure sections.

Where reinforcing bars are used in wingwalls, the maximum spacing for wingwall
reinforcing bars shall be 18 in. for horizontal bars and 12 in. for vertical bars.

Exterior corner reinforcement for flat-topped structure sections shall be fully

developed beyond the point where it is no longer required to resist flexure.
160
(c) Working Drawings
Working drawings shall be submitted in accordance with 105.02 for fabrication
of a precast or cast-in-place reinforced concrete three-sided structure, precast or cast-
in-place reinforced concrete three-sided structure extension, precast or cast-in-place
headwalls, precast or cast-in-place wingwalls, and precast or cast-in-place spandrel
walls. The working drawings shall include all details, dimensions, and quantities

751
 723.04

necessary to construct the structure, headwalls, wingwalls, or spandrel walls and shall
include, but not be limited to, the following information.

170 1. Structure span and rise.

2. Structure section details showing all concrete dimensions

and reinforcement requirements. An analysis of the precast
segment modeled as a simple span and designed in
accordance with AASHTO LRFD Bridge Design
Specifications Section 5.7.3. This analysis shall
demonstrate that the precast segment is designed to
withstand the forces of erection. Details for providing
horizontal restraint of the structure legs during installation
180 until after the completion of backfill placement shall be
included unless the analysis indicates such details are not
needed.

3. Headwall details showing all concrete dimensions,

elevations, reinforcing bar sizes, reinforcing bar bending
diagrams, lengths, spacings, and anchorage details.
Headwall elevation and section views shall be provided.

4. Wingwall design calculations and details showing all

190 concrete dimensions, elevations, reinforcement sizes,
bending diagrams, lengths, spacings, and anchorage
details. Wingwall plan, elevation, and section views shall
be provided.

5. Spandrel wall details showing all concrete dimensions,

elevations, reinforcement sizes, bending diagrams, lengths,
spacings, and anchorage details. Spandrel wall elevation
and section views shall be provided.

200 6. Footing design calculations and details showing all

concrete dimensions, elevations, reinforcing bar sizes,
reinforcing bar bending diagrams, lengths, and spacings
indicated. Footing plan and section views shall be
provided. If a pile footing is required, the pile layout shall
be shown. The actual soil bearing pressure shall be shown
on the footing detail sheets.

7. Design calculations and details for pedestals or closure

pours, if required.
210
8. Structure backfill type and limits for the structure and
wingwalls.

752
 723.07

9. Minimum concrete strength for all concrete portions of the

structure.

10. Bridge load rating calculations and load rating summary

shall be submitted with the working drawings where the
structure span length measured along the roadway
220 centerline is greater than 20 ft, except where the height of
cover is greater than 8 ft and exceeds the perpendicular
span length. The structure shall load rate greater than 1.0
for the loading described herein or as shown on plans. The
load rating methodology shall be in accordance with the
AASHTO Manual of Bridge Evaluation using the LRFR
methodology.

723.05 Manufacture
The structure sections, headwalls, wingwalls, footings and spandrel walls shall be
230 free of fractures. Headwalls, wingwalls, and spandrel walls shall be given a finish in
accordance with 702.21.

The structure units shall not be stored in an upright position until the designated
handling and storage compressive strength, as shown on the working drawings, has
been achieved.

723.06 Rejection
Structure sections, wingwalls, footings, or spandrel walls will be rejected due to
the following conditions.
240
(a) fractures or cracks passing through the section or wall, except
for a single end crack which does not exceed one-half the
thickness of the section or wall;

(b) defects which indicate proportioning, mixing, or molding which

are not in accordance with this specification;

(c) honeycombed or open texture; or

250 (d) damaged section ends, where such damage prevents making a
satisfactory joint.

723.07 Repairs
Structure sections, headwalls, wingwalls, footings or spandrel walls shall be
repaired, if necessary, due to imperfections in manufacture, handling damage, or
construction. Repairs will be acceptable if it is determined that the repairs are sound,
properly finished and cured, and if the repaired structure section headwall, wingwall,
footing, or spandrel wall is in accordance with the requirements herein.

753
 723.08

260 723.08 Trench Compaction

The soils in the bottom of the excavation shall be compacted to 95% of the
maximum dry density in accordance with 203.23. If 95% of the maximum dry density
cannot be obtained in the bottom of the excavation or in other areas, the Office of
Geotechnical Services shall be contacted for additional recommendations. If during
construction, soft soils are encountered at depths that make removal impractical, the
Office of Geotechnical Services shall be contacted for additional recommendations.

723.09 Footings
All footings shall be given a smooth float finish. Footing concrete shall reach a
270 compressive strength of 2,000 psi or flexural strength in accordance with 702.24(c)
prior to placement of the structure sections or wingwalls. The surface shall not vary
more than 1/4 in. in 10 ft when tested with 10 ft straightedge.

An 8 in. layer of coarse aggregate No. 8 in accordance with 301 shall be placed
under the full width of the footing. Precast footings shall be made into a continuous
strip footing by the use of closure pours between the precast units. Closure pours shall
be as detailed in the working drawings and shall be designed to accommodate the
design loads.

280 723.10 Pedestals

Where a reinforced concrete pedestal is required between the base of the structure
leg and the top of the footing, the Contractor shall have the option of providing a
structure with extended legs or constructing the pedestals.

723.11 Placement of Structure Sections and Wingwalls

For three-sided arch-topped structures and three-sided flat-topped structures, the
structure sections shall be set on masonite or steel shims. Each wingwall that is not
precast as one unit with the footing shall be set on masonite or steel shims. A minimum
gap of 1/2 in. shall be provided between the footing and the bottom of each section or
290 wingwall. Once the wingwalls or structure sections are placed, the space underneath
the wingwall or structure leg section to the top of the keyway sides shall be filled with
prepackaged grout in accordance with ASTM C 1107, or conventional or self-
consolidating fine grout in accordance with ASTM C 476, except as modified herein.
If conventional fine grout is used, it shall be troweled into the keyway and mounded
on one side of the leg or wingwall. The mound of conventional fine grout shall be
vibrated until it passes through to the other side of the leg or wingwall. After
completing this process on one side, if the conventional fine grout has not passed
through to the other side, the process shall be repeated on the other side. Conventional
or self-consolidating fine grout shall be from a prepackaged source or composed of
300 one of the following mixtures:

(a) 930 lbs/cu yd Type I portland cement with No. 23 natural sand
or mortar sand.

754
 723.12

(b) 930 lbs/cu yd Type M masonry cement with No. 23 natural sand
or mortar sand.

(c) 828 lbs/cu yd Type I portland cement and 75 lbs/cu yd hydrated

lime with No. 23 natural sand or mortar sand.
310
The maximum water/cement ratio shall be 0.446 for both conventional and self-
consolidating fine grout. An air entraining agent from the Department’s list of
approved PCC admixtures may be used. A type F or G chemical admixture from the
Department’s list of approved PCC admixtures shall be used in self-consolidating fine
grout in order to achieve the slump flow and visual stability index requirements. Filling
procedure B of ASTM C 1611 will be used for measuring slump flow. Appendix X1
of ASTM C 1611 will be used for determining the visual stability index value.

Acceptance of conventional fine grout will be based on an air content of 12%

320 ±4%. Acceptance of self-consolidating fine grout will be based on tests for air content,
slump flow, and visual stability index. Air content shall be 12% ±4%. Slump flow
shall be 27 in. ±3 in. Visual stability index value shall not exceed 1.

Where prepackaged grout is used, a type C certification in accordance with 916

shall be provided.

True arch shape structures may have grout leveling pads poured in the footing
keyways to ensure the correct seating of the true arch sections. Leveling pads shall be
approximately 2 in. thick and 16 in. long to ensure that each true arch section is resting
330 on approximately 8 in. of pad at each joint. The leveling pads shall be poured within
1/8 in. of the required elevation. No loads shall be placed on the grout leveling pads
within 72 h of their placement. Masonite shims may also be used as leveling pads.
Concrete blocks of 1 1/2 in. thickness, hardwood wedges, and steel or plastic shims
shall be placed to retain the true arch sections in their proper positions until grout can
be placed in the keyway. Grout shall be consolidated in the keyway to ensure that the
entire area around the true arch section is completely filled. The grout used to construct
the leveling pads and to fill the keyways shall be in accordance with this section. Grout
shall not be placed if the air temperature is expected to be below 35°F for a period of
72 h following grout placement.
340
723.12 Extension of Existing Structure
All applicable requirements of this specification shall apply to the extension of an
existing three-sided arch-topped structure with headwalls and wingwalls, a three-sided
flat-topped structure with headwalls and wingwalls, or a true arch shape structure with
spandrel walls and wingwalls. Such portions of the existing structure designated for
removal shall be removed. All portions of the existing structure which are to remain
in place and are damaged shall be repaired or replaced as directed. Those portions left
in place which are wholly or partially filled with debris shall be cleaned out. Material
removed shall be disposed of in accordance with the applicable requirements of
350 202.02.

755
 723.13

Before removing concrete from an existing structure with wingwalls, the

Contractor shall saw around the perimeter of the removal area on the interior and
exterior of the existing structure a depth of 1 in. All existing reinforcement in the top
slab and sidewalls exposed after concrete removal shall be cleaned and straightened in
preparation for lapping with reinforcement from adjacent new work. Where existing
reinforcement has deteriorated or been damaged during the removal operation, holes
shall be drilled into the face of the existing structure to provide embedment for
replacement reinforcing bars. The holes shall be of the diameter and depth required by
360 the approved chemical anchor system manufacturer. The holes shall be cleaned prior
to placing the approved chemical anchor system and the reinforcing bars.

No concrete shall be removed from an existing structure that has a headwall but
no wingwalls. Reinforcing bars to tie the existing structure to the new structure section
shall be installed by drilling holes into the face of the existing structure to provide
embedment for reinforcing bars. The diameter and depth of the holes shall be in
accordance with the recommendations of the manufacturer of the approved chemical
anchoring system. The holes shall be cleaned prior to placing the approved chemical
anchor system and the reinforcing bars.
370
An existing structure shall be extended by means of one of the following methods.

(a) Precast Reinforced Concrete Three-Sided Structure Extension

A cast-in-place concrete splice shall be constructed as a transition between the
existing structure and the precast structure extension. The splice reinforcement in the
precast structure extension section that will abut the existing structure shall be exposed
18 in. on the tongue end of the precast structure extension section. It shall be lapped
18 in. with either exposed existing structure reinforcement, in the case of an existing
structure with wingwalls, or newly installed reinforcing bars in the existing structure,
380 in the case of an existing structure with a headwall only as shown on the plans. Existing
exposed structure reinforcement from an existing structure with wingwalls shall be cut
off 1 in. from the face of the new precast extension.

If the existing tongue or groove joint end is acceptable and matches the mating
joint on the new precast reinforced concrete structure extension section, the new
extension may be installed using the mating joint of the existing structure. No cutting
of the structure or splicing of reinforcement is then required. The joint between the
new precast structure extension and the existing structure shall be sealed as directed
below.
390
(b) Cast-In-Place Concrete Three-Sided Structure Extension
The reinforcement for the structure extension shall be lapped with the exposed
reinforcement of the existing structure as shown on the plans.

723.13 Blank

756
 723.16

723.14 Joints
Joints between structure sections for three-sided arch-topped structures and true
arch shape structures, and for flat-topped structures with cover of 3 ft or more, may be
400 either butt joints or keyway joints.

The sections of flat-topped structures with less than 3 ft of cover shall be produced
with a minimum 4 in. depth by 1 1/2 in. width keyway joint. Non-shrink grout in
accordance with 707.09 shall be placed in the keyway joint.

All butt joints between structure sections shall be covered with a joint wrap in
accordance with ASTM C 877. The surface shall be free of dirt before the joint
material is applied. The entire joint shall be continuously covered. Joints between
structure sections and wingwalls, between wingwalls and spandrel walls, and between
410 structure sections and headwalls or spandrel walls shall be covered with either the
same wrap used between structure sections or with geotextile in accordance with
918.02.

The joint wrap shall be kept in its proper location over the joint. It shall not be
damaged during the backfilling operation.

Joints in true arch shape structures shall be sealed with 1 1/2 in. diameter
preformed pipe joint sealant before placement of the joint wrap.

420 723.15 Backfilling

Structure backfill shall be placed and compacted in accordance with 211.
Structure backfill shall be placed and compacted on each side of the structure to the
fill line shown on the plans. During the backfill operation, the difference in elevations
of the fill on each side of the structure shall not exceed 24 in.

Unless otherwise specified by the manufacturer on the working drawings, once

the level of structure backfill reaches the top of the structure, two lifts shall be spread
and hand compacted over the structure without traversing the structure with heavy
equipment. Compaction with heavy equipment will not be allowed until a minimum
430 of two lifts have been placed, hand compacted, and accepted.

The operation of equipment over the structure shall be in accordance with the
structure manufacturer’s recommendations.

723.16 Scour Protection

When riprap is specified, geotextile shall first be placed on the in-situ soil in
accordance with 616.11. Riprap shall then be placed in accordance with 616.

For concrete base slabs, concrete shall be placed in accordance with 702.
440

757
 723.17

723.17 Method of Measurement

Precast reinforced concrete three-sided flat-topped structures or structure
extensions, precast reinforced concrete three-sided arch-topped structures or structure
extensions, precast reinforced concrete true arch structures or structure extensions,
cast-in-place reinforced concrete three-sided flat-topped structures or structure
extensions, cast-in-place reinforced concrete three-sided arch-topped structures or
structure extensions, and cast-in-place reinforced concrete true arch structures or
structure extensions will not be measured. The accepted quantities for payment will
be the quantities shown on the plans.
450
Structure backfill will be measured in accordance with 211.09. Flowable backfill
will be measured in accordance with 213.08. Geotextile and riprap will be measured
in accordance with 616.12. Field drilled holes will be measured in accordance with
702.27.

Plain or coated reinforcement or WWR used in precast reinforced concrete three-

sided flat-topped structures or structure extensions, precast reinforced concrete three-
sided arch-topped structures or structure extensions, precast reinforced concrete true
arch structures or structure extensions, precast headwalls, precast wingwalls, cast-in-
460 place reinforced concrete three-sided flat-topped structures or structure extensions,
cast-in-place reinforced concrete three-sided arch-topped structures or structure
extensions, cast-in-place reinforced concrete true arch structures or structure
extensions, cast-in-place headwalls, or cast-in-place wingwalls will not be measured
for payment.

If the Contractor elects to provide a box structure in lieu of the three-sided

structure shown on the plans, it will be measured in accordance with 714.11.

723.18 Basis of Payment

470 The accepted quantities of precast reinforced concrete three-sided flat-topped
structures or structure extensions, precast reinforced concrete three-sided arch-topped
structures or structure extensions, precast reinforced concrete true arch structures or
structure extensions, cast-in-place reinforced concrete three-sided flat-topped
structures or structure extensions, cast-in-place reinforced concrete three-sided arch-
topped structures or structure extensions, and cast-in-place reinforced concrete true
arch structures or structure extensions, of the size specified will be paid for at the
contract unit price per linear foot.

Structure backfill will be paid for in accordance with 211.10. Flowable backfill
480 will be paid for in accordance with 213.09. Geotextile and riprap will be paid for in
accordance with 616.13. Field drilled holes will be paid for in accordance with 702.28.

If the Contractor elects to provide a box structure in lieu of the three-sided

structure shown on the plans, it will be paid for in accordance with 714.12. The
Department will not incur additional cost for allowing the Contractor to substitute a
box structure for the three-sided structure shown on the plans.

758
 723.18

Payment will be made under:

490 Pay Item Pay Unit Symbol

Structure Extension, Coated Reinforced Concrete,

Three-Sided Sections, ____ in. x ____ in. .......................... LFT
span rise
Structure Extension, Reinforced Concrete,
Three-Sided Sections, ____ in. x ____ in. .......................... LFT
span rise
Structure, Coated Reinforced Concrete,
Three-Sided Sections, ____ in. x ____ in. .......................... LFT
500 span rise
Structure, Reinforced Concrete,
Three-Sided Sections, ____ in. x ____ in. .......................... LFT
span rise

The cost of all design, coring, testing, pedestals or extended legs, excavation,
repairs, plugging core and handling holes, mortar, grout, sealer, cylinder molds, and
necessary incidentals shall be included in the cost of the structure or structure
extension. The cost of spandrel walls, concrete base slab, footings, and aggregate base
under footings shall be included in the cost of the structure or structure extension.
510
The cost of precast concrete headwalls, precast concrete wingwalls,
cast-in-place headwalls, or cast-in-place wingwalls shall be included in the cost of the
structure or structure extension.

The cost of plain or coated reinforcement or WWR used in precast reinforced

concrete three-sided structures, precast reinforced concrete three-sided structure
extensions, precast headwalls, precast wingwalls, cast-in-place reinforced concrete
three-sided structures, cast-in-place reinforced concrete three-sided structure
extensions, cast-in-place headwalls, or cast-in-place wingwalls shall be included in the
520 cost of the structure or structure extension.

The cost of concrete used in a cast-in-place splice shall be included in the cost of
the structure extension.

The cost of footings for wingwalls and aggregate base under the wingwall
footings shall be included in the cost of the structure or structure extension.

The quantities for payment shall remain as shown on the plans whether the
Contractor installs the three-sided arch-topped structure or structure extension, the
530 three-sided flat-topped structure or structure extension, or the true arch shape structure
or structure extension.

759
 724.01

No additional payment will be made for carrying an underground drain through a

structure or structure extension. However, no deduction will be made for the volume
of concrete occupied by the drain pipe in a cast-in-place structure or structure
extension.

No additional payment will be made for the repair or replacement of existing

concrete damaged by Contractor operations.

SECTION 724 – STRUCTURAL EXPANSION JOINTS

724.01 Description

(a) Structural Expansion Joint

This work shall consist of furnishing and placing, for new construction, structural
expansion joints of the type specified, in accordance with 105.03.

(b) Replacement of Existing Structural Expansion Joint

10 This work shall consist of the removal and replacement of an existing structural
expansion joint with a joint of the type specified, in accordance with 105.03.

(c) Replacement of Existing Structural Expansion Joint Seal

This work shall consist of the replacement of the joint seal in an existing structural
expansion joint of the type specified.

MATERIALS

724.02 Materials
20 Materials shall be in accordance with the following:

Concrete, Class C ........................................................ 702

Expansion Joint M ....................................................... 906.07(b)
Expansion Joint SS ...................................................... 906.07(a)
Inorganic Zinc Primer.................................................. 909.02(a)1
Structural Steel ............................................................ 910.02

The joint manufacturer shall prepare and submit working drawings in accordance
with 105.02. The working drawings shall include details of the assembly, installation
30 details for where changes in the joint direction are required, manufacturer’s
specifications, and joint setting data.

(a) Expansion Joint SS

The joint assembly shall consist of one of the allowable alternates for this type of
joint as shown on the plans. The strip seal shall be sized to accommodate a minimum
of 4 in. of movement. The strip seal shall be furnished in one continuous length for the
entire limits of the installed joint. Field splicing of the strip seal will not be allowed.

760
 724.05

(b) Expansion Joint M

40 The joint assembly shall be manufactured in accordance with the details shown
on the working drawings as prepared by the manufacturer of the joint assembly. The
strip seals shall be furnished in one continuous length for the entire limits of the
installed joint. Field splicing of the strip seals will not be allowed.

CONSTRUCTION REQUIREMENTS

724.03 General Requirements

All welding shall be in accordance with 711.32. All splice welds shall develop
full strength. All welds which come in contact with the seals shall be ground smooth.
50 All metal surfaces in direct contact with the seal shall be cleaned and properly treated
in accordance with the manufacturer’s recommendations. Lubricants and adhesives
shall be used in accordance with the joint manufacturer’s recommendations. All excess
lubricant and adhesive shall be removed before it has set.

Final adjustment of the assembly shall be made as directed at the time of

installation. All movements due to such factors as shrinkage, creep, and mid-slab
deflection shall be accounted for prior to this final adjustment.

(a) Replacement of Existing Structural Expansion Joint

60 The existing joint and adjacent concrete shall be removed to the limits shown on
the plans. Additional removal, as directed, may be required to encounter sound
concrete adjacent to the joint area. The replacement joint shall be in accordance with
the requirements contained herein for the specified type. Concrete shall be class C in
accordance with 702.

(b) Replacement of Existing Structural Expansion Joint Seal

The existing seal shall be removed in its entirety. The new seal shall be installed
in accordance with the requirements contained herein for the specified joint type.

70 724.04 Method of Measurement

Structural expansion joints will be measured by the linear foot along and parallel
to the plane of the finished joint surface. Replacement of existing structural expansion
joints will be measured by the linear foot along and parallel to the plane of the finished
joint surface. Concrete removal and class C concrete required for the replacement of
existing structural expansion joints will not be measured for payment. Sliding cover
plates will not be measured for payment. Replacement of existing structural expansion
joint seals will be measured by the linear foot along and parallel to the plane of the
finished seal installation.

80 724.05 Basis of Payment

Structural expansion joint will be paid for at the contract unit price per linear foot
of the type specified, complete in place. Replacement of existing structural expansion
joint will be paid for at the contract unit price per linear foot for structural expansion

761
 725.01

joint, of the type specified, replace, complete in place. Replacement of existing

structural expansion joint seals will be paid for at the contract unit price per linear foot
for structural expansion joint seal, of the joint type specified, replace.

Payment will be made under:

90 Pay Item Pay Unit Symbol

Structural Expansion Joint, ____ ............................................... LFT

type
Structural Expansion Joint, ____, Replace ................................ LFT
type
Structural Expansion Joint Seal, ____, Replace ........................ LFT
type

The cost of sliding cover plates shall be included in the cost of structural
100 expansion joint or structural expansion joint, replace, as applicable. The cost of
reinforcing bars, concrete removal and class C concrete for the replacement of existing
structural expansion joint shall be included in the cost of structural expansion joint,
replace.

SECTION 725 – SLIP LINING OF EXISTING PIPE

725.01 Description
This work shall include installing a thermoplastic liner pipe into an existing pipe
and filling the space between the liner pipe and the existing pipe with cellular concrete
grout all in accordance with 105.03.

MATERIALS

10 725.02 Materials
Materials shall be in accordance with the following:

Admixture.................................................................... *
Cellular Concrete Grout .............................................. ASTM C 796
Cement, Type I or Type III.......................................... 901.01(b)
Concrete, A.................................................................. 702
Fine Aggregate** ........................................................ 904
Flowable Backfill ........................................................ 213
Foaming Agent ............................................................ 912.05
20 Profile Wall HDPE Liner Pipe .................................... 907.25(b)
Profile Wall PVC Liner Pipe ....................................... 907.25(c)
Solid Wall HDPE Liner Pipe ....................................... 907.25(a)
Water ........................................................................... 913.01
* An admixture may be used as recommended by and in accordance with
the foaming agent manufacturer’s specifications.

762
 725.02

** The supplier may elect to use gradations in accordance with 904.02(h)

or may propose the use of alternate gradations.

Where circular liner pipe is shown on the plans, the pipe structure shall be lined
30 with solid wall HDPE liner pipe; profile wall HDPE liner pipe; or profile wall PVC
liner pipe. Where deformed liner pipe is shown on the plans, the pipe structure shall
be lined with solid wall HDPE liner pipe or profile wall HDPE liner pipe.

The maximum number of joints and corresponding maximum length of each

section of liner pipe used in each pipe structure to be lined shall be as shown on the
plans. If the Contractor has obtained the necessary right-of-entry from all affected
property owners and all necessary new permits or amendments to existing permits to
enable work in areas accessible via Contractor-obtained right-of-entry, the Department
will consider a written request by the Contractor to use liner pipe sections which
40 exceed the maximum length shown on the plans. A corresponding reduction in the
maximum allowable number of joints shall be included with the written proposal. The
Contractor shall not install longer sections of liner pipe until written approval has been
received from the Engineer.

The liner pipe shall either be chosen from those shown on the Department’s list
of approved Plastic Pipe and Pipe Liner Sources or shall be accompanied by a
certification in accordance with 907.25. If the liner pipe is not on the Department’s list
of approved Plastic Pipe and Pipe Liner Sources, then the certification shall be
furnished. Liner pipe shall be submitted to the Engineer for review and approval prior
50 to installation.

Proper care shall be taken to ensure that no damage is done to the liner pipe during
the unloading process. All liner pipes shall be unloaded with straps and lifting
equipment.

Liner pipe joints shall be bell and spigot, screw type, grooved press-on, butt fused,
extrusion welded, or other joint as recommended by the liner pipe manufacturer and
shall be installed according to the manufacturer’s recommended methods.

60 CONSTRUCTION REQUIREMENTS

Where a deformed HDPE liner pipe is specified, the liner pipe shall be made
deformed by using equipment specifically designed to take a circular liner pipe and
deform it without causing damage to the liner pipe. The equipment and method used
to deform the liner pipe shall be described in the QCP. Once the liner pipe has been
deformed, it shall be structurally reinforced in the horizontal and vertical planes.
Structural reinforcement shall be spaced at a maximum distance of 3 ft on centers.
Structural reinforcement shall not be removed until the installation of the liner pipe
and cellular concrete grout at that structure has been completed.
70

763
 725.03

725.03 Right-of-Entry Areas

If the Contractor desires more working room than the right-of-way provides, the
Contractor may elect to pursue rights-of-entry from all necessary adjacent property
owners in accordance with 107.14. A temporary fence shall be installed as required to
prevent encroachment of the public or livestock into the work area. Upon completion
of the work, disturbed areas on private property shall be restored in accordance with
107.14.

725.04 Quality Control

80 A QCP shall be submitted in accordance with ITM 803. No work on the pipe
lining operation shall begin until written notice has been received that the QCP has
been accepted by the Engineer. Acceptance of the QCP in no way relieves the
Contractor of the responsibility for installation procedures and testing requirements.

A QC representative shall be present at the jobsite for the initial testing of the first
welding or fusing at each liner pipe installation location and for the joining, welding,
or fusing of the liner pipe at each location.

725.05 Filling of Cavities Outside of the Existing Pipe

90 All obvious cavities outside the existing pipe shall be filled with non-removable
flowable backfill in accordance with 213 prior to the liner pipe installation or with
cellular concrete grout placed in conjunction with the grouting operation after the liner
pipe is installed.

725.06 Joining Liner Pipe

Each liner pipe joint shall be welded, fused, or joined according to the
manufacturer’s recommended methods. Welded liner pipe joints shall be welded with
a continuous weld for the circumference of the liner pipe both inside and outside.
Welded liner pipe joints shall have weld beads that are smooth and shall not project
100 further than 3/8 in. into the inside of the liner pipe and shall not reduce the hydraulic
capacity of the liner pipe. The ends of liner pipe that are to be welded or butt fused
shall be at the same temperature ±5º F.

A visual inspection will be conducted for acceptance of all liner pipe joined by
methods other than by welding or fusing joints. All joints that do not pass visual
inspection shall be removed, shall have a new joint fabricated, and will be re-inspected.

All liner pipe joints shall have sufficient mechanical strength to withstand the liner
pipe installation and cellular concrete grouting operations.
110
(a) Welder, Butt Fuser, or Joiner Joint Testing
Welding, butt fusing, or joining shall be performed at all times by an operator
trained and certified by either the manufacturer of the liner pipe or the manufacturer
of the welding, butt fusing, or joining equipment. A copy of the operator’s certification
shall be provided to the Engineer prior to the start of work. Prior to fabricating a
production joint on a liner pipe, each operator who is performing welding, butt fusing,
or joining, shall demonstrate that they can produce a joint that will withstand a
764
 725.07

destructive test prior to being allowed to join liner pipe. This test shall be repeated as
many times as necessary in order to produce a joint that will pass the destructive test.
120 One passing joint test is required per operator per contract. The method of joint testing
shall be in accordance with section (b) or (c) below.

(b) Solid Wall HDPE Liner Pipe

Solid Wall HDPE liner pipe joined using butt fusion shall be in accordance with
ASTM F 2620.

Solid wall HDPE liner pipe that is to have extrusion welded joints shall have
destructive testing performed on a test section of liner pipe of the same material as the
liner pipe being installed. The Contractor shall propose and describe in the QCP a
130 destructive test, such as but not limited to a bend strap test, to demonstrate that an
operator can produce an extrusion welded joint that will not fail. Once an extrusion
welded joint is produced on a test section that passes the destructive test, each
subsequent joint fabricated that same day by that operator will be visually inspected
for acceptance. A destructive test in accordance with the approved QCP shall be
conducted on the test section at the beginning of each day that solid wall HDPE liner
pipe joining is being done.

(c) Profile Wall HDPE Liner Pipe

Profile Wall HDPE liner pipe joined using extrusion welding shall be in
140 accordance with ASTM F 894. The Contractor shall propose and describe in the QCP
a destructive test, such as but not limited to a bend strap test, to demonstrate that an
operator can produce an extrusion welded joint that will not fail. Destructive testing
shall be performed on two flat pieces of HDPE sheet stock that has been butt welded
together to verify the extrusion gun is working properly and that the operator can
produce an extrusion welded joint that will not fail. Once an extrusion welded joint is
produced on a test section that passes the destructive test, each subsequent joint
fabricated that same day by that operator will be visually inspected for acceptance. A
destructive test in accordance with the approved QCP shall be conducted on the test
section at the beginning of each day that profile wall HDPE liner pipe joining is being
150 done.

725.07 Cellular Concrete Grout

The cellular concrete grout shall be designed in accordance with ASTM C 796
except as herein modified.

The admixtures, retarders, and plasticizers used in the grout shall be in accordance
with the foam concentrate supplier’s specifications.

The grout shall be made using the preformed foam process using foam generating
160 equipment calibrated daily by the foam manufacturer to produce a precise and
predictable volume of foam. The foam concentrate shall be certified by the
manufacturer to have specific liquid/foam expansion ratio at a constant dilution ratio
with water.

765
 725.08

The specific job mix shall be submitted to the Engineer by either the foam
concentrate supplier or the certified or licensed grouting contractor for approval prior
to use on the contract. The mix shall have a minimum 28-day compressive strength of
150 psi. The mix shall be tested by a laboratory approved by the Department or shall
be approved based on prior acceptable performance on Department contracts.
170
The cellular concrete grout pump gauges shall be calibrated a minimum of once
per month in the presence of the Engineer by the method described in the QCP.

Grout mixed off site shall be delivered to the job site in a truck mixer in
accordance with 702.09 filled to half its capacity. The foaming agent shall then be
added to the cement mix in the truck and mixed to a uniform consistency.

Grout mixed on site shall be batched in a deck mate or similar device. Small
batches of approximately 1 cu yd shall be mixed and pumped in a continuous
180 operation.

For each day worked or for each 100 cu yds placed, four test cylinders measuring
3 in. by 6 in. shall be cast at the point of placement of the grout. Sampling, molding,
curing, and compressive strength testing of the cylinders shall be in accordance with
ASTM C 495, except as modified herein.

Initial curing shall be at a temperature of 70°F 10°F and shall be from two to
five days. After the initial curing, the test specimens shall be placed in a moist closet
or moist room or stored in an enclosed curing tank above the water level. All
190 specimens shall be kept in their molds in the moist storage for the remainder of the
curing period. The specimens shall be tested at 28 days. At that time the specimens
shall be prepared for testing in accordance with ASTM C 495 except the bearing
surface may be ground or cut with a dry saw to meet surface tolerance. The specimens
shall not be capped. Specimens shall be tested in compression as rapidly as possible
to minimize drying. If more than one specimen is removed from the moist storage at
the same time, these specimens shall be covered with a damp cloth until time of testing.
The Contractor shall provide a type A certification in accordance with 916 that
provides the compressive strength results.

200 725.08 Liner Pipe Installation

Prior to commencing the liner pipe installation, all jagged existing pipe edges or
other deformities shall be repaired. All debris and foreign material shall be removed
from the existing pipe and disposed of in accordance with 203.08. A visual walk-
through inspection shall be performed after all debris and foreign material has been
removed from the existing pipe in order to assess the current condition of the pipe. If
visual inspection is not possible, a video inspection of the existing pipe shall be
performed. A copy of the video inspection shall be provided to the Engineer. If, upon
completion of the inspection of the existing pipe, the Contractor believes that they
cannot proceed with the work as shown on the plans, the Engineer shall be notified.

766
 725.09

210
The cross-sectional area of the liner pipe shall be as shown on the plans.

Prior to commencing the liner pipe installation operation, steps shall be taken to
verify that a liner pipe meeting the required cross-sectional area can be successfully
placed inside the existing pipe. If it is discovered prior to installation that a liner pipe
with the required opening area cannot fit, the inside and outside diameters of a
substitute liner pipe shall be submitted to the Engineer for approval. If this discovery
is not made until after the liner pipe installation has begun, the partially installed liner
pipe shall be removed. Inside and outside diameters for a substitute liner pipe shall
220 then be submitted to the Engineer for approval.

After the liner pipe installation is complete and the liner pipe has cooled to the
temperature of the existing pipe, the liner pipe shall be cut so that each end is 8 in.
outside the end of the existing pipe.

The cellular concrete grout within the annular space between the existing pipe and
the liner pipe shall be contained by bulkheads. The bulkheads shall be constructed at
each end of the structure. Each bulkhead shall be constructed to withstand the pressure
of the grouting operation. The bulkhead shall be free from leaks and the exterior
230 surface shall be given a smooth trowel finish. The bulkhead shall extend from the end
of the existing pipe inward a minimum depth of 18 in.

Cellular concrete grout shall be injected into the annular space between the
existing pipe and the liner pipe. The injection operation shall provide sufficient cellular
concrete grout to fill all voids between the existing pipe and the liner pipe over the
entire structure length, but shall also be performed in a manner that does not distort
the liner pipe. Injection of the cellular concrete grout in lifts, use of spacers, or other
safeguards shall be taken in order to keep the liner pipe in position and prevent the
liner pipe from floating. The pressure developed in the annular space between the liner
240 pipe and the existing pipe shall not exceed the liner pipe manufacturer’s recommended
maximum value.

All existing culverts, storm drains, underdrain pipes, drain tile, or other pipes that
are directly connected to the lined structure shall be perpetuated. Cellular concrete
grout shall not leak through the liner pipe at these connections.

725.09 Method of Measurement

All thermoplastic liner pipe will be measured by the linear foot, for the shape and
cross-sectional area of the liner pipe, complete in place. Perpetuation of existing pipes
250 through the liner pipe will be measured by the number of existing pipes perpetuated.

No measurement will be made of liner pipe joints or the length of joint welding
or fusing, or other incidentals necessary to join sections of liner pipe in accordance
with the manufacturer’s recommendations. The liner pipe or flat sheet stock used for

767
 725.10

destructive testing will not be measured for payment. No measurement will be made
of a liner pipe meeting the required opening area that does not fit.

No measurement will be made for debris removal and disposal, filling existing
voids, or trimming, cutting, jacking, or other corrective measures performed on jagged
260 edges or other deformities of the existing pipe in order to facilitate installation of the
liner pipe. No measurement will be made for visual or video inspection of the existing
pipe.

No measurement will be made for the bulkhead.

725.10 Basis of Payment

The accepted quantities of thermoplastic liner pipe will be paid for at the contract
unit price per linear foot for the shape and cross-sectional area of the liner pipe,
complete in place. Perpetuation of existing pipes through the liner pipe will be paid
270 for by the number of existing pipes perpetuated.

Payment will be made under:

Pay Item Pay Unit Symbol

Liner Pipe, Thermoplastic, Circular, _______sq ft ................... LFT

cross-sectional area
Liner Pipe, Thermoplastic, Deformed, _______ sq ft ............... LFT
cross-sectional area
280 Perpetuation, Existing Pipe ....................................................... EACH

The cost of repairing, trimming, or cutting jagged edges or deformities to existing

pipe, filling cavities around the existing pipe with cellular concrete grout, acquisition
and restoration of right-of-entry areas, acquiring all necessary new permits or
amendments to existing permits to work in areas accessible via Contractor-obtained
right-of-entry, erection, maintenance, and removal of temporary fence, removal and
disposal of debris and foreign material from the existing pipe, visual or video
inspection of the existing pipe, deforming a circular liner pipe, supplying and
constructing the bulkheads, grouting the annular space between the existing pipe and
290 the liner pipe, and other incidentals will not be paid separately, but shall be included
in the cost of the pay items in this section.

The cost of liner pipe joints other incidentals necessary to join sections of liner
pipe in accordance with the manufacturer’s recommendations, and all test sections of
liner pipe and test sections of HDPE sheet stock shall be included in the cost of the
pay items in this section. All costs associated with having a QC representative on site
shall be included in the cost of the pay items in this section.

The cost of training and certifying an operator, destructive and non-destructive

300 testing, liner pipe, and incidentals used in destructive testing, and all costs associated

768
 726.02

with the development of an acceptable QCP shall be included in the cost of the pay
items in this section.

Any joint that does not pass the visual inspection and needs to be re-fused, re-
welded, or re-joined shall be done at no additional cost to the Department.

In situations where the condition of the existing pipe requires that a substitute liner
pipe be utilized, there will be no reduction in payment for the installation of the
substitute liner pipe. There will be no additional payment for the additional cellular
310 concrete grout required to fill the larger void between the existing pipe and the smaller
liner pipe.

There will be no payment for the installation or removal of any liner pipe that
cannot be successfully installed due to the condition of the existing pipe. There will
be no payment for a liner pipe meeting the required cross-sectional area that does not
fit.

If the existing pipe or any other object not designated for removal is damaged
while performing this work, it shall be considered unauthorized work and repaired or
320 replaced in accordance with 105.11.

SECTION 726 – BEARING ASSEMBLIES

726.01 Description
This work shall consist of furnishing and installing bearing assemblies in
accordance with 105.03. Elastomeric bearings shall include plain bearings consisting
of elastomer only, and laminated bearings consisting of layers of elastomer restrained
at their interfaces by bonded laminates.

MATERIALS
10
726.02 Materials
The materials shall be in accordance with the following:

Anchor Bolts................................................................ 910.02(g)

Elastomer ..................................................................... 915.04
Grout............................................................................ 707.09
Polytetrafluoroethylene Sliding Surfaces .................... 915.05
Side Retainers .............................................................. 910.02(a)
Shim and Fill Plates ..................................................... 910.02(a)
20 Threaded Studs and Hex Nuts ..................................... 910.02(c)

769
 726.03

CONSTRUCTION REQUIREMENTS

726.03 Construction Requirements

Elastomeric bearings without external load plates may be placed directly on a
concrete or steel surface provided the surface is flat to within a tolerance of 0.005 of
the nominal dimension for steel reinforced bearings or 0.01 of the nominal dimension
for other types. Bearings shall be installed on surfaces that are horizontal and parallel
between the top of the bearing and the underside of the girder.
30
The elastomer or the bond shall not be subjected to temperatures higher than
390ºF.

Masonry plates for polytetrafluoroethylene, PTFE, bearings shall be perfectly

level. The tolerance between the top face of the masonry plate and the bottom face of
the top plate shall be a maximum of 1/16 in., measured at the ends of a diameter of the
bottom plate of the bearing assembly. Other dimensional tolerances shall be as shown
on the plans or in accordance with 915.04(d).

40 Immediately prior to setting bearings, the concrete and metal surfaces that are to
be in contact shall be cleaned.

726.04 Method of Measurement

Elastomeric bearing pads will not be measured for payment. PTFE bearing
devices will be measured by the number of devices placed.

726.05 Basis of Payment

Elastomeric bearing pads will not be paid for separately.

50 PTFE bearing devices will be paid for at the contract unit price per each device,
complete and in place.

Payment will be made under:

Pay Item Pay Unit Symbol

Bearing Assembly, PTFE .......................................................... EACH

The cost of the pads, side retainers, anchor bolts, shim plates, and other incidentals
60 shall be included in the cost of the structural member, or for PTFE bearing assemblies.

770
 727.04

SECTION 727 – STRUCTURAL CONCRETE REPAIR BY EPOXY

INJECTION

727.01 Description
This work shall consist of structurally rebonding concrete cracks, fractures, or
delaminations by means of an epoxy injection system in accordance with 105.03.

727.02 Materials
Materials shall be accordance with the following:
10
Epoxy Resin Additives ................................................ 909.12

727.03 Approvals
The epoxy injection system proposed for use shall be subject to approval prior to
the start of the repair work. One copy of preparation, mixing, and application
instructions shall be furnished. Such instructions shall have been developed especially
for use with the proposed epoxy injection system.

CONSTRUCTION REQUIREMENTS
20
727.04 Construction Requirements
The location and extent of cracks to be repaired by epoxy injection will be
determined.

The work shall be performed with two-component automatic metering and mixing
equipment.

Concrete surfaces adjacent to the cracks shall be cleaned to the extent necessary
to achieve adequate bond of the surface seal material. Entry ports shall be provided
30 along the crack at intervals determined in the field to ensure full depth penetration of
the injection resin. Surface seal shall be applied between entry ports, and on both faces
of through cracks when possible.

Epoxy injection shall begin at the lower entry port and continue until there is an
appearance of epoxy at the adjacent entry port. Injection shall continue until all cracks
are filled. If port to port travel is not apparent, the work shall be stopped immediately.
The Engineer shall be notified.

Upon completion of the injection, the adhesive shall cure for sufficient time to
40 enable removal of surface seal without draining or runback of material from the cracks.
Surface seal material and injection adhesive runs or spills shall be removed from
concrete surfaces. The face of the crack shall be finished flush to the adjacent concrete.
The face of the concrete shall show no indentations or protrusions caused by the
placement of entry ports.

771
 727.05

727.05 Method of Measurement

Furnishing equipment for epoxy injection will not be measured for payment.
Crack preparation for epoxy injection will be measured by the linear foot of prepared
crack. Epoxy material will be measured by the gallon placed.
50
727.06 Basis of Payment
This work will be paid for at the contract lump sum price for epoxy injection,
furnishing equipment. Crack preparation will be paid for at the contract unit price per
linear foot for epoxy injection, crack preparation. Epoxy resin adhesive will be paid
for at the contract unit price per gallon for epoxy injection, epoxy material.

Payment will be made under:

Pay Item Pay Unit Symbol

60
Epoxy Injection, Crack Preparation........................................... LFT
Epoxy Injection, Epoxy Material............................................... GAL.
Epoxy Injection, Furnishing Equipment .................................... LS

SECTION 728 – BLANK

SECTION 729 – BLANK

SECTION 730 – BLANK

SECTION 731 – MECHANICALLY STABILIZED EARTH RETAINING

WALLS

731.01 Description
This work shall consist of the design, furnishing materials, and placement of MSE
retaining walls in accordance with 105.03.

731.02 General Design Requirements

An MSE retaining wall shall consist of a non-structural concrete leveling pad,
10 concrete face panels, precast or cast-in-place concrete coping, ground reinforcement
elements mechanically connected to each panel, and accommodations for
appurtenances behind, in front of, under, mounted upon, or passing through the wall.
Ground reinforcement shall have sufficient strength, frictional resistance, and quantity
as required by design. If a drainage system is shown on the plans, the wall design shall
accommodate the drainage system.

772
 731.03

The MSE retaining wall system shall be selected from the Department’s list of
approved retaining wall systems. A retaining wall system manufacturer will be
considered for inclusion on the Department’s list by following ITM 806, Procedure J.
20 The quantities shown in the Schedule of Pay Items will be the same for each MSE
retaining wall system. The MSE retaining wall panels shall be constructed as shown
on the panels’ working drawings, based on the requirements herein.

If the wall manufacturer needs additional information to complete the design, the
Contractor shall be responsible for obtaining such information.

All appurtenances behind, in front of, under, mounted upon, or passing through
the wall such as drainage structures, utilities, or other appurtenances shown on the
plans, shall be accounted for in the design of the wall.
30
The Contractor shall determine the final leveling-pad layout and step elevations
that provide the wall envelope shown on the plans. The Contractor shall use this
information to provide a final horizontal plan and vertical elevation profile along the
front face of the wall to account for the wall envelope shown on the plans. The final
coping or top-of-wall elevations shall be at or above those shown on control line 1 on
the plans. The final top-of-leveling-pad elevations shall be at or below those shown on
control line 3 on the plans. Leveling-pad steps shall be in 2.5 ft increments.

Where a coping or barrier is utilized, the wall face panel shall extend up into the
40 coping or barrier a minimum of 2 in. The top of the face panels may be level or sloped
to meet the top of the face panel line shown. Cast-in-place concrete will not be an
acceptable replacement for panel areas indicated by the wall envelope.

Where walls or wall sections intersect with an included angle of 130° or less, a
vertical corner element separate from the standard panel face shall abut and interact
with the opposing panels. The corner element shall have ground reinforcement
connected specifically to that panel. All turn-point locations where the wall forms an
angle that are shown on the working drawings shall correspond to those shown on the
plans unless otherwise approved in writing by the Engineer.
50
Face panels shall be designed to accommodate a differential settlement of 1 linear
unit in 100. Face panels of an area greater than 32 sq ft through 64 sq ft shall be
designed to accommodate differential settlement of 1 linear unit in 200. Where shown
on the plans, slip joints to accommodate excessive or differential settlement shall be
included.

Only one typical face panel shape and architectural finish shall be used per
contract.

60 731.03 Design Criteria

The internal, external, and compound stability shall be the responsibility of the
Contractor. The global stability of the wall mass will be the responsibility of the
Engineer.
773
 731.03

The Contractor shall use the information supplied in the contract documents
including but not limited to the plans and the geotechnical report when designing the
wall. The design of the wall including the internal, external, and compound stability
shall be in accordance with the AASHTO LRFD Bridge Design Specifications and the
requirements specified herein.
70
The splay angle of soil reinforcement measured from a line perpendicular to the
wall face, in order to avoid an obstruction, shall not be more than 15°. The tensile
capacity of the splayed reinforcement shall be reduced by the cosine of the splay angle.

The design for internal stability shall include connection strength design. Each
design case shall present maximum tension capacity, soil overburden pressure, and
horizontal pressure at each reinforcement level, pullout capacity at each reinforcement
level, the length of embedment in the resisting zone, and the total length of
reinforcement at each level.
80
The design for the external stability shall include applied bearing pressure,
overturning, sliding, and stability of temporary construction slopes.

The design for the compound stability shall include the slope present on top of
and at the toe of the MSE wall.

The value of the pullout resistance factor, F*, used in design calculations shall be
obtained from AASHTO LRFD Bridge Design Specifications figure 11.10.6.3.2-2.

90 The minimum embedment at the front face of the wall shall be in accordance with
the AASHTO LRFD Bridge Design Specifications, section 11.10.2.2. However, the
minimum embedment depth to the top of the leveling pad shall never be less than 3 ft
unless founded on rock. A 4 ft horizontal bench in front of the wall shall be provided
for slopes steeper than 4.0H:1.0V.

The embedment and bench material, at the front face of the wall, shall match the
structural backfill material used for the wall and shall be incased in accordance with
203.09. It shall be 6 in. minimum depth measured perpendicular to the face of the
slope. Geotextiles, in accordance with 918.02(a), Type IB, shall be installed over the
100 bench material in accordance with 616.11. The embedment and bench shall be
daylighted at the bottom of the slope with uniform riprap placed at a minimum 12 in.
depth for erosion control.

An MSE wall shall be designed for a service life of 75 years.

(a) Geotechnical Considerations

The theoretical failure plane within the soil mass shall be analyzed so that the soil-
stabilizing component extends sufficiently beyond the failure plane to stabilize the
material. External loads which affect the internal stability such as those applied

774
 731.03

110 through piling, bridge footings, traffic, crashwall, or slope surcharge, shall be
accounted for in the design. The sizes of all structural elements shall be determined
such that the design load stresses do not exceed the factored stresses shown in the
AASHTO LRFD Bridge Design Specifications.

The material used as backfill in the reinforced backfill zone shall be assumed to
have a unit weight of at least 120 lb/cu ft unless lightweight fill has been specified.
The φ angle for the internal design of the reinforced backfill shall be 34°. The φ angle
of the retained backfill zone shall be 30° for design. For the external design parameters,
such as but not limited to, bearing capacity, sliding, overturning, eccentricity, and
120 global stability, the actual soil strength parameters and the expected settlement of the
existing soil under the reinforced backfill zone shall be obtained from the geotechnical
report.

(b) Height of Wall

The wall limits shall be defined by the wall envelope shown on the plans. For
internal stability design purposes, the design height of wall shall be as follows:

1. For a wall with a level surcharge, the design height of the

wall, H, shall be measured from the theoretical top of the
130 leveling pad to the top of the coping or to the gutter line of
the traffic barrier. The top of the wall shall be the
theoretical top of the face panels only where a coping or
barrier is not used.

2. For a wall with a sloping surcharge, the design height of

the wall, Z, shall be measured from the theoretical top of
the leveling pad to a point above the top of the wall as
calculated from the formula as follows:

0.3H tan β
140 Z=H+
1 0.3 tan β
where:

β = surcharge slope angle as measured from the top of the coping, and
H = height of the wall from the theoretical top of the leveling pad to
the top of the coping.

3. For an abutment face, the design height of the wall, H, shall

be measured from the theoretical top of the leveling pad to
the top of the roadway surface.

(c) Ground Reinforcement

The ground reinforcement length shall be the controlling length resulting from the
150 internal or external design.

775
 731.03

The ground reinforcement shall be the same length from the bottom to the top of
each wall section regardless of the type of ground reinforcement used. Differing
ground reinforcement elements shall be marked for ease of construction. This element
may be used individually or in a prefabricated grouping.

The ground reinforcement for the MSE volume shall be sized using the lesser of
the factored loads for each specific connection and each specific reinforcing element.
The connection’s applied factored load and effective pullout length shall be
160 determined in accordance with the AASHTO LRFD Bridge Design Specifications.

For mats, grids, or strip steel, the minimum zinc coating thickness shall be 2 oz/sq
ft. Such thickness shall be assumed to be 4 mils for purpose of calculation of reduced
structural section.

The factored applied bearing pressures under the stabilized mass for each
reinforcement unit’s length shall be shown on the working drawings. It shall not
exceed the maximum factored soil bearing resistance shown on the plans. Passive
pressure in front of the wall mass shall be assumed to be zero for design purposes.
170
(d) Other Criteria

1. Traffic Load Considerations

Traffic load shall be considered as live load surcharge. The load factor of traffic
load shall be 1.75 in accordance with AASHTO LRFD Bridge Design Specifications
table 3.4.1-1.

2. Traffic Impact Considerations

Where traffic barriers are constructed above an MSE wall or reinforced backfill
180 zone, the MSE wall supporting traffic shall include computations showing that the
Extreme Event II limit state due to traffic impact has been met.

Loadings for MSE wall design for the Extreme Event II limit state shall be in
accordance with the following table:

Maximum Nominal Tension Rupture

and Pullout Impact Loads
Layer Tension Impact Load Pullout Impact Load
First Top Layer 2,300 lbs/ft 1,300 lbs/ft
Second Top Layer 600 lbs/ft 600 lbs/ft

The Extreme Event II design for the top two layers shall be separately prepared
and compared with the routine internal stability design.

190 3. Tributary Area – Design Basis

For internal stability analysis of MSE walls, each layer of reinforcement is
assigned a tributary area, Atrib in accordance with FHWA publication No. FHWA-

776
 731.04

NHI-10-025, Design and Construction of Mechanically Stabilized Earth Walls and

Reinforced Soil Slopes Volume II and as follows:

Atrib = (wp) (Svt)

where:

wp = the wall system concrete panel width of the precast facing element, and
Svt = the vertical tributary spacing of the reinforcement based on the location of
the reinforcement above and below the level of the reinforcement under
consideration.
200
For a wall system with steel reinforcement, within each tributary area, the factored
reinforcement tensile resistance, Tr, and the factored pullout resistance, Prr, shall be no
less than the maximum factored tension load, Tmax. If the calculated minimum number
of strips is a decimal number, the minimum number required shall be rounded up to
the next whole number.

731.04 Submittals
The Contractor shall submit working drawings in accordance with 105.02. The
Contractor shall submit design calculations in accordance with 105.02 and the
210 following additional requirements. In case of discrepancy, the requirements listed
below supersede those listed in 105.02. Design calculations shall include each design
case of the MSE wall analyzed. Calculations may be in either longhand or computer-
printout format and shall follow a systematic and logical methodology. A summary
sheet that shows design assumptions and their source, controlling parameters and load
cases, and other pertinent input and output information shall be included with the
calculations package. Wall construction operations shall not begin until the Contractor
receives written notice that the working drawings are approved.

(a) The working drawings shall include all details, dimensions,

220 quantities and cross-sections necessary to construct the wall.
They shall include, but shall not be limited to, the following:

1. Plan and elevation views along the front face of wall

alignment, which shall include the following:

a. A final profile along the front face of the wall.

b. A plan layout of the front face of the wall showing all

alignment points with stations and offsets.
230
2. A plan view of the wall that indicates the offsets from the
construction centerline to the face of the wall at all changes
in horizontal alignment. A plan view and elevation view
which detail the placing position and connection of all

777
 731.04

ground reinforcement units in areas where piling, utility, or

other structures are near the wall.

3. An elevation view along the front face of the wall with

respect to the wall alignment, which shall include the
240 following:

a. The elevation at the top of the wall at all horizontal and

vertical break points at least every 50 ft along the face
of the wall.

b. All steps in the leveling pad.

c. The designation as to the type of wall unit.

250 d. The length of ground reinforcement units.

e. A wall-elevation envelope that encompasses such

envelope shown on the plans.

4. All general notes required for constructing the wall.

(b) Panel details shall show all dimensions necessary to construct

the element, all reinforcement in the element, and the location
of ground reinforcement connection devices embedded in the
260 panels.

(c) Details for construction of the wall around drainage facilities

including outletting of internal drainage from the MSE volume.

(d) Details of the architectural treatment.

(e) Details for diverting ground reinforcement around obstructions

such as piles, catch basins, or utilities.

270 (f) Details for the connections between the concrete panel and the
ground reinforcement.

(g) Determination of φ angle for reinforced materials and retained

materials.

(h) Detailed differential settlement calculations.

(i) Detail standard summary sheet of the input values in the

following format:
280

778
 731.05

Wall Detail Design Value

Design Life
Type
Configuration(Strip or grid)
Width, in.
Reinforcement
Ec (Corroded Thickness), in.
Reinforcement Strength (Fy), ksi
Coverage Ratio (Rc)
Type
Reinforced Fill Unit Weight, pcf
Friction Angle, degrees
F*
Reinforcement Pullout Resistance
α
Type
Retained Fill Unit Weight, pcf
Friction Angle, degrees
Type
Unit Weight, pcf
Foundation Soil
Friction Angle or cohesionA,
degrees or lb/sq ft
A Use only one value, whichever is applicable.

MATERIALS

731.05 Materials
Materials shall be in accordance with the following:

Admixtures for Concrete ............................................. 912.03

Air Cooled Blast Furnace Slag .................................... 901.09
Alignment Pins ............................................................ 910.07(d)
290 B Borrow ..................................................................... 211.02
Coarse Aggregate, Class A or Higher,
Size No. 8 or 91 .................................................... 904
Components of MSE Retaining Walls......................... 901.10
Concrete, Class A or Class C....................................... 702
Deformed and Smooth Steel WWR............................. 910.01(b)5
Fine Aggregate, Size No. 23........................................ 904
Fly Ash ........................................................................ 901.02
Geotextile for Use Under Riprap ................................. 918.02
Joint Spacers and Joint Covering................................. 901.10(b)
300 Portland Cement .......................................................... 901.01(b)
Rapid Setting Patch Materials ..................................... 901.07
Reinforcing Bars.......................................................... 910.01
Steel Components ........................................................ 910.07
Structure Backfill ........................................................ 211.03.1, 904.05
Underdrains ................................................................. 718
779
 731.06

Underdrains for MSE Walls ........................................ 718.03

Water ........................................................................... 913.01

MSE wall backfill, and the horizontal bench in front of the wall, shall consist of
310 structure backfill type 3 in the reinforced backfill zone in accordance with 211, except
that nominal size aggregate No. 30 shall not be used. Structure backfill in the retained
backfill zone shall be type 3 or B borrow as shown on the plans.

If coarse aggregate No. 5, No. 8, No. 9, or No. 11 is used in the reinforced backfill
zone and the Contractor elects to use a different material in the retained backfill zone,
geotextiles shall be installed at the interface between the reinforced and retained
backfill zones. If the Contractor elects to use coarse aggregate No. 5, No. 8, No. 9, or
No. 11 in both the reinforced and retained backfill zones, geotextiles shall be installed
along the interface between the retained backfill zone and the adjacent soil. In addition,
320 geotextiles shall be installed over the top of the No. 5, No. 8, No. 9, or No. 11 aggregate
used in the reinforced or retained backfill zones.

Concrete for the leveling pad and coping shall be class A. Concrete used in
openings to accommodate appurtenances behind, in front of, under, mounted upon, or
passing through the wall shall be class C.

The Contractor shall supply the MSE retaining wall components listed above,
including tie strips, fasteners, bearing pads, and all necessary incidentals, through a
manufacturer listed on the Department’s list of approved retaining wall systems.
330
CONSTRUCTION REQUIREMENTS

731.06 General Requirements

The wall manufacturer’s representative shall provide technical instruction,
guidance in preconstruction activities including the preconstruction conference, and
on-site technical assistance to the Contractor during construction.

731.07 Foundation Preparation

Prior to wall construction, the foundation for the structure shall be graded for a
340 width equal to or exceeding the length of the ground reinforcement or as shown on the
plans. The foundation, if not in rock, shall then be compacted in accordance with 203.
After the foundation has been compacted, the resulting grade of the foundation shall
be 1 in. per foot sloped from the back of the foundation downward toward the leveling
pad. The portion of the foundation beneath the leveling pad shall not be sloped. The
foundation shall be proofrolled in accordance with 203.26. If unsuitable foundation
material is encountered, it shall be removed and replaced with B borrow in accordance
with 211.02 and compacted in accordance with 211.04.

After proofrolling has been completed and all unsuitable foundation material has
350 been removed and replaced, compaction of the portion of the foundation beneath the

780
 731.08

reinforced backfill zone will be verified by dynamic cone penetrometer, DCP, testing
in accordance with ITM 509.

One DCP measurement for every 500 sq ft within the reinforced backfill zone and
five DCP measurements per end bent will be performed.

A DCP measurement is defined as the number of blows per 6 in. increment for a
total penetration of 30 in., based on five sets of DCP readings at each location. A
minimum of five blows of the DCP for each 6 in. increment is considered acceptable.
360
Unsuitable areas shall be removed, replaced, and compacted in accordance with
203 and 211. DCP verification of compaction beneath the reinforced backfill zone will
not be required if the foundation is in an embankment section that is constructed in
accordance with 203.

An unreinforced concrete leveling pad shall be provided at each foundation level

as shown on the plans. The leveling pad shall be cured in accordance with 702.22 for
a minimum of 12 h before placement of concrete face panels.

370 731.08 Retaining Wall Excavation

The Contractor shall notify the Engineer a minimum of 7 calendar days or other
time as mutually agreed upon before beginning the excavation so that measurements
can be taken of the undisturbed ground.

Prior to starting excavation operations at the wall site, clearing and grubbing shall
be in accordance with 201.03. The area shall be cleared and grubbed to the excavation
in accordance with the limits shown on the plans. All timber, stumps, or debris shall
be disposed of in accordance with 201.03. Excavation shall include the construction
and subsequent removal of all necessary bracing, shoring, sheeting, and cribbing.
380 Excavation shall also include all pumping, bailing, and draining.

The excavation shall be shored or braced in accordance with State and local safety
requirements. Excavation and related work shall be performed such that no portion of
the wall is endangered by subsequent operations.

Where excavation for the wall requires shoring, sheeting, or bracing, the method
shall be shown on the working drawings. Excavation operations shall not begin until
the Contractor receives notice that the working drawings are approved.

390 After the excavation for the wall has been performed, the Contractor shall notify
the Engineer. The material beneath the leveling pad shall be compacted in accordance
with 203. Concrete for the leveling pad shall not be placed until the Engineer has
approved the depth of the excavation and the foundation material. The leveling pad
shall be in accordance with 731.07.

781
 731.09

When an internal drainage system is shown on the plans, the drain pipe shall be 6
in. underdrain pipe in accordance with 715.02(d). The remainder of the internal
drainage system shall be in accordance with 718, longitudinal underdrains. Video
inspection will not be required.
400
731.09 Wall Erection
Concrete face panels shall be handled by means of a lifting device set into the
upper edge of each panel. Panels shall be placed in successive horizontal lifts in the
sequence shown on the plans as backfill placement proceeds. As backfill material is
placed behind the panels, the panels shall be maintained in vertical position by means
of temporary wooden wedges placed in the joint at the junction of the two adjacent
panels on the external side of the wall. External bracing will be required for the initial
lift.

410 Panels shall be stored on blocking to minimize contact with the ground or being
covered by standing water. Panels placed in contact with the ground or covered by
standing water shall have face discoloration removed by means of a chemical wash.

Plumb, vertical tolerances, and horizontal alignment tolerances shall not exceed
3/4 in. as measured with a 10 ft straightedge. The maximum allowable offset in panel
joints shall be 3/4 in. For a wall of over 10 ft height, the overall plumb from top to
bottom of the wall shall not exceed 0.05 in./ft of wall height.

For aesthetic considerations and to make differential settlement unnoticeable, the

420 panels shall be erected such that the horizontal site line is discontinuous at every other
panel. This shall be accomplished by starting erection with the lower panel level of
each wall by alternating full-height and half-height panels. Panels above the lowest
level shall be of a uniform size, except as required to top out the wall, to be in
accordance with the plan elevations.

The Contractor shall perform the necessary work to verify that the foundation is
at the correct elevation, that the wall is constructed to the correct alignment, and that
the work is in accordance with the specified tolerances. The checking of alignments
and tolerances shall include verifying that the plumb of the face panels is in accordance
430 with 731.10 over the entire height of the wall. Alignment shall be checked at each
layer of panels after the backfill behind the panels has been compacted, and the results
shall be recorded.

The connections of the ground reinforcement to the panels shall be in two

elevations for full height panels. The connections shall not be more than 30 in.
vertically apart. To prevent out-of-plane rotation, full height face panels shall be
connected to the ground reinforcement on at least three different points in two different
planes. However, a preapproved system utilizing a horizontal stabilizing leg to prevent
rotation shall require only ground reinforcement attachments in one plane. Partial size
440 panels shall have three different connection points, but only one plane shall be attached

782
 731.11

to the ground reinforcement. Panels located at the top of the wall shall not be attached
to the coping or traffic barrier.

Ground reinforcement shall be placed normal to the face of the wall, unless
otherwise shown on the plans or as directed. Prior to placement of the ground
reinforcement, backfill shall be compacted in accordance with 731.11.

731.10 Joint Spacers and Joint Covering for Wall Panels

Horizontal and vertical joint spacers shall be provided between adjacent face
450 panels to prevent concrete-to-concrete contact and chipping if differential settlement
occurs. Panels without an uninterrupted vertical joint shall have a minimum joint
thickness of 3/4 in. Joint covering shall be provided and attached to the rear face of
the panels. Geotextiles used to cover the joint behind the MSE wall facing panels shall
be in accordance with 918.02(a), Type IB.

731.11 Backfill Placement

Backfill placement shall follow erection of each course of panels and ground
reinforcement. All sheeting and bracing shall be removed as the backfilling progresses.
Backfill shall be placed so as to avoid damage or disturbance to the wall materials or
460 misalignment of the concrete face panels. All material for backfill shall be subject to
approval and shall be free from lumps, wood, or other undesirable material. Wall
materials that become damaged or disturbed during backfill placement shall be
removed and replaced or corrected as directed. All misalignment or distortion of the
concrete face panels due to placement of backfill outside the limits described herein
shall be corrected as directed.

B borrow and structure backfill type 3 shall be compacted in accordance with

203.23 or 203.24. Compaction equipment shall be in accordance with 409.03(d). For
all other structure backfill material used, compaction shall consist of four passes with
470 a vibratory roller and one pass with the same roller in static mode. The vibratory roller
shall be equipped with a variable amplitude system and a speed control device. It shall
have a minimum vibration frequency of 1,000 vibrations per minute. A roller in
accordance with 409.03(d)4 may be used. All displacement or rutting of the aggregate
shall be repaired prior to placing subsequent material.

The maximum loose lift thickness shall not exceed 8 in. However, lifts within 3
ft of the wall shall not exceed 5 in. in loose thickness. This lift thickness shall be
decreased if necessary, to obtain the specified density.

480 Compaction within 3 ft of the back face of the concrete face panels shall be
achieved by means of a minimum of five passes with a lightweight mechanical tamper,
roller, or an alternative vibratory system.

At the end of each day's operation, the last level of backfill shall be sloped away
from the wall units. Surface runoff from adjacent areas shall not enter the wall
construction site.

783
 731.12

Subsurface drainage for the pavement section shall be underdrains for MSE walls
and shall be as shown on the plans.
490
Cutting or altering of the basic structural section of ground reinforcement at the
site will be prohibited, unless the cutting is preplanned and detailed on the approved
working drawings. Cutting shall be considered only if adequate additional ground
reinforcement is provided to produce the required strength shown in the approved
calculations. If the ground reinforcement is shortened in the field, the cut ends shall be
covered with a galvanized paint or coal tar to prevent corrosion of the metal.

731.12 Method of Measurement

The measurement of concrete face panels and wall erection will be based on the
500 square foot of area contained within the neat line limits of the wall envelope shown on
the plans and not that of the wall system supplier.

Concrete leveling pad will be measured by the linear foot. Common excavation
will be measured by the cubic yard in accordance with 203.27(a) to the neat lines
shown on the plans. Structure backfill and B borrow will be measured in accordance
with 211.09. Unsuitable foundation materials, if found, will be measured in
accordance with 211.09. Geotextile used in conjunction with MSE wall construction
will not be measured for payment. Underdrains for MSE walls and components of the
internal drainage system will be measured in accordance with 718.09. If unsuitable
510 foundation material is encountered in the portion of the foundation beneath the
leveling pad in a section constructed on original ground or in a cut section, the removal,
replacement, and compaction of the new material will be measured in accordance with
203 and 211.

Precast or cast-in-place concrete coping will not be measured.

731.13 Basis of Payment

The accepted quantities of concrete face panels will be paid for at the contract unit
price per square foot. Wall erection will be paid for at the contract unit price per square
520 foot. Concrete leveling pad, complete and in place, will be paid for at the contract unit
price per linear foot for leveling pad. Common excavation will be paid for in
accordance with 203.28. Structure backfill and B borrow will be paid for in accordance
with 211.10, except that structure backfill used in the retained backfill zone will be
paid for as B borrow. Unsuitable foundation materials, if found, will be paid for in
accordance with 211.10. Underdrains for MSE walls and components of an internal
drainage system will be paid for in accordance with 718.10.

Payment will be made under:

530 Pay Item Pay Unit Symbol

Face Panels, Concrete ................................................................ SFT

784
 731.13

Leveling Pad, Concrete ............................................................. LFT

Wall Erection ............................................................................. SFT

The cost of designing the wall system, services including the testing laboratory,
certified testing personnel, and the testing and inspection of the concrete panels shall
be included in the cost of face panels, concrete.

540 The cost of all wall materials including concrete face panels, ground
reinforcement, tie strips, fasteners, joint materials, joint covering, precast or cast-in-
place concrete coping, repair or replacement of face panels damaged or removed due
to backfill placement, and incidentals shall be included in the cost of face panels,
concrete.

The cost of all labor and materials required to prepare the wall foundation, place
the ground reinforcement, and erect the concrete face panels shall be included in the
cost of wall erection.

550 If unsuitable foundation material is encountered in the portion of the foundation

beneath the reinforced backfill zone in a section constructed on original ground or in
a cut section, the cost of removal, replacement, and compaction of new material will
be paid for in accordance with 203 and 211.

If unsuitable foundation material is encountered in the portion of the foundation

beneath the reinforced backfill zone that is constructed on an embankment section that
is constructed under the same contract, the cost of removal, replacement, and
compaction of new material will not be considered for payment.

560 The cost for geotextile used in MSE wall construction shall be included in the cost
of the pay items in this section.

The cost of refilling and refinishing of the core holes from verification coring shall
be included in the cost of face panels, concrete.

The cost of performing the laboratory tests by an approved geotechnical

laboratory for structure backfill or ACBF slag shall be included in the cost of the pay
items in this section.

570 The cost of cutting, altering, or recoating the ground reinforcement at the site shall
be included in the cost of wall erection.

785
 732.01

SECTION 732 – MODULAR CONCRETE BLOCK RETAINING WALL

732.01 Description
This work shall consist of design as required, furnishing materials, and placement
of modular block wall units in accordance with 105.03. The modular block wall unit
shall have ground reinforcement if shown on the plans or required by the manufacturer.

732.02 General Design Requirements

The modular block wall shall consist of an aggregate leveling pad, concrete
10 modular block wall units, and if specified, ground reinforcement elements. Ground
reinforcement shall have sufficient strength, frictional resistance, and quantity as
required by design, and shall be frictionally or mechanically connected to the facing
units.

Modular block wall units shall be constructed as shown on the approved working
drawings based on the requirements herein. The recommendations of the wall system
supplier shall not override the minimum performance requirements shown herein.

The top of the modular block wall shall be designed to prevent the removal of the
20 top course of blocks.

If the wall system provider needs additional information to complete the design,
the Contractor shall be responsible for obtaining such information.

All appurtenances behind, in front of, under, mounted upon, or passing through
the wall such as drainage structures, utilities, or other appurtenances shown on the
plans shall be accounted for in the stability design of the wall.

The modular block wall design shall follow the general dimensions of the wall
30 envelope shown on the plans. The working drawings shall show the location of the
leveling pad at or below the theoretical leveling pad elevation shown on the plans. The
top of the modular block wall unit shall be at or above the top of the wall elevation
shown on the plans.

Cast-in-place concrete will not be an acceptable replacement for modular block

wall unit areas indicated by the wall envelope.

Modular block wall units shall be designed to accommodate a differential

settlement of 1 linear unit in 100. Where shown on the plans, slip joints to
40 accommodate excessive or differential settlement shall be included.

Only one typical modular block face finish shall be used per contract.

732.03 Design Criteria

The maximum modular block wall unit face area shall be 1 sq ft. The minimum
depth of modular block wall units shall be 9 in.

786
 732.03

Modular block wall units shall be dry stacked in a running bond configuration.
Vertically adjacent units shall be connected with an approved shear connection.
50 Approved shear connections consist of steel pins, concrete lips on the blocks, or other
connections as approved by the Engineer.

The internal stability shall be the responsibility of the Contractor. The design for
internal stability shall be in accordance with the AASHTO LRFD Bridge Design
Specifications. The design by the Engineer will consider the external stability of the
modular block wall mass including the applied bearing pressure, overturning, sliding,
and stability of temporary construction slopes.

(a) Geotechnical Considerations

60 The theoretical failure plane within the soil mass shall be analyzed so that the soil-
stabilizing component extends sufficiently beyond the failure plane to stabilize the
material. External loads which affect the internal stability such as those applied
through piling, bridge footings, traffic, crashwall, or slope surcharge, shall be
accounted for in the design. The sizes of all structural elements shall be determined
such that the design load stresses do not exceed the factored stresses shown in the
AASHTO LRFD Bridge Design Specifications.

The internal friction angle, φ, for the internal design of the modular block wall
backfill volume shall be assumed to be 34°. The φ of the backfill behind the modular
70 block wall backfill volume shall be assumed to be 30°. The φ for the internal design
of the foundation soils shall be assumed to be 30°. For the external design parameters,
such as but not limited to, bearing capacity, sliding, overturning, eccentricity, and
global stability, the actual soil strength parameters used shall be obtained from the
geotechnical report.

The minimum embedment at the front face of the wall shall be in accordance with
the AASHTO LRFD Bridge Design Specifications, section 11.10.2.2, and the
minimum embedment depth to the top of the leveling pad shall be at least 3 ft unless
founded on rock. A 4 ft horizontal bench in front of the wall shall be provided for
80 slopes steeper than 4.0H:1.0V.

The factored applied bearing pressures under the stabilized mass for each
reinforcement unit’s length shall be indicated on the working drawings. It shall not
exceed the maximum factored soil bearing resistance shown on the plans. Passive
pressure in front of the wall mass shall be assumed to be zero for design purposes.

(b) Height of Wall for Internal Stability

The wall limits shall be defined by the wall envelope shown on the plans.

90 1. For a wall with a level surcharge, the design height of the

wall, H, shall be measured from the theoretical top of the
leveling pad to the top of the coping or to the gutter line of

787
 732.03

the traffic barrier. The top of the wall shall be the

theoretical top of the face panels only where a coping or
barrier is not used.

2. For a wall with a sloping surcharge, the design height of

the wall, Z, shall be measured from the theoretical top of
the leveling pad to a point above the top of the wall as
100 calculated from the formula as follows:

0.3H tan β
Z=H+
1- 0.3 tan β

where:

β = surcharge slope angle as measured from the

top of the coping, and
H = height of the wall from the theoretical top of
the leveling pad to the top of the coping.

3. For an abutment face, the design height of the wall, H, shall

be measured from the theoretical top of the leveling pad to
the top of the roadway surface.
110
(c) Ground Reinforcement
The ground reinforcement length shall be the controlling length resulting from the
internal or external design or as shown on the plans. All of the ground reinforcement
shall extend to and shall be connected to the modular block wall units.

The ground reinforcement shall be the same length from the bottom to the top of
each wall section regardless of the type of ground reinforcement used. Differing
ground reinforcement elements shall be marked for ease of construction. This element
may be used individually or in a prefabricated grouping.
120
The ground reinforcement for modular block wall sections shall be sized using
the lesser of the factored loads for each specific connection and each specific
reinforcing element. The connection’s applied factored load and effective pullout
length shall be determined in accordance with the AASHTO LRFD Bridge Design
Specifications.

For mats, grids, or strip steel, the minimum zinc coating thickness shall be 2 oz/sq
ft. Such thickness shall be assumed to be 4 mils for purpose of calculation of reduced
structural section.
130
Where the presence of opposing walls limits the length of ground reinforcing, the
design shall account for the reduced length and internal and external stability
calculations shall be made to check for adequate factor of safety.

788
 732.04

732.04 Submittals
The Contractor shall submit working drawings and design calculations in
accordance with 105.02. Wall construction operations shall not begin until the
Contractor receives written notice that the working drawings are approved.

140 (a) The working drawings shall include all details, dimensions,
quantities, cross-sections, and general notes necessary to
construct the wall and shall include, but shall not be limited to
the following:

1. Plan and elevation sheets showing views which detail the

placing position and connection of all ground reinforcing
elements in areas where piling, utility, or other structures
are near the wall.

150 2. Plan sheets of the wall that indicate the offsets from the
construction centerline to the face of the wall at all changes
in horizontal alignment.

3. Elevation views of the wall which shall include the

following:

a. elevations at the top of the wall at all horizontal and

vertical break points at least every 50 ft along the face
of the wall;
160
b. all steps in the aggregate leveling pad;

c. the designation as to the type of modular block wall

unit;

d. the length of ground reinforcement units;

e. the distance along the face of the wall to where changes

in length of the ground reinforcement occur;
170
f. an indication of the original and final ground lines and
maximum bearing pressures.

(b) All modular block wall units shall show all dimensions
necessary to construct the element and the location of soil
reinforcing system devices embedded in the units.

(c) The details for construction of walls around drainage facilities

and the outletting of internal drainage from the modular block
180 wall volume.
789
 732.05

(d) All details of the architectural treatment.

(e) The details for diverting ground reinforcement around

obstructions such as piles, catch basins, landscape plantings
where the bottom of the root ball extends below the top level of
ground reinforcement, and other obstructions.

(f) The details for mechanical connection between the modular

190 block wall unit and the ground reinforcement.

MATERIALS

732.05 Materials
Materials shall be in accordance with the following:

Admixtures for Concrete* ........................................... 912.03

Air Cooled Blast Furnace Slag .................................... 901.09
B Borrow ..................................................................... 211.02
200 Coarse Aggregate, Class A or Higher,
Size No. 91 ........................................................... 904
Coarse Aggregate, Class D or Higher,
Size No. 8 ............................................................. 904
Concrete ...................................................................... 702
Fine Aggregate, Size No. 23........................................ 904
Fly Ash ........................................................................ 901.02
Geogrid, Type III ......................................................... 918.05
Geotextile .................................................................... 918.02
Portland Cement .......................................................... 901.01(b)
210 Structure Backfill ........................................................ 211.03.1
Water ........................................................................... 913.01
* Admixtures in accordance with ASTM C 1372 may be used for the
modular block if approved by the Engineer.

Aggregate for the leveling pad shall be compacted aggregate No. 53 and shall be
in accordance with applicable requirements of 303. Drainage fill used immediately
behind the modular block wall, as shown on the plans, shall be coarse aggregate No.
8 crushed stone in accordance with 904.03.

220 Backfill material used in the modular block wall volume shall be structure backfill
type 3, in accordance with 211. Where ground reinforcement is required, nominal size
aggregate No. 30 shall not be used. The size of the structure backfill selected for use
in the reinforced area of the modular block volume shall remain the same for that
wall’s volume. If coarse aggregate No. 8 is used, and soil, B borrow, structural backfill,
or coarse aggregate No. 53 are to be placed above the coarse aggregate No. 8, a single
layer of geotextile shall be placed on top of the coarse aggregate No. 8 in accordance
with 616.11.
790
 732.05

If ground reinforcement is required, it shall be either steel in accordance with

230 910.07 or geogrid. The ground reinforcement supplied shall be the same type as that
used with the pullout test and shall be consistent throughout the contract work. If the
ground reinforcement is steel, structure backfill shall be in accordance with the backfill
requirements for retaining wall systems contained in 211.03.1.

(a) Concrete Modular Block Wall Units

Concrete modular block retaining wall units shall be in accordance with ASTM C
1372, except for the modifications below, and shall have a minimum compressive
strength of 4,000 psi at 28 days. Modular block wall units utilizing type I or II cement
will be considered acceptable for placement in the wall when 7-day strengths exceed
240 3,500 psi. The modular block wall unit’s compressive strength shall be considered
acceptable regardless of curing age when compressive test results indicate that the
compressive strength is in accordance with the requirements stated above.

Retarding agents, accelerating agents, coloring pigments, or additives containing

chloride shall not be used without approval.

1. Testing and Inspection

a. Material properties shall be in accordance with the

250 requirements of 732.05 in lieu of Section 4.

b. Table 1, “Strength and Absorption Requirements”,

shall be modified to require that the average
compressive strength, when sampled and tested in
accordance with ASTM C 140, of a three CMU
compressive strength sample shall be 4,000 psi with no
individual unit less than 3,500 psi. Maximum
absorption shall be 6%.

260 c. Freeze-thaw durability testing shall be completed in

accordance with Section 8.3 by a laboratory approved
by the Department. Test results on all mix designs used
in the manufacture of modular blocks shall have been
completed in accordance with ASTM C 1372. If a
change to the mix design, such as proportioning or
material source, is desired, the modified mix design
shall be retested for freeze-thaw. A type A certification
in accordance with 916 for the freeze-thaw durability
testing shall be submitted to the Engineer prior to use
270 of the blocks.

d. Sampling and testing of the manufacturer's production

lots will be conducted by the Engineer in accordance

791
 732.06

with ASTM C 140. If the compressive strength test

result does not meet the requirements of 732.05(a), the
production lot units may not be used. The manufacturer
may resample the same production lot in the presence
of the Engineer for retesting. The Engineer will test the
additional samples in accordance with ASTM C 140. If
280 the retested samples meet the requirements of
732.05(a), the production lot may be used. If the
retested samples do not meet the requirements of
732.05(a), all the units from the production lot may not
be used.

2. Rejection
Units shall be subject to rejection due to failure to be in accordance with the
requirements specified above. In addition, the following defects may be sufficient
cause for rejection.
290
a. Defects which indicate imperfect molding.

b. Defects which indicate honeycombed or open texture

concrete.

c. Defects in the physical characteristics of the concrete,

such as broken or chipped concrete, or color variations,
or dunnage marks on the front face due to excessive
form oil or other reasons.
300
The Engineer will determine whether spalled, honeycombed, chipped, or
otherwise defective concrete shall be repaired or be cause for rejection. Repair of
concrete, if allowed, shall be completed in a satisfactory manner. Repair to concrete
surfaces, which are to be exposed to view after completion of construction shall be
subject to approval.

3. Marking
The date of manufacture, the production lot number, and the place mark shall be
clearly scribed on the rear face of each unit or on each shipping pallet.
310
4. Handling, Storage, and Shipping
All modular block wall units shall be handled, stored, and shipped so as to
eliminate the danger of chipping, cracks, fractures, and excessive bending stresses.

(b) Blank

CONSTRUCTION REQUIREMENTS

732.06 General Requirements

320 The wall supplier representative shall provide technical instruction, guidance in
792
 732.10

preconstruction activities including the preconstruction conference, and on-site

technical assistance to the Contractor during construction.

732.07 Foundation Preparation

The foundation for the modular block wall shall be graded level for the width
shown on the plans. Foundation preparation shall otherwise be in accordance with
731.07.

At each foundation level, an aggregate leveling pad shall be provided as shown

330 on the plans.

732.08 Retaining Wall Excavation

Excavation shall be in accordance with 731.08.

732.09 Wall Erection

Modular block wall units shall be stored to minimize contact with the ground or
being covered by standing water. Modular block wall units having face discoloration
shall not be used.

340 The Contractor shall perform the necessary work to verify that the foundation is
at the correct elevation, that the wall is constructed to the correct alignment, and that
the work is in accordance with the specified tolerances.

Modular block wall units shall be placed in successive horizontal lifts in the
sequence shown on the plans as backfill placement proceeds. As backfill material is
placed behind the units, the units shall be maintained in vertical position. Horizontal
alignment tolerances shall not exceed 3/4 in. when measured with a 10 ft straightedge.
Alignment shall be checked at each layer of modular block wall units after the backfill
behind the modular block wall units has been compacted, and the results shall be
350 recorded. Checking of alignments and tolerances shall include verifying that the
modular block wall units are plumb over the entire height of the wall.

Ground reinforcement shall be placed normal to the face of the wall, unless
otherwise shown on the plans and shall be constructed in accordance with 214.04.

732.10 Backfill Placement

Backfill placement shall follow erection of each course of modular block wall
units. All sheeting and bracing shall be removed as the backfilling progresses. Backfill
shall be placed so as to avoid damage or disturbance to the wall materials or
360 misalignment of the modular block wall units. All material for backfill shall be subject
to approval and shall be free from large or frozen lumps, wood, or other undesirable
material. Wall materials that become damaged or disturbed during backfill placement
shall be removed and replaced or corrected as directed. All misalignment or distortion
of the modular block wall units due to placement of backfill outside the limits
described herein shall be corrected as directed.

793
 732.11

The work shall also include backfilling beyond the theoretical length of the
ground reinforcement in accordance with the details shown on the plans, and the
disposal of surplus of unsuitable excavated materials, as allowed.
370
Backfill placement and compaction shall otherwise be in accordance with 731.11.

732.11 Method of Measurement

The measurement of concrete modular block wall units with or without ground
reinforcement and wall erection will be based on the square foot area contained within
the neat line limits of the wall envelope shown on the plans and not that of the wall
system supplier.

Common excavation will be measured by the cubic yard in accordance with

380 203.27(a) to the neat lines shown on the plans. Structure backfill and B borrow will be
measured in accordance with 211.09. Unsuitable foundation materials, if found, will
be measured in accordance with 211.09. Coarse aggregate No. 8 used as drainage fill
will be measured by the cubic yard based on the theoretical volume to the neat lines
as shown on the plans. Compacted aggregate No. 53, and ground reinforcement will
not be measured. Geotextile materials will not be measured. Drainage of the backfill
including piping and geotextile materials used in the drainage system will not be
measured.

732.12 Stockpiled Modular Block Units

390 Partial payment may be made for block wall units stockpiled on the project site or
at the Contractor’s approved storage location. Partial payment will include the
delivered cost of the units, as verified by invoices that include freight charges. The
Contractor shall furnish the invoices. The partial payment will not exceed 75% of the
contract unit price for modular block wall with or without ground reinforcement. Prior
to authorizing partial payment, the Engineer will verify that the units are in accordance
with 732.05(a).

732.13 Basis of Payment

The accepted quantities of modular block wall units with or without ground
400 reinforcement will be paid for at the contract unit price per square foot. Erection of
modular block wall units will be paid for by the square foot. Common excavation will
be paid for in accordance with 203.28. Structure backfill and B borrow will be paid
for in accordance with 211.10. Unsuitable foundation materials will be paid for in
accordance with 211.10. The accepted quantities of coarse aggregate No. 8 used as
drainage fill will be paid for as aggregate for drainage fill at the contract unit price per
cubic yard, complete in place.

Payment will be made under:

410 Pay Item Pay Unit Symbol

Aggregate for Drainage Fill....................................................... CYS

794
 733.03

Modular Block Wall Erection.................................................... SFT

Modular Block Wall with Ground Reinforcement .................... SFT
Modular Block Wall .................................................................. SFT

The cost of designing the wall system, services including the testing laboratory,
certified testing personnel, and the testing and inspection of modular block wall units
shall be included in the cost of the pay items of this section.
420
The cost of materials, ground reinforcement if required, fasteners, cutting or
altering the ground reinforcement at the site, repair or replacement of units damaged
or removed due to backfill placement, compressive-strength retesting if required,
retesting or replacing failed block units, and incidentals shall be included in the cost
of the pay items of this section.

The cost of all labor and materials required for preparing the wall foundation,
compacted aggregate No. 53, coarse aggregate No. 8 placed outside the neat lines as
shown on the plans, replacement materials damaged during backfill placement if
430 required, and erecting the modular block units shall be included in the cost of wall
erection.

The cost of all labor and materials for geotextiles shall be included in the cost of
the pay items of this section.

SECTION 733 – STEEL BIN-TYPE RETAINING WALL

733.01 Description
This work shall consist of furnishing materials and placement of steel bin-type
retaining walls in accordance with 105.03.

MATERIALS

733.02 Materials
10 Materials shall be in accordance with the following:

Fasteners ...................................................................... 910.02(g)1

Steel Bin-Type Retaining Wall Units .......................... 910.08
Structure Backfill ........................................................ 211.03.1, 904.05

Backfill material used in the bin-wall sections shall be type 3 structure backfill in
accordance with 211.

CONSTRUCTION REQUIREMENTS
20
733.03 General
All units shall be fabricated such that units of the same nominal size shall be fully

795
 733.04

interchangeable. Drilling, punching, or drifting to correct defects in manufacture will

not be allowed. Each unit with unauthorized holes shall be replaced. The ends of all
stringers and spacers shall be bolted to corner columns by means of connecting
channels.

The proper curvature for the face of a wall constructed on a curve shall be obtained
through the use of shorter stringers in the front or rear panels of retaining walls as
30 shown on the plans or as otherwise directed.

The wall height and depth may be varied. Two or more retaining wall designs may
be incorporated in the same wall by the use of standard split columns to make the
connection on the step back.

733.04 Foundation Preparation

The foundation for the structure shall be graded level or as shown on the plans.
Prior to wall construction, the foundation, if not in rock, shall be compacted in
accordance with 203. The base of the wall excavation shall be proofrolled with a
40 vibratory roller weighing not less than 10 t, or with other approved compacting
equipment. If unsuitable foundation material is encountered, it shall be removed and
replaced with B borrow in accordance with 211.02 and compacted in accordance with
211.04.

733.05 Retaining Wall Excavation

Retaining wall excavation shall be in accordance with 731.08.

733.06 Backfill Placement

The fill material for the interior of the bin and behind the wall shall be structure
50 backfill placed in layers not to exceed 6 in. in thickness. Backfilling behind the wall
shall progress with the filling of the bins and shall not be carried ahead of the interior
bins. Existing slopes, which are shaped so as to cause a wedge action in the backfill,
shall be benched before backfilling.

The moisture content of the backfill material prior to and during compaction shall
be uniformly distributed throughout each layer. Backfill material shall have placement
moisture content between optimum and -3 percentage points of the optimum moisture
content. Backfill material with placement moisture content in excess of the optimum
moisture content shall be removed and reworked until the moisture content is
60 uniformly acceptable through the entire lift.

Compaction within 3 ft of the back face of the bins shall be achieved by means of
a minimum of three passes with a lightweight mechanical tamper, roller, or an
alternative vibratory system.

Backfill placement shall otherwise be in accordance with 731.11.

796
 734.02

733.07 Method of Measurement

The measurement of steel bin walls will be based on the square foot of area
70 contained within the neat line limits of the wall envelope shown on the plans and not
that of the wall system supplier. Common excavation will be measured in accordance
with 203.27. Structure backfill will be measured in accordance with 211.09.
Unsuitable foundation materials, if found, will be measured in accordance with
211.09.

733.08 Basis of Payment

This work will be paid for at the contract unit price per square foot for binwall,
steel. Common excavation will be paid for in accordance with 203.28. Structure
backfill will be paid for in accordance with 211.10. Unsuitable foundation materials
80 will be paid for in accordance with 211.10.

Payment will be made under:

Pay Item Pay Unit Symbol

Binwall, Steel ............................................................................ SFT

The cost of furnishing, handling, and installing the steel units, including all
materials, bolts, and appurtenances; necessary excavation and structure backfill
90 testing; and all labor, equipment, all necessary incidentals, or replacement of steel
units with unauthorized holes, or those damaged and replaced during construction shall
be included in the cost of the pay item.

SECTION 734 – PERMANENT EARTH RETENTION SYSTEM FOR CUT-

WALL APPLICATION

734.01 Description
This work shall consist of designing and constructing a permanent earth retention
system utilizing a cut-wall application in accordance with 105.03. Cut-wall
applications refer to a class of earth retention systems in which construction of the
system is performed from the top of the wall to the base utilizing either externally or
internally stabilized elements or a combination of both. Geotechnical Engineering
10 Circular No. 2 – Earth Retaining Systems, Report No. FHWA-SA-96-038 provides
further discussion of cut-wall applications.

734.02 Contractor Design Requirements

The permanent earth retention system utilizing a cut-wall application shall be
designed by a professional engineer having experience in the design of at least three
completed permanent earth retention systems involving cut-wall applications. The
permanent earth retention system shall be designed using the procedure described in
the AASHTO LRFD Bridge Design Specifications, or in the FHWA-IF-03-017, Soil
Nail Walls. The required partial safety factors or allowable strength factors for Service

797
 734.02

20 Load Design, SLD, and load and resistance factors for LRFD, shall be in accordance
with the above-referenced publications. The minimum factor of safety for SLD global
stability or minimum required LRFD global stability shall be in accordance with the
above-referenced publications, unless specified otherwise. Structural design of an
individual wall element not addressed in the FHWA report shall be designed in
accordance with the AASHTO specifications. Geometric data and design criteria
including shear strength parameters and unit weights for soil and rock, corrosion
protection, internal and external drainage requirements, horizontal and vertical
alignment of the wall, and all known site and construction constraints, wall facing, and
facing architectural requirements shall be as shown on the plans.
30
(a) Design Calculations
Design calculations shall include, but not be limited to, the following:

1. A written summary report which describes the overall

design.

2. Applicable code requirements and design references.

3. Design cross-section geometry including soil and rock

40 strata and location, magnitude and direction of design
slope, external surcharge loads, and piezometric levels
with the most critical slip surface shown along with the
minimum calculated SLD factor of safety for global
stability or minimum required LRFD global stability soil
resistance to load ratio.

4. Design criteria including the undrained and drained shear

strength parameters and unit weights for soil and rock.

50 5. Unit bond resistances for externally and internally

stabilized elements.

6. Partial safety factors and strength factors for SLD or load

and resistance factors for LRFD used in the design on the
pullout resistance, surcharges, unit weights of soil and
rock, and all materials proposed for the system including,
but not limited to shotcrete, steel and concrete.

7. Seismic design acceleration coefficient.

60
8. Design calculation sheets with the contract number,
designation number, wall location and designation, date of
preparation, initials of designer and checker, page number
shown on each page, and an index page.

798
 734.02

9. Design notes including an explanation of all symbols and

computer programs used in the design.

10. Structural design calculations for all temporary and

70 permanent facing and facing connections, including
consideration of flexural and shear strength of the facing
and all externally stabilized elements, tensile strength of all
headed studs, upper cantilever, minimum reinforcement
ratio, mechanical splices, welds, built-up sections, and
cover and splice requirements.

(b) Working Drawings

The limits of the wall and ground survey data shall be verified before preparing
the drawings. Working drawings shall include all details, dimensions, quantities,
80 ground profiles, cross sections necessary to construct the wall, and the following:

1. A plan view of the wall identifying the following:

a. A reference centerline and elevation datum.

b. The offset from the construction centerline to the

finished face of the wall at its base and at all changes in
horizontal alignment.

90 c. Beginning and ending stations of the wall.

d. Right-of-way and permanent or temporary construction

easement limits, location of all known active and
abandoned existing utilities, adjacent structures, or
other potential interferences.

e. The centerline of each drainage structure or drainage

pipe behind, passing through, or passing under the wall.

100 f. Limit of externally and internally stabilized elements.

g. Subsurface exploratory locations with appropriate

reference base lines to fix the locations of the
explorations relative to the wall.

2. An elevation view of the wall identifying the following:

a. The elevations at the top of the wall, at all horizontal

and vertical break points, and at least every 30 ft along
110 the wall.

799
 734.02

b. Elevations at the base and top of the wall for casting the
facing.

c. Beginning and ending stations of the wall.

d. The distance along the face of the wall to all steps in

the base of the wall.

120 e. All externally and internally stabilized elements as well

as vertical and horizontal spacing.

f. The location of drainage elements and permanent

facing expansion and contraction joints along the wall
length.

g. Existing and finished grade profiles, both behind and in

front of the wall.

130 3. Design parameters and applicable codes.

4. General notes for constructing the wall including

sequencing and all special construction requirements, such
as dewatering, if required.

5. Horizontal and vertical curve data affecting the wall and

control points.

6. Match lines or other details to relate the wall stationing to

140 centerline stationing.

7. A listing of the summary of quantities on the elevation

drawing of each wall showing estimated square feet of
exposed wall face areas and other pay items.

8. Typical sections including staged excavation elevations,

wall elements, and corrosion protection details.

9. Typical details of production and test anchors or nails

150 defining the orientation and dimensional relationships of
the unbonded and bonded lengths.

10. Details, dimensions, and schedules for all externally and

internally stabilized elements, reinforcing bars, steel
welded wire reinforcement, bearing plates, headed studs,
and attachment devices for pneumatically placed mortar,
cast-in-place, or prefabricated facings.

800
 734.03

11. Details and dimensions for appurtenances such as barriers,

160 coping, drainage gutters, and fences.

12. Details for constructing the wall around drainage facilities.

13. Details for terminating the wall and adjacent slope

construction.

14. Facing finishes, color and architectural treatment

requirements for permanent facing elements.

170 (c) Submittals

The Contractor shall submit working drawings and design calculations in
accordance with 105.02.

At least 30 calendar days before the start of the wall construction, the Contractor
shall submit a quality control plan, QCP, for approval. The QCP shall include, but not
be limited to, personnel qualifications, wall construction procedures and sequencing,
a verification testing program, and a performance monitoring program. Work shall not
begin until written notice has been received from the Engineer that the QCP has been
accepted.
180
1. Personnel Qualifications
The field superintendent or field foreman shall have supervised the construction
of a minimum of three completed walls of the same type as that submitted by the
Contractor.

2. Verification Testing Program

The program shall include a verification testing program of all production and test
anchors and nails. The program shall identify the test locations and the type of test,
such as proof, performance, or pullout, testing procedures, acceptance criteria, and
190 load and measuring devices to be used.

MATERIALS

734.03 Materials
Materials shall be in accordance with the following:

Geotextile Under Riprap.............................................. 918.02

Pneumatically Placed Mortar....................................... 708
Reinforcing Bars.......................................................... 703
200 Steel H Piles ................................................................ 915.02
Steel Pipe Piles ............................................................ 915.01
Steel Sheet Piling......................................................... 910.21
WWR, Smooth and Deformed..................................... 910.01
Structural Concrete ...................................................... 702
Structural Steel ............................................................ 910.02
801
 734.04

Structure Backfill ........................................................ 904.05

Uncoated Seven-Wire Strand ...................................... 910.01(b)7

Drainage pipe shall be underdrain pipe in accordance with 715.02(d).

210
CONSTRUCTION REQUIREMENTS

734.04 General Requirements

Excavation and embankment shall be in accordance with 203.

Welding shall be in accordance with 711.32.

734.05 Performance Monitoring During Construction

The program shall identify points of monitoring interest, in accordance with
220 Geotechnical Engineering Circular No. 2 – Earth Retaining Systems, Report No.
FHWA-SA-96-038, and the frequency of monitoring during and following
construction of the wall. The program shall also include a baseline survey for points
of monitoring interest.

The Contractor shall notify the Engineer if indications of ground movement in the
vicinity of the wall, increased size of old cracks, or separation of joints in structures,
foundations, streets, or paved or unpaved surfaces are observed. The Contractor shall
monitor the performance of the wall and movements of buildings, roads, or other
facilities within a distance of three times the excavation depth for the wall. If the
230 Engineer determines that the movements exceed those anticipated for construction, the
Contractor shall take corrective actions necessary to arrest the movement, or make
repairs.

Within 30 days after completion of the work, as-built drawings shall be submitted
to the Engineer. Revised design calculations signed by the professional engineer shall
be provided for all design changes made during the construction of the permanent earth
retention system.

734.06 Performance Monitoring After Construction

240 Performance monitoring by the Contractor shall be done during construction and
for a period of one year from the date the Contractor has been relieved of further
maintenance, as set out in the final acceptance letter from the Department. The
Contractor shall post a warranty bond for the performance monitoring that occurs after
the Contractor has been relieved of further maintenance. The Contractor shall make
evaluations of the test and monitoring data and performance of the wall at the
frequency defined in the approved performance monitoring program. The Contractor,
if necessary during the monitoring period or as directed, shall correct deficiencies in
the capacities of individual elements or take other corrective measures which may be
required to prevent damage or excessive movement of the wall and adjacent facilities.
250 The Contractor shall submit all test and monitoring data to the Engineer on a weekly
basis or as otherwise directed.

802
 735.02

734.07 Method of Measurement

Cut wall will be measured by the square foot of exposed face area of wall above
finished grade as shown on the plans.

734.08 Basis of Payment

The accepted quantities of cut wall will be paid for at the contract unit price per
square foot for cut wall.
260
Payment will be made under:

Pay Item Pay Unit Symbol

Cut-Wall, No. ____ ................................................................... SFT

The costs of all professional services, labor, excavation, structure backfill,

equipment, materials, tests, QCP, and incidentals necessary to design, construct, and
monitor the wall including all drainage required by the wall design and all temporary
270 construction facing or permanent facing, if applicable, and correction required by the
wall design of deficiencies which may be required to prevent damage or excessive
movement of the wall shall be included in the cost of this work. No additional payment
will be made for the costs of providing and taking corrective actions.

SECTION 735 – TEMPORARY WIRE-FACED MECHANICALLY

STABILIZED EARTH RETAINING WALLS

735.01 Description
This work shall consist of the design, furnishing materials, and placement of
temporary wire-faced mechanically stabilized earth retaining walls in accordance with
105.03.

735.02 General Design Requirements

10 A temporary wire-faced MSE wall shall consist of wire-facing elements, ground
reinforcement elements mechanically connected to the wire-facing elements, and a
drainage system if required. Concrete face panels will be required for the lower course
of the wall if shown on the plans. Ground reinforcement shall have sufficient strength,
frictional resistance, and quantity as required by the design.

A temporary wire-faced MSE wall shall be constructed in accordance with the

approved plans and panels working drawings based on the requirements herein. The
recommendations of the wall system supplier shall meet or exceed the minimum
performance requirements included herein.
20
If appurtenances interfere with connecting ground reinforcement to face panels,
back up panels shall be provided.

803
 735.03

The top of the wire-facing elements shall be at or above the top of the wall
envelope shown on the plans.

The maximum dimensions for wire-face panels shall be limited to 2 ft vertical and
8 ft horizontal.

30 735.03 Design Criteria

The design life of the wall shall be 36 months. The minimum allowable yield
stress for reinforcement shall be 65 ksi. The maximum allowable stress in the reduced
section after sacrificial steel has been removed at the end of the design life shall be
0.55Fy for WWR. The maximum allowable stress may be increased to 0.77Fy if the
design life does not exceed 36 months. The reduced section of ground reinforcement
shall be limited to the allowable stress shown above at the end of the 36-month design
life.

The connections of the ground-reinforcing steel to the wire-facing shall not be

40 more than 24 in. apart vertically.

The design shall otherwise be in accordance with 731.02 and 731.03.

735.04 Submittals
The Contractor shall submit working drawings in accordance with 105.02. The
Contractor shall submit design calculations in accordance with 105.02 and the
following additional requirements. In case of discrepancy, the requirements listed
below supersede those listed in 105.02. Design calculations shall show the complete
design of the temporary wire-faced wall. Calculations may be in either longhand or
50 computer-printout format and shall follow a systematic and logical methodology. A
summary sheet that shows design assumptions and their source, controlling parameters
and load cases, and other pertinent input and output information shall be attached to
the calculations package. Wall construction operations shall not begin until the
Contractor receives written notice that the working drawings are approved.

(a) The working drawings shall include all details, dimensions,

quantities and cross sections necessary to construct the wall.
They shall include, but shall not be limited to, that listed in
731.04(a) and (b).
60
(b) Wire-facing details shall show all dimensions necessary to
construct the element, all wire in the element, and the location
of ground-reinforcing-system devices attached to the wire-
facing.

MATERIALS

735.05 Materials
Materials shall be in accordance with the following:
804
 735.07

70
Admixtures for Use in Concrete .................................. 912.03
Air-Cooled Blast-Furnace Slag ................................... 901.09
Alignment Pins ............................................................ 910.07(d)
B Borrow ..................................................................... 211.02
Coarse Aggregate, Class A or Higher,
Size No. 8 or 91 .................................................... 904
Components of MSE Retaining Walls......................... 901.10
Concrete, Class A ........................................................ 702
Fine Aggregate, Size No. 23........................................ 904
80 Fly Ash ........................................................................ 901.02
Geotextile for Underdrains .......................................... 918.02
Joint Spacers and Joint Covering................................. 901.10(b)
PCC Components ........................................................ 901.10
Portland Cement .......................................................... 901.01(b)
Rapid Setting Patch Materials ..................................... 901.07
Reinforcing Bars.......................................................... 910.01
Steel Components ........................................................ 910.07
Steel WWR, Smooth ................................................... 910.01(b)5
Water ........................................................................... 913.01
90
Backfill material used in the temporary wire-faced MSE wall volume shall be type
3 structure backfill in accordance with 211 with the exception that nominal size
aggregate No. 30 shall not be used.

All retention fabric or filter cloth shall be geotextile for use with underdrains.

The Contractor shall supply the MSE retaining wall components described above,
including wire-facing, concrete face panels, retaining strips or mesh, tie strips,
fasteners, earth-retention materials, drainage system components, and all necessary
100 incidentals, through a manufacturer shown on the Department’s list of approved
retaining wall systems.

CONSTRUCTION REQUIREMENTS

735.06 General Requirements

Foundation preparation shall be in accordance with 731.07. Retaining-wall
excavation shall be in accordance with 731.08.

735.07 Wall Erection

110 The wall system components shall be constructed in accordance with the wall
system supplier’s recommendations and construction manual.

The Contractor shall perform the necessary work to verify that the foundation is
at the correct elevation, that the wall is constructed to the correct alignment, and that
the work is in accordance with the specified tolerances.

805
 735.08

Ground reinforcement shall be placed normal to the face of the wall, unless
otherwise shown on the plans or as directed. Prior to placement of the ground
reinforcement, backfill shall be placed and compacted in accordance with 731.11.
120
Where shown on the plans, backing mats shall be placed behind the wire-facing.

Where shown on the plans, galvanized screens with openings not exceeding 1/2
in. shall be placed behind the wire-facing to retain the earth.

735.08 Method of Measurement

The measurement of temporary wire-facing and temporary wall erection will be
based on the square foot of area contained within the neat line limits of the wall
envelope shown on the plans and not that of the wall system supplier.
130
Common excavation will be measured in accordance with 203.27. Structure
backfill and B borrow will be measured in accordance with 211.09. Unsuitable
foundation materials, if found, will be measured in accordance with 211.09. If
unsuitable foundation material is encountered in the portion of the foundation beneath
the reinforced backfill zone in a section constructed on original ground or in a cut
section, the removal, replacement, and compaction of the new material will be
measured in accordance with 203.27 and 211.09.

Geotextile materials will not be measured. Drainage of the backfill including

140 piping, aggregates, and incidentals will not be measured.

735.09 Basis of Payment

The accepted quantities of temporary wire-facing and temporary wall erection
will be paid for at the contract unit price per square foot. Common excavation will be
paid for in accordance with 203.28. Structure backfill and B borrow will be paid for
in accordance with 211.10. Unsuitable foundation materials will be paid for in
accordance with 211.10.

Payment will be made under:

150
Pay Item Pay Unit Symbol

Temporary Wall Erection .......................................................... SFT

Temporary Wire-Facing ............................................................ SFT

The cost of all MSE retaining wall components including wire-facing elements,
concrete face panels, ground reinforcing, tie strips, fasteners, soil retention materials,
repair or replacement of wire-facing elements damaged or removed due to backfill
placement, and incidentals shall be included in the cost of temporary wire-facing.
160

806
 737.02

If unsuitable foundation material is encountered in the portion of the foundation

beneath the reinforced backfill zone in a section constructed on original ground or in
a cut section, the cost of removal, replacement, and compaction of new material will
be paid for in accordance with 203.28 and 211.10.

If unsuitable foundation material is encountered in the portion of the foundation

beneath the reinforced backfill zone that is constructed on an embankment section that
is constructed under the same contract, the cost of removal, replacement, and
compaction of new material will not be considered for payment.
170
The cost of geotextiles shall be included in the cost of the pay items in this section.

The cost of all labor and materials required to prepare the wall foundation, to place
the ground reinforcement, and to erect the concrete face panels shall be included in the
cost of temporary wall erection.

The cost of labor and materials required to provide for the drainage of the backfill
including piping, aggregates, or geotextile materials shall be included in the cost of
temporary wire-facing.
180
The cost of performing the laboratory tests by an approved geotechnical
laboratory for structure backfill or ACBF slag shall be included in the cost of the pay
items in this section.

The cost of all labor and materials for geotextile materials used shall be included
in the cost of the pay items in this section.

The cost of cutting, altering, and recoating of the ground reinforcement at the site
shall be included in the cost of temporary wall erection.

SECTION 736 – BLANK

SECTION 737 – WELDED WIRE REINFORCEMENT, WWR

737.01 Description
This work shall consist of furnishing and placing WWR as an alternative to
furnishing and placing reinforcing bars in concrete superstructures, reinforced
concrete bridge approaches, crash walls, and cast-in-place retaining walls in
accordance with 105.03.

MATERIALS
10
737.02 Materials
Materials shall be in accordance with the following:

807
 737.03

Deformed and Smooth Steel WWR............................. 910.01(b)5

CONSTRUCTION REQUIREMENTS

737.03 Design Requirements

The nominal yield strength shall be the minimum as specified for the grade of
20 steel selected, except that the maximum nominal yield strength used for design
purposes shall not exceed 75 ksi. The nominal yield strength shall not be less than 65
ksi for smooth WWR and 70 ksi for deformed WWR. The area of steel in the
longitudinal and transverse directions may be reduced in proportion to the nominal
yield strength specified for the grade of steel up to the maximum allowable. For
purposes of crack control, spacing of reinforcement in the WWR sheet shall not be
greater than 8 in. in either direction.

If the plans show uncoated reinforcing bars, the Contractor shall use uncoated
WWR. If the plans show epoxy coated reinforcing bars, the Contractor may elect to
30 supply either epoxy coated or galvanized WWR.

737.04 Working Drawings

Working drawings shall be submitted for approval in accordance with 105.02.
Fabrication shall not begin until the working drawings are approved.

737.05 Fabrication
WWR shall be cut and bent to the shapes shown on the working drawings. All
WWR shall be cold bent, unless otherwise approved by the Engineer. Hook
dimensions and diameters of bends shall be as shown on the working drawings. WWR
40 partially embedded in concrete shall not be field bent, except as shown on the approved
working drawings or allowed by the Engineer. Coated WWR shall not be field cut,
unless allowed by the Engineer. If allowed, field cutting of coated WWR shall be
performed using hydraulic-powered or friction cutting tools to minimize coating
damage and field touch-up. Field cut coated WWR shall be repaired with compatible
patching material that is deemed suitable for repairs in the field. Flame cutting of
coated WWR will not be allowed.

737.06 Handling and Storage

All WWR shall be handled and stored by methods that will not damage the coating
50 or WWR, and in accordance with the applicable requirements of 703.04. Bundles shall
not be dropped or dragged. WWR shall be transported and stored so as to not damage
the applied coating. The coated WWR shall not be exposed to fire or flame.

Prior to placement of concrete, all WWR shall be free from dirt, loose rust or
scale, mortar, paint, grease, oil, or other materials that can reduce bond. Coated WWR
shall be free from cracks or laminations. For uncoated WWR, bonded rust, surface
irregularities, or mill scale will not be cause for rejection, provided the minimum

808
 737.08

dimensions, cross sectional area, and tensile properties of the WWR specimen satisfy
the physical requirements for the size and grade of WWR specified.
60
737.07 Placing and Securing
WWR shall be placed as shown on the approved working drawings and held in
position during the placing and finishing of concrete. WWR shall be lapped and tied
around the perimeter of each sheet in order to maintain proper positioning of the
WWR. Lap splices shall have a minimum of two ties per spliced length. Unless
otherwise shown on the approved working drawings, WWR sheets shall overlap a
minimum of 8 in. in each direction to make a splice. Plastic or wire bar supports, such
as chairs and bolsters, shall be in accordance with the requirements herein and industry
practice as described in the Wire Reinforcing Institute, WRI, WWR-500, Manual of
70 Standard Practice. All metal bolsters or chairs which bear against the forms for
exposed surfaces shall be equipped with snug fitting, high density, polyethylene tips
which provide 1/2 in. minimum clearance between the metal and an exposed surface.
The spacing of slab bolster rows and high chair rows for deck slabs shall be as
described in the WRI WWR-500, Manual of Standard Practice unless otherwise
directed. For epoxy-coated WWR, tie wires, chair and bar supports, and metal clips
shall be epoxy, plastic, or nylon coated. For galvanized WWR, tie wires, chair and bar
supports, and metal clips shall be plastic coated or hot dipped galvanized after
fabrication in accordance with ASTM A 1060. Tie-down bars shall be placed as shown
on the approved working drawings. With the exception of tie-down bars, tack welding
80 will not be allowed, unless shown on the approved working drawings.

WWR shall be supported in its specified position by use of plastic or wire bar
supports, supplementary tie-down bars, side-form spacers, or other approved devices.
Such devices shall be placed at intervals so as to maintain the WWR cover as shown
on the approved working drawings. Platforms for the support of workers and
equipment during concrete placement shall be supported directly by the forms and
shall not alter the positioning of the WWR.

737.08 Repair of Coated WWR

90 All damaged, cut, or otherwise compromised areas of the coating shall be
repaired.

(a) Epoxy-Coated
In addition to the requirements of ASTM A 884, all visible damage, including but
not limited to scratches, nicks and cracks to the epoxy coating caused during shipment,
storage, or placement shall be repaired on the project site with approved patching
material. Ends of WWR that have been sheared, sawed, or cut by other means shall be
coated with approved patching material. Areas on the WWR sheets and tie-down bars
damaged due to welding shall be repaired with approved patching material. Patching
100 of damaged areas shall be performed in accordance with the patching material
manufacturer’s recommendations. If the damaged surface area exceeds 10% of the
total WWR sheet surface area, the sheet shall be removed and replaced with an
acceptable sheet. All patching material shall be fully cured prior to placing concrete.

809
 737.09

Patching material shall be compatible with the epoxy coating, deemed inert in
concrete, and deemed suitable for repairs in the field. Patching material shall be
identified on the container as satisfying ASTM A 775, Annex A2, or shall be
accompanied by a type C certification in accordance with 916 certifying that the
material satisfies or exceeds the requirements of Annex A2.

110 (b) Galvanized

All visible damage, including but not limited to scratches, nicks and cracks to the
galvanized coating caused during shipment, storage, or placement shall be repaired on
the project site in accordance with ASTM A 1060. Ends of WWR that have been
sheared, sawed, or cut by other means shall be coated. Areas on the WWR sheets and
tie-down bars damaged due to welding shall be repaired and recoated. Field coating of
damaged areas shall be performed in accordance with the coating manufacturer’s
recommendations. Galvanized coating shall be in accordance with ASTM A 1060. It
shall be applied to achieve a dry film equal to or exceeding that designated in ASTM
A 1060. All touchup coating material shall be fully cured prior to placing concrete.
120
737.09 Final Inspection
After being placed, WWR shall be subject to approval of the Engineer before
beginning concrete placement. Concrete placed prior to approval of the WWR will be
subject to rejection and removal.

737.10 Method of Measurement

This work will not be measured for payment.

737.11 Basis of Payment

130 The accepted quantity for payment will be the quantity for reinforcing bars or
epoxy-coated reinforcing bars shown on the plans. This work will be paid for as
reinforcing bars or epoxy-coated reinforcing bars in accordance with 703.08,
regardless of whether the WWR design results in a reinforcement weight that is
different from that shown on the plans.

If galvanized WWR is supplied, it will be paid for as epoxy-coated reinforcing

bars.

The cost of tie wires, chair and bar supports, metal clips, spacers, or other
140 mechanical means used for fastening or holding WWR in place, and laps shall be
included in the cost of WWR. The cost of epoxy-coating materials or galvanizing
materials and repair of damaged or removed coating materials on WWR and on tie
wires, chair and bar supports, metal clips, spacers, or other mechanical means used for
fastening or holding WWR in place, and laps shall be included in the cost of WWR.

If reinforcing bars or epoxy-coated reinforcing bars are not paid for separately,
but instead included in the cost of a pay item, and WWR is substituted for reinforcing
bars or epoxy-coated reinforcing bars, the WWR will not be paid separately, but shall
be included in the cost of the pay item.

810
 801.02

DIVISION 800 – TRAFFIC CONTROL DEVICES AND LIGHTING

SECTION 801 – TRAFFIC CONTROLS FOR CONSTRUCTION AND

MAINTENANCE OPERATIONS

801.01 Description
This work shall consist of furnishing, placing, and maintaining signs, barricades,
temporary pavement markings, and other traffic control devices at construction and
maintenance operations in accordance with 105.03.

MATERIALS
10
801.02 Materials
Materials shall be in accordance with the following:

Automated Flagger Assistance Devices ...................... 923.08

Coarse Aggregate, Class D or Higher,
Size No. 73 ........................................................... 904
Construction Warning Lights ...................................... 923.03
Delineator Posts ........................................................... 910.15
Delineators................................................................... 926.02
20 Field Paint ................................................................... 909.04
Flashing Arrow Sign.................................................... 923.04
Flexible Delineator Posts ............................................. 926.01
Pavement Marking Materials....................................... 921
Portable Changeable Message Sign ............................. 923.05
Steel Posts ................................................................... 910.14
Temporary Barrier Delineator ..................................... 926.02(d)
Temporary Highway Illumination Materials ............... 807
Temporary Panel Signs................................................ 919.01
Temporary Pavement Marking Tape ........................... 923.01
30 Temporary Raised Pavement Markers......................... 923.02
Traffic Signal Materials and Equipment...................... 922
Traffic Signs ................................................................ 802
Tubular Marker............................................................ 923.07
Wood Sign Posts ......................................................... 911.02(e)
Worksite Speed Limit Sign Assembly......................... 923.06

Non-ground mounted temporary traffic sign backing material and supports shall
both be certified to meet NCHRP 350 crash test standards and approved for use by the
FHWA. A copy of the FHWA acceptance letter shall be provided to the Engineer upon
40 request. Roll-up materials will not be allowed except as specified in 801.16.

The reflective sheeting type used for construction signs, channelizing and
delineation devices such as drums, tubular markers, vertical panels, and 42 in. cones,

811
 801.03

shall be the same for the entire project and shall be in accordance with 919.01(b)1.
The background for all construction signs shall be fluorescent orange reflective
sheeting.

Steel sign posts need not be galvanized.

50 Wood posts for temporary panel signs shall be dense southern yellow pine or
design calculations shall be provided to the Engineer identifying the type of wood and
verifying the location and size of the holes to be drilled through the posts to provide
break-away capability.

All temporary traffic control devices which will become the property of the
Department shall be a new product at the time of final acceptance.

The basis for use for traffic paint; durable pavement marking materials; temporary
marking tape type II; glass beads; barrels; barricades; construction warning lights;
60 steel posts; temporary panel signs; traffic signs, except non-ground mounted signs;
tubular markers; and wood sign post used for temporary traffic control will be visual
inspection.

The connecting bolt or threaded rod used to connect adjoining sections of

temporary barrier wall shall have a tensile strength of 120,000 psi. The spacers used
between adjoining sections of temporary barrier wall shall be in accordance with
ASTM A 36 with a tensile strength of 58,000 psi.

CONSTRUCTION REQUIREMENTS
70
801.03 General Requirements
The applicable requirements of the MUTCD shall apply to the installation and
materials for traffic control devices subject to the requirements of 107.08 and 107.12.
When the plans do not include a maintenance of traffic plan, the Engineer will provide
such a plan to the Contractor. The Contractor shall be responsible for the field layout,
placement, operation, maintenance, and removal of temporary traffic control devices.
A worksite traffic supervisor certified by the American Traffic Safety Service
Association, ATSSA, or approved equal certifying organization, shall direct all field
layout, placement, operation, maintenance, and removal of temporary traffic control
80 devices. The certified worksite traffic supervisor, CWTS, shall ensure that all traffic
control devices, except temporary concrete barrier, meet acceptable standards as
outlined in the plans, specifications, and ATSSA’s “Quality Standards for Work Zone
Traffic Control Devices” prior to installation. The CWTS shall also, prior to
installation, ensure that all traffic control devices can be installed in accordance with
the plans, specifications, and the MUTCD. All problems shall be reported to the
Engineer so a resolution can be worked out prior to installation. The field layout will
be reviewed and concurred with by the Engineer prior to placement of any temporary
traffic control devices. The CWTS shall be present for the initial setup and all phase
changes during the life of the project. The CWTS may designate responsible

812
 801.03

90 Contractor personnel to perform day to day operation and maintenance of the

temporary traffic control devices. These responsible personnel shall work under the
direction of the CWTS and their names shall be given to the Engineer on the project.
A copy of the CWTS’s certification shall be provided to the Engineer prior to the start
of construction or placement of temporary traffic control devices or if the worksite
traffic supervisor changes.

Regulatory control devices shall be erected only as directed.

Advisory speeds to be posted will be determined by the Department.

100
The names and telephone numbers of the superintendent and one other responsible
employee shall be furnished. Such employees shall be on call or available at night, on
weekends, or during other non-working periods to repair or replace all traffic control
devices which may become damaged or inoperative.

When traffic lanes are restricted and when specified as a pay item, a patroller shall
inspect and maintain traffic control devices. The patroller shall patrol the construction
zone and shall immediately correct, maintain, and repair traffic control devices or
notify the Contractor designated persons for immediate repair to such traffic control
110 devices. A full time patroller shall be on duty during periods when work is not in
progress.

Temporary traffic control devices shall be maintained to ensure visibility and to

protect the public. All reflective sheeting backgrounds and lights shall be kept clean
of foreign matter. The Contractor shall complete and submit a “Traffic Control Device
Report” when a temporary traffic control device has been installed, removed,
relocated, repaired, or at a minimum of once per week based on field observations.
This report is supplied in the Proposal Book for the contract and is to ensure that the
traffic control devices are looked at daily. The report shall be completed or reviewed
120 by the CWTS. Each report shall be signed by the person who filled it out and initialed
by the CWTS that it was reviewed. The Engineer will sign and date the report when
received. The Engineer will not be responsible for the report’s completeness and
accuracy.

The location by reference post and the date and time of operation of Temporary
Worksite Speed Limit sign assemblies shall be recorded daily on a form provided by
the Department. The completed report shall be submitted weekly to the Engineer. The
report shall be completed and signed by the CWTS or their designee and shall be
reviewed by the CWTS for completeness and accuracy.
130
Except for construction warning lights and temporary signals, the ATSSA
brochure titled Quality Standards for Work Zone Traffic Control Devices will be used
as a guide to determine if temporary traffic control devices are Acceptable, Marginal,
or Unacceptable as defined in the brochure. Upon initial setup and phase changes of
temporary traffic control devices, all individual devices shall be of the Acceptable

813
 801.04

classification. A device not completely covered or removed when the message does
not apply or when directed, will be considered unacceptable.

A temporary traffic control device will be deemed to be in non-compliance when

140 considered Unacceptable. A type of temporary traffic control device will be deemed
to be in non-compliance when 25% or more of the individual devices are considered
Marginal. Damages may be assessed in accordance with 105.14 for non-compliance.

Non-compliance of construction warning lights will be in accordance with 801.14.

All barricades, signs, or flashing arrow signs shall be moved from one location
and re-erected at another location as shown on the plans or as directed.

Traffic shall be maintained for maintenance activities or for HMA resurface work.
150 The Contractor shall have an extra set of construction signs and an extra flashing arrow
sign on the project site so that the taper may be moved forward without suspending
the operations and clearing the work area. Additional traffic control devices shall be
furnished for situations determined to be more complex, for protection in hazardous
areas, and when traffic conditions warrant.

All non-fixed signs shall be removed at the completion of each day’s operations.
All fixed signs shall remain in place until all temporary pavement markings have been
removed. All lanes shall be open to normal traffic during non-daylight hours. If a
traffic lane is directed to remain closed during non-daylight hours, traffic shall be
160 maintained on the remaining lanes as shown on the plans.

Where two-way traffic is to be maintained on a one-way pavement, and where the

existing shoulders on such roadway are earth, aggregate No. 73 shoulders shall be
compacted in accordance with 303.06 as shown on the plans. Compacted aggregate
shoulders shall remain in place unless subsequent construction activities on the
contract require its removal.

Temporary drainage structures, temporary concrete median barrier units, and

other temporary devices required and used for traffic maintenance shall remain the
170 property of the Contractor.

801.04 Construction Signs

Construction signs shall include the typical sign standards or posts which support
the sign, all necessary hardware, and specified construction warning lights.

A route or lane closure notice sign shall consist of a construction sign type A, in
accordance with 801.04(a), which indicates route or lane closure. The sign shall be
mounted for a maximum of 14 calendar days and a minimum of seven calendar days
before the closure date shown on the sign. The sign shall be removed when the route
180 or lane is closed.

814
 801.05

Trailers in accordance with 910.14(f) may be used as supports for portable

construction signs. The trailer shall be located to hold the sign in a proper position.
The position of the tongue shall be so as to cause no hazard to traffic. Wheel chocks
other than sandbags shall not be used. The tongue may be pinned to reduce
wind-induced rolling if designed to pull up or break from vehicle impact. During non-
working hours, trailers with signs that do not apply to existing conditions shall be
stored in accordance with 107.08(c).

190 Sign posts and their foundations shall be located and constructed to hold signs in
a proper position; to resist swaying, turning, or displacement; and minimize the hazard
to motorists. No rigidly fixed sign supports will be allowed in exposed areas where it
would be practicable to utilize a breakaway or yielding type design. Signs shall be
completely covered or removed when the message does not apply.

If the work on a project, or a portion thereof, is not active, and the roadway is
open to unrestricted traffic, construction signs may be removed until work resumes.
Removal of such signs shall not relieve the Contractor of responsibilities or liabilities
described elsewhere herein.
200
(a) Type A
A type A sign shall consist of a construction sign as detailed in the MUTCD or on
the standard drawings which is 9 sq ft or more in area.

(b) Type B
A type B sign shall consist of a construction sign as detailed in the MUTCD or on
the standard drawings which is less than 9 sq ft in area.

(c) Type C
210 A type C sign shall consist of a construction sign which is not detailed in the
MUTCD or on the standard drawings and which is 9 sq ft or more but less than 33 sq
ft in area.

(d) Type D
A type D sign shall consist of a construction sign which is not detailed in the
MUTCD or on the standard drawings and which is less than 9 sq ft.

(e) Temporary Panel Sign

A temporary panel sign shall consist of a sign fabricated and constructed in
220 accordance with 919.01 and which is greater than 33 sq ft. Temporary panel signs shall
be mounted on wood posts as shown on the plans or as approved by the Department.
External bracing shall not be used.

801.05 Detour Route Marker Assembly

Detour route marker assemblies shall be on a single post for a single route or may
be on multiple posts for multiple routes. When two routes are being detoured across a
common roadway, each route shall be shown by a separate detour route marker

815
 801.06

assembly. A detour route marker assembly-multiple route shall be used for three or
more routes across a common roadway.
230
801.06 Road Closure Sign Assembly
Road closure sign assemblies shall be used at each road closure location where
type III-A barricades or type III-B barricades are used. Road closure sign assemblies
shall not be used within lane closures where adjacent lanes remain open to traffic,
unless otherwise directed. Road closure sign assemblies may be required at other
locations as directed.

Permanent road closure sign assemblies shall be left in place after the contract is
completed and shall become the property of the Department. They shall be installed
240 just prior to final acceptance of the contract. Supports shall be painted with white field
paint for wood.

801.07 Barricades
Barricades shall include rails, posts, and all incidentals necessary to complete this
part of the work.

High intensity reflective sheeting shall be placed on specified rails of all

barricades. The colors for temporary barricades shall be orange and white, and for
permanent barricades red and white.
250
All type III barricades shall be skid mounted within pavement, shoulder, or
sidewalk areas, and on ground mounted posts in all other areas. Type III barricades
shall be used on all slopes which are 3:1 or flatter for roadway closures.

(a) Type III-A Barricade

The type III-A barricade shall have rails which are reflectorized on one side and
shall be used for roadway closures and lane closures where traffic can approach from
only one side.

260 (b) Type III-B Barricade

Type III-B barricades shall have rails which are reflectorized on both sides and
shall be used for roadway closures and lane closures where traffic can approach the
barricade from both sides.

(c) Permanent Type III Barricade

Permanent type III barricades shall be 10 ft sections and shall be left in place after
the contract is completed, and shall become the property of the Department. Permanent
type III barricades shall be installed just prior to final acceptance of the contract. All
non-reflectorized wood and non-galvanized steel shall be painted with white field
270 paint. Such barricades shall otherwise be in accordance with 801.07(a).

801.08 Cones and Tubular Markers

Cones shall be made of a material to withstand impact without damage to striking

816
 801.09

vehicles. They shall have a substantial base to restrict overturning. Cones and tubular
markers shall be as shown on the plans.

Cones shall be used only during temporary activities where portability is

advantageous and they remain in place and do not create a hazard to traffic. The use
of cones in lieu of drums will be allowed as shown on the plans except cones shall not
280 be used for interstate lane restrictions.

Tubular markers shall be used for separating two-lane two-way traffic as shown
on the plans or as directed.

Cones and tubular markers shall be secured in place either by weighting or

adhesives. The use of metal bases will not be allowed.

801.09 Drums
Drums shall be molded orange polyethylene.
290
The shape of the drum shall appear basically cylindrical to the motorist from any
direction in any given application. The top outside diameter shall not exceed the
bottom outside diameter. Drums shall be multisided, elliptical or have a flattened side
to inhibit rolling.

The top section of the drum shall have at least one construction warning light
mounting bracket. The minimum drum height is exclusive of lifting handles or
construction warning light mounting brackets.

300 The drums shall stand on end, be stable against overturning, and shall be internally
or externally ballasted to resist wind speeds of up to 50 mph and gusts created by
traffic. The weight of the ballast shall be 45 to 55 lb. The top of the drum shall be free
from openings. Internally ballasted and externally collar ballasted drums shall not be
mixed in each continuous set-up.

Internal ballast shall be sandbags, a molded plastic base filled with sand and
closed with a locking cover, or a solid rubber base. The internal ballast shall be placed
in the lower 1/4 of the drum. The ballast device shall be self-draining.

310 The external ballast shall be two rubber tire base collars. The tire base collars shall
have a circumferential contact with the road surface. The maximum diameter of the
tire base collar shall not exceed 36 in. The height of two tire base collars at the outside
edge shall not exceed 5 in. The rubber ballasting collars shall be clean cut, proper in
size, black in color, and not curved up at the edges. The interior and exterior
circumference of the collar shall not be slit or cut. Drums which are external collar
ballasted shall not be used in situations where the width of the collar interferes with
proper placement of the drum. The Department’s Guidelines for External Ballast will
be used for determining acceptability of rubber tire base collars.

817
 801.10

320 Upon impact by a vehicle traveling at a speed of 55 mph, the drum and ballast
device shall be of a type that enables the body of the drum to separate from the base,
thus allowing vehicles to easily pass over the base.

Construction warning lights shall be used in accordance with 801.14 and as shown
on the plans and shall be securely fastened to the mounting brackets. Signs shall not
be mounted on drums.

Permanent drums shall be left in place after the contract is complete, and shall
become the property of the Department. They shall be installed just prior to final
330 acceptance of the contract.

801.10 Temporary Traffic Barriers

Temporary traffic barrier shall be one of the following four types as shown on the
plans.

Type 1
Type 1 temporary traffic barriers shall be used to separate two-way traffic and
shall be precast concrete in accordance with applicable requirements of 707 and 602
and as shown on the plans. Type 1 barriers may also be used to separate traffic from
340 the work zone. The surfaces of individual precast units shall vary no more than 1/4 in.
in 10 ft from the specified cross section, as measured from a longitudinal straightedge.
The maximum variation in the vertical and horizontal alignment of adjacent units shall
be 1/4 in. across the joint, as measured from a 10 ft longitudinal straightedge. Sections
that have obvious defects or visual cracks shall not be used. Sections that develop any
of these conditions during the contract shall be repaired with concrete or replaced
within a reasonable amount of time.

Type 1 barrier units precast prior to 2003 shall not be used after January 1, 2012.
Units precast after March 1, 2003 shall be clearly marked with the name or trademark
350 of the manufacturer, the year of manufacture, and “INDOT”. The markings shall be
indented on an end or on the top of each barrier section. Units precast after January 1,
2007 shall be from the Department’s list of Certified Precast Concrete Producers.

Type 2
Type 2 barriers may be used to separate traffic from the work zone. Type 2
temporary traffic barriers shall meet the appropriate test level 2 or 3 NCHRP 350 crash
test standards and shall be approved for use by the FHWA. A 350 crash test letter of
approval from the FHWA shall be provided the Engineer prior to placing the unit. The
unit selected shall be appropriate for the location considering the maximum posted
360 speed limit on the project and the allowable area for deflection. The unit shall be
installed according to the manufacturer’s recommendations.

If concrete barriers are used as type 2 barriers, they shall be in accordance with
the requirements for type 1 barriers.

818
 801.10

Type 3
Type 3 temporary traffic barriers shall be those type 1 temporary traffic barriers
that are to be left in place at the completion of the contract and shall become the
property of the Department. They shall be in like-new condition at the completion of
370 the contract. All necessary delineation and required anchor systems shall be left in
place.

Type 4
Type 4 temporary traffic barriers shall be those types that are intended to be
readily moveable to accommodate the shifting of traffic lanes on a daily basis to better
facilitate the changing volumes of traffic during the peak hours of a day. Type 4
temporary traffic barriers shall meet the appropriate test level 3 NCHRP 350 crash test
standards and shall be approved for use by the FHWA. A 350 crash test letter of
approval from the FHWA shall be provided the Engineer prior to placing the unit.
380
(a) Placement
Temporary traffic barriers shall be located as shown on the plans or as directed.
Temporary traffic barriers used to close a lane of traffic shall be flared at the rates as
shown on the plans for the applicable regulatory speed within the construction zone.
If field conditions are such that the required flare rate cannot be utilized, the tapered
alignment may be altered, with approval, to a 10:1 flare rate with a 20 ft minimum
offset from the edge of the through traffic lane to the approaching end of the flared
temporary traffic barrier. If field conditions are such that that the 10:1 flare rate cannot
be utilized, the tapered alignment may be further altered, with approval, to a 6:1 flare
390 rate with the 20 ft minimum offset. Flare rates for ends of temporary traffic barriers at
locations where a lane of traffic is not being closed to traffic or where the lane has
already been closed shall be the same as above, however the minimum offset from the
edge of the through traffic lane may be 10 ft. The use of flare rates sharper than those
shown on the plans may require additional traffic control devices as directed.

Type 2 barriers shall not be intermixed with type 1 or type 3 barriers in any run.
Type 2 barriers from different manufacturers shall not be intermixed in any run.

(b) Connection
400 Type 1 and type 3 barrier sections shall be connected as follows:

1. The adjacent barrier sections shall be placed end to end,

with sufficient overlapping of the smooth bar hooks to
allow placement of the connecting bolt or threaded rod and
the top spacer.

2. The adjacent barrier sections shall then be moved in

opposite directions for a sufficient distance to develop the
maximum contact between the smooth bar hooks and the
410 connecting bolt or threaded rod.

819
 801.10

3. The bottom spacer and nut shall then be placed as shown

on the plans. The nut shall be sufficiently tightened to
eliminate all gaps between the adjacent bolt heads, spacers,
nuts, and washers which form the connection.

Type 1 and type 3 precast units which have previously been cast meeting earlier
Department standards may be used. The Contractor will be allowed to mix type 1 and
type 3 units in a run as long as the units are in good condition and the connecting
420 devices are compatible. If units meeting earlier Department standards are used, a 1 in.
bolt will be allowed to link the units together. The spacer detail shall, however, be in
accordance with the current standard. Units cast after March 1, 2003 shall be linked
with the 1 1/4 in. bolt.

Type 2 temporary traffic barriers shall be connected as recommended by the

barrier manufacturer.

(c) Anchorage
Type 1 and type 3 temporary traffic barriers shall be anchored in accordance with
430 the methods shown on the plans, at the locations described herein. Type 2 barriers shall
be anchored as recommended by the barrier manufacturer and at locations described
herein. Temporary concrete traffic barriers shall be anchored when located on or
within 60 ft of a bridge, and along tapered alignments. Anchoring at locations in
addition to those described herein will be required when directed.

Chemical anchor systems with removable bolts, or mechanical anchors may be

used to anchor type 1 barriers to bridge decks, concrete pavement, and concrete
shoulders. Mechanical anchors may be ferrous or non-ferrous material. All anchors
shall have a shear strength of 10,000 lb and an ultimate pullout strength of 6,500 lb.
440
Non-ferrous mechanical anchors shall be installed such that the top end of the
sleeve is a minimum of 2 1/2 in. below the final finished concrete surface.

Ferrous mechanical anchors shall be completely removed when no longer

required. All damage to the pavement shall be repaired as directed.

Non-ferrous anchor sleeves and the chemical adhesive component of chemical

anchor systems may remain in place when no longer required. The holes remaining in
the pavement shall be filled with appropriate material as directed.
450
(d) Delineation
Type 1 barriers used to separate two-way traffic shall be delineated with top
mounted temporary barrier delineators and with side mounted delineators. The top
mounted delineators shall be two-sided, shall be yellow, and shall be placed on every
other section of barrier wall. The top mounted delineators shall be mounted
perpendicular to the direction of traffic flow. The side mounted delineators shall be
yellow and shall be mounted in accordance with 602.03(f).

820
 801.10.1

Temporary traffic barriers in locations other than separating two-way traffic shall
460 be delineated with either type C construction warning lights or top mounted temporary
barrier delineators and with side mounted barrier delineators. The type C lights or the
top mounted barrier delineators shall be spaced at the number of feet equal to the
number of miles per hour in the posted speed limit with a minimum spacing of 20 ft.
Bi-directional lenses will be required on the warning lights when the barrier is adjacent
to a lane that is carrying alternating one-way traffic. The color of the barrier delineators
shall be white when located on the right side of the traffic lane, and yellow when
located on the left side of the traffic lane. The color of the barrier delineators shall be
white when located adjacent to a lane that is carrying alternating one-way traffic.

470 Where the temporary traffic barrier is located along a tapered alignment and is
located behind drums or other reflective delineation devices, the type C construction
warning lights and barrier delineators shall not be used.

(e) End Treatment

Where possible, the ends of temporary traffic barriers shall be flared in accordance
with 801.10(a). Where conditions do not allow the temporary traffic barrier to be flared
in accordance with 801.10(a), appropriate end treatments shall be incorporated to
protect vehicles from the ends of the barriers. The end treatments shall have re-direct
capability and shall meet the appropriate test level 2 or 3 NCHRP 350 crash test
480 standards and be approved for use by the FHWA.

(f) Storage
No barrier segments shall be stored on the right-of-way unless written permission
is given by the Department. Requests for permission to store traffic barrier segments
on the right-of-way will not be accepted until after the contract has been awarded.

801.10.1 Construction Zone Energy Absorbing Terminal, CZ

The construction zone energy absorbing terminal, CZ, shall have passed NCHRP
350 level 3 crash test for all Interstate and other construction sites having a
490 construction zone speed limit in excess of 45 mph and level 2 for non-Interstate
construction sites having a construction zone speed limit of 45 mph or less. All energy
absorbing terminal, CZ, shall have redirect capabilities and shall be approved by the
FHWA. A copy of the crash test results and a copy of the FHWA approval letter shall
be furnished to the Engineer prior to the installation of the unit. The Contractor may
also use the Guard Rail Energy Absorbing Terminal CZ, manufactured by Energy
Absorption Systems, Inc. until January 1, 2011. All units of this type in use shall be
replaced with a compliant product immediately after this date regardless of the date of
letting. No additional payment will be made for this replacement.

500 The unit’s nose cover shall be reflectorized to provide improved visibility.

Assembly and installation of the unit shall be supervised or performed at all times
by an installer trained and certified by the unit’s manufacturer. The size, assembly,

821
 801.11

and installation shall be in accordance with the manufacturer’s recommendations at

the locations shown on the plans. When required for bi-directional traffic protection,
transition panels and all other necessary hardware shall be included in the installation.
A copy of the installer’s certificate shall be provided to the Engineer prior to the start
of work.

510 The Contractor shall provide the Department with all necessary manufacturer’s
installation manuals and working drawings in accordance with 105.02.

Sufficient spare parts or complete units shall be stored in a safe, convenient,

nearby location. Such standby materials are not shown in the Schedule of Pay Items.
The standby materials shall be utilized to repair or replace damaged units in the
shortest time possible. Standby materials used in the repair of damaged units shall be
replaced within 24 h of their use.

801.11 Temporary Crossovers

520 Temporary crossovers shall be either type A or type B as shown on the plans and
shall be constructed in accordance with the applicable sections of 207, 402 or 502. If
applicable, a CMDS shall be submitted to the Engineer for approval. Utilization of the
Department provided spreadsheet is not required. When required to maintain median
drainage, a 15 in. diameter pipe shall be placed at the centerline of the median under
the crossover. If the crossover is to remain in place for future construction, the pipe
shall have appropriate grated box ends in accordance with 715.

The pavement structure for the temporary crossover shall be as shown on the
plans.
530
Traffic control devices, including temporary pavement markings, shall be as
shown on the plans. Separation of opposing vehicular traffic between two crossovers
shall be as shown on the plans.

Refurbishing of a temporary crossover shall consist of the removal of drums or

earth cover from an existing temporary crossover. The temporary crossover shall be
patched and resurfaced as directed. Excavated soil resulting from the refurbishing
operation, if not used as a part of the contract work, shall become the property of the
Contractor. Removed drums will remain the property of the Department.
540
After construction is complete, and prior to the opening of all lanes to traffic, the
temporary crossover shall be removed or closed.

Where guardrail is required to be removed for construction or refurbishing of

crossovers, such removal and subsequent re-erection shall be done as shown on the
plans or as directed.

Acceptance of HMA for temporary crossovers will be in accordance with 402.09.

822
 801.12

550 801.12 Temporary Pavement Marking

Temporary pavement markings shall be new materials placed in accordance with
808.04 and 808.05. However, when temporary markings are to be in place for 14
calendar days or less the dashed line pattern used on center line and lane lines may be
4 ft line segments on 40 ft centers and gore areas shall be marked by outline only and
may be 5 in. wide lines. No-passing zones on all undivided two-way roadways shall
be identified with signs and centerline markings. All temporary markings shall be
maintained and replaced until they are no longer applicable.

Where possible, when non-removable temporary markings are used on a final

560 surface, such markings shall be placed at the same location where permanent markings
will later be affixed or parallel to and within 12 in. of the permanent marking pattern.

Where temporary pavement markings are to be placed on a pavement which has

existing markings, the existing markings which conflict with the temporary markings
shall be removed in accordance with 808.10. On asphalt pavement, black temporary
tape Type I, may be used to cover conflicting markings. The black temporary tape
shall extend at least 1/2 in. beyond the edges of the marking to be covered. Overlapping
of temporary tape will not be allowed.

570 When working under traffic, the temporary pavement markings shall be placed
before opening the lane to traffic. This shall include, but not be limited to, the marking
patterns of gore areas, outside edge line of deceleration and acceleration lanes, narrow
bridge markings, lane reduction transitions, lane lines, centerlines, and transverse
markings as appropriate.

Temporary pavement markings which are to be in service from December 1

through the following March 31 shall be painted markings. Such markings shall be
placed in the standard pavement marking pattern and applied prior to the suspension
of the work, or within seven work days after the Contractor is directed to place the
580 markings. Adjustments to these dates to accommodate actual seasonal suspension and
continuance of work are subject to approval by the Engineer upon written request.

The prismatic reflectors shall be removed from snowplowable raised pavement

markers which conflict with the temporary traffic marking pattern. Snowplowable
raised pavement marker castings damaged by the removal of the reflector shall be
replaced in accordance with 808.11. New prismatic reflectors shall be mounted on
existing castings in accordance with 808.11 when the final traffic pattern is
established.

590 Removal of temporary pavement markings shall be in accordance with 808.10.

(a) Temporary Pavement Marking Methods

Pavement markings shall be installed in accordance with 808.07 except that
measurement of retro-reflectivity is not required by the Contractor and quality
adjustments will not apply. All other performance measures shall apply.

823
 801.12

1. Paint
Painted markings shall require a second application of paint and beads as soon as
practical after the first application is dry.
600
2. Temporary Pavement Marking Tape
Temporary pavement marking tape shall be applied in accordance with the
manufacturer’s recommendations. Temporary marking tape shall be new type I or type
II material.

All temporary pavement marking tape shall be removed prior to placing the next
pavement course, prior to placing an overlay, prior to recycling the pavement, or prior
to placing the final pavement markings, except as otherwise described herein.

610 a. Type I
Type I tape is a removable material. It may be used for longitudinal and transverse
markings.

Type I tape shall be removed without the use of solvents, grinding, abrasive
blasting, or other methods which may damage the pavement. All visible adhesive
residue shall be removed without use of solvents or grinding.

b. Type II
Type II tape is a non-removable material. It may be used on PCCP to be removed
620 or on PCCP to be overlaid with an HMA course greater than 165 lb/sq yd. Type II tape
placed on HMA pavement shall be removed prior to placing the next pavement course.

If it is necessary to remove type II tape, it shall be removed without the use of

solvents. All damage to the pavement shall be repaired.

3. Temporary Raised Pavement Marker

The temporary raised pavement marker shall be grade 1 or grade 2. When used, it
shall be a supplement to other temporary pavement markings. The color of the reflector
shall be in accordance with the other temporary pavement marking. The color of the
630 shell of the grade 1 marker shall be in accordance with the color of the other temporary
pavement marking.

Temporary raised pavement markers shall be removed before the next layer of
pavement is placed and before the final pavement markings are applied. All damage
to the pavement shall be repaired.

4. Temporary Buzz Strips

Temporary buzz strips shall be a set of transverse markings constructed of
removable or durable marking material. Durable marking material shall be used in
640 accordance with 808.07(b).

824
 801.14

(b) Quality Assurance Unit

A quality assurance unit for longitudinal line shall be 500 lft on marked pavement
in any combination or pattern, or portion thereof. A quality assurance unit for
transverse marking shall be each. If a marking fails to be in accordance with the
marginal standard as defined in the ATSSA Quality Standards for Work Zone Traffic
Control Devices, the quality assurance assessment will be assessed in accordance with
801.03.

650 801.13 Temporary Illumination

The temporary highway illumination shall be in accordance with applicable
requirements of 807 except as modified herein.

The electric energy necessary to power the luminaires on a continuous basis is the
responsibility of the Contractor.

At completion of the contract work, the temporary illumination shall be removed

and shall remain the property of the Contractor. After removal of the temporary
illumination equipment, all holes and trenches shall be backfilled with B borrow.
660
801.14 Construction Warning Lights
Construction warning lights shall be portable, lens directed, enclosed lights that
emit an amber color. All warning lights shall be mounted a minimum of 36 in. above
the traveled way to the bottom of the lens, unless otherwise directed. Lights not
working shall be repaired or replaced immediately. For each day that more than 5% of
the required warning lights are not operating, a sum equal to $4.00 per non-working
light will be deducted from the monies due the Contractor.

(a) Type A
670 Type A lights shall be low intensity flashing warning lights. These lights shall be
visible on a clear night from a minimum distance of 3,000 ft when there is no external
illumination directly on or in the immediate vicinity of the light. They shall operate
from dusk to dawn or when conditions exist which tend to obscure vision. Traffic
control devices used for maintaining traffic will not require Type A warning lights
during unobscured daylight hours.

(b) Type B
Type B lights shall be high intensity, flashing, warning lights. These lights shall
be visible on a sunny day from a minimum distance of 1,000 ft when viewed without
680 the sun directly on or behind the light.

(c) Type C
Type C lights shall be steady burning warning lights. These lights shall be visible
on a clear night from a minimum distance of 3,000 ft when there is no external
illumination directly on or in the immediate vicinity of the light. They shall operate
from dusk to dawn or when conditions exist which tend to obscure vision.

825
 801.15

(d) Vehicle Warning Lights

Vehicle warning lights shall be amber and shall be a strobe light or a flashing,
690 oscillating, or rotating directed beam light. They shall be visible to all approaching
traffic for a distance of 1,000 ft.

801.15 Electronic Devices

(a) Flashing Arrow Sign

Where specified, a flashing arrow sign shall be furnished, installed, and
maintained. It shall be operated continuously, when necessary, to divert traffic.

The flashing arrow sign may be of the solar power assisted type only in stationary
700 operations when the horizontal or vertical curvature in the road is such that motorists
do not drive into and out of the beam width of the lighted arrow while within sight of
the sign.

(b) Portable Changeable Message Signs, PCMS

This shall consist of furnishing, installing, and maintaining a trailer-mounted,
portable sign upon which varying electronically generated messages will be displayed
to traffic. The message being relayed to traffic shall be legible and easily understood
for a minimum distance of 650 ft.

710 The messages shall be as shown on the plans or as approved or directed by the
Engineer. Messages shall be formatted in accordance with the Department’s
Guidelines for Portable Changeable Message Signs. Only upper case letters shall be
used. Each message phase shall be displayed for at least 2 s. Display time for an entire
message shall not exceed 8 s.

Placement of PCMSs shall be as shown on the plans or as directed by the

Engineer. A minimum clearance of 7 ft from pavement to the bottom of the PCMS
shall be provided. Units shall be level and PCMSs shall be turned away from traffic,
placed in stand-by mode, or left blank until there is a valid message to be displayed.
720 When in use PCMSs shall be turned approximately 3° from perpendicular towards
oncoming traffic to minimize glare. A drum shall be placed immediately in front of
the PCMS trailer at both corners for delineation.

(c) Temporary Worksite Speed Limit Sign Assembly

This shall consist of furnishing and placing portable speed limit signs as shown
on the plans or as directed in areas of work activity. When used, the worksite speed
limit flashing strobe lights shall be activated when the worksite speed limit is in effect.
This shall be only where and while work is actually in progress and workers are
present. Each strobe light shall be visible through a range of 120° when viewed facing
730 the sign and shall be visible from a distance of 750 ft.

Wherever a permanent speed limit sign exists within the limits controlled by the
worksite speed limit sign assemblies, additional worksite speed limit sign assemblies

826
 801.15

shall be placed at the permanent signs. The permanent signs shall be covered or
removed during continuous worksite speed limit use.

A worksite speed limit authorized for intermittent use shall only be activated when
workers are present at the site. The intermittent worksite speed limit shall only be used
in the area of work. A worksite speed limit authorized for continuous use shall not
740 include the flashing strobe lights or the S4-4 “WHEN FLASHING” plaque.

The worksite speed zone signage shall be placed and maintained by the
Contractor. The worksite speed limit will be as shown on the plans or as directed by
the Engineer and at least 10 mph below the posted speed limit for the roadway under
construction.

A worksite reduced speed advance warning sign assembly shall be placed in

advance of the first worksite speed limit sign assembly when the reduction in speed
limit is greater than 10 mph.
750
(d) Temporary Traffic Signals
This work shall consist of furnishing, installing, and maintaining temporary traffic
signals in accordance with 805 except as modified herein.

Except as shown on the plans, all materials not furnished by the Department shall
remain the property of the Contractor after work is completed and the equipment is
removed.

The traffic signal equipment shall be as specified, but may be either new or used.
760 Used equipment shall be in satisfactory working condition and will be approved prior
to use.

Two signal heads shall be displayed for each approach. Signal cable may be
extended across bridges through conduit which shall be attached to the underside of
the coping. Type and spacing of clamps shall be approved prior to installation.

Conduit shall be steel or plastic. Flexible conduit will be an acceptable alternate

for use as ground rod entry, magnetometer, or microloop installations.

770 1. Fixed Temporary Signals

Fixed temporary signals shall be displayed overhead on a span, catenary, and
tether utilizing an aircraft cable, unless otherwise directed.

Electric energy necessary to power the fixed temporary signal is the responsibility
of the Contractor. Prior to the start of construction, the schedule of activities shall be
coordinated with the power company.

The Contractor shall obtain permits from local officials, companies, or individuals
for the use of poles, right-of-way, or other property incidental to the installation of

827
 801.15

780 fixed temporary signals. Although entering into the contract implies permission and
authority to install conduit under pavement, sidewalks, and alleys, all damage to
underground utilities or interruption of such service shall be the responsibility of the
Contractor.

The location, spacing, and timing of fixed temporary signals will be determined
by the Engineer.

An IMSA certified level II Traffic Signal Construction Technician or a level II

Traffic Signal Field Technician shall be available 24 h a day to respond within 2 h for
790 the maintenance of the traffic signal equipment.

The controller shall be traffic actuated solid state digital. For used controllers, the
model selected shall be from a manufacturer with a controller on the Department's list
of approved Traffic Signal and ITS Control Equipment.

Vehicle detection shall be provided and shall be either inductive loop or wireless
unless otherwise noted on the plans.

2. Portable Signals
800 Portable signals shall be selected from the Department’s list of approved Portable
Signals. Prior to the activation, the Contractor shall provide a completed inspection
checklist to the Engineer certifying that the portable signal is functioning properly.

The portable signal shall be equipped with remote monitoring. Unless otherwise
shown on the plans, Microwave or Doppler vehicle detection as shown on the
Department's list of approved Portable Signals shall be provided. A minimum of three
drums shall be placed immediately in front of the portable signal trailer for delineation.

A technician certified by the manufacturer shall be available 24 h a day to respond

810 within 2 h for the maintenance of the traffic signal equipment. Copy of the certification
shall be provided to the Engineer prior to the placement of the portable signals.
Maintenance of the portable signal includes adjustments to the phasing or timing as
indicated on the plans or directed by the Engineer. The Contractor shall replace
portable signals that cannot be returned to normal operation or that fail two times
during the contract.

The Contractor shall provide a record of any modifications to the signal timing
plan, failures, and all maintenance issues, to the Engineer prior to final acceptance and
when otherwise requested. The report shall indicate the date, time, and nature of each
820 event.

(e) Automated Flagger Assistance Devices

An Automated Flagger Assistance Device, AFAD, may be used to control a single
lane of approaching traffic on a two-lane highway for flagging operations.

828
 801.16

Only qualified flaggers who have been trained on the operation of the AFAD shall
operate the AFAD. AFAD operators shall provide written proof that they have been
trained by the AFAD manufacturer. Two trained flaggers shall be available on-site to
provide flagging in case of an AFAD malfunction. The flagger operating the AFAD
830 shall be positioned to have an unobstructed line of sight to approaching traffic and the
AFAD. A single flagger may be used to control both approaches to the work site if
adequate unobstructed sight distance exists between the AFAD operator and both
approaching directions of traffic and both AFADs.

The flagger operating the AFAD shall not leave the device unattended at any time
while the AFAD is in use. The operating flagger shall be positioned at such point to
be in full view of oncoming traffic and the AFAD at all times the AFAD is in use. The
flagger operator shall keep a backup handheld remote readily available at all times
when the device is being operated.
840
The AFAD shall be positioned so that the end of the gate arm, if used, shall extend
at least to the center of the lane being controlled but shy of the roadway centerline.

A drum shall be placed immediately in front of the AFAD trailer at both corners
for delineation.

801.16 Temporary Traffic Control Zone

A temporary traffic control zone is a work zone with frequently changing
operation, a maximum duration of seven calendar days; mobile operation; or a
850 temporary traffic stoppage.

Daytime lane closures on two-lane two-way roads shall be limited in length to a

maximum of 1 mi or the length of a half day’s operation, whichever is less, or as shown
on an approved alternate traffic control plan.

(a) Temporary Mounted Construction Signs

When the vertical mounting height for TTCS is between 12 in. and 18 in. to the
bottom of the sign, tripod supports may be used. Temporary mounted construction
signs, which are mounted on portable supports such as sign stands and tripods may be
860 used for the construction signs in a temporary traffic control zone. The bottom of a
temporary mounted construction sign shall be at least 12 in. above the traveled way.
Signs on tripod supports shall be installed so that the angle from vertical does not
exceed 30°.

Roll-up materials will only be allowed for mobile, short duration, or short-term
stationary work which will not exceed one daytime period. Roll-up materials shall be
selected from the Department’s List of approved reflective sheeting. Roll-up sign
supports shall be ballasted in accordance with the manufacturer’s recommendations.

829
 801.17

870 (b) Maintenance of Traffic for Mobile Operations

Signs, flagging, flashing arrow signs, and other required traffic control devices
shall be furnished in accordance with the details shown on the plans or as directed.
The Engineer reserves the right to stop work at any time to relieve traffic congestion.

Flagging operations shall be conducted under the supervision of either the

designated CWTS or a flagger certified by ATSSA or approved equal certifying
organization. The person supervising the flagging operation shall ensure that the
flaggers are trained in proper flagging procedures and that the flagging operation is in
compliance with the applicable sections of the MUTCD.
880
(c) Traffic Control for Temporary Traffic Stoppage
Traffic shall not be allowed to pass directly beneath personnel or equipment
working on an overhead structure. Traffic stoppage during an overhead operation shall
not exceed 20 minutes at one time. There shall be enough time between consecutive
stoppages to allow traffic to return to normal flow.

Three working days prior to commencing work which necessitates temporary

stoppage of traffic, written notice shall be given to the Department and the Indiana
State Police that highway traffic shall be stopped temporarily at a specific location,
890 time, and date to accomplish specified work. Traffic shall be safely controlled during
the stoppage. The following minimum requirements shall be met.

1. On Multi-Lane Divided Highways

Advance warning signs shall be located as specified or as otherwise directed. For
each direction of road closure two flaggers shall be located at the site of the work and
a minimum of two additional flaggers shall be used to warn approaching traffic.

2. On Non-Divided Highways
Advance warning signs shall be located as specified or as otherwise directed. For
900 each direction of road closure, one flagger shall be located at the site of the work and
a minimum of one additional flagger shall be used to warn approaching traffic.

801.17 Method of Measurement

Construction signs, detour route marker assemblies, detour route marker
assemblies-multiple routes, temporary worksite speed limit sign assemblies, road
closure sign assemblies, portable changeable message signs, Aries Field Processor for
PCMS, and temporary raised pavement markers will be measured by the number of
units installed, maintained, and removed.

910 Temporary panel signs will be measured by the square foot. Temporary panel sign
supports, when required, will be measured by the linear foot, complete and in place.

Type III-A, type III-B, and permanent type III barricades will be measured by the
linear foot of the width of closure.

830
 801.17

Temporary traffic barrier will be measured by the linear foot per the type
specified. Anchored traffic barrier will be measured by the linear foot, separately from
unanchored temporary concrete barrier per the type specified. End treatments used on
a type 2 or type 4 temporary traffic barrier will be measured by the linear foot as part
920 of the barrier.

Construction zone energy absorbing terminals, CZ, used on type 1 and type 3
temporary traffic barriers will be measured by the number of terminals placed.

Temporary crossovers type A and type B will be measured per each crossover.
The refurbishing of temporary crossovers will be measured per each type of crossover
refurbished. HMA mixtures for temporary crossovers will be measured by the ton in
accordance with 109.01(b). Initial resurfacing and initial patching of refurbished
crossovers will be measured in accordance with 402.19. Temporary drainage pipe for
930 temporary crossovers will be measured by the linear foot. Seeding and sodding placed
due to the construction and removal or refurbishing and closing of temporary
crossovers, will be measured in accordance with 621.13. Removal and subsequent
replacement of permanent pavement markings and snowplowable raised pavement
markers for temporary crossovers will be measured in accordance with 808.12.
Removal and resetting of guardrail, if required for temporary crossovers, will be
measured in accordance with 601.13.

Flashing arrow signs will be measured by the number of calendar days each unit
is operated.
940
Patroller will be measured by the number of calendar days during the phase or
phases of traffic control, as shown on the plans or as otherwise directed, that require
the patroller’s presence. Each portion of a day will be measured as a whole day.

Temporary pavement message markings will be measured by the number of each

type placed. Longitudinal and transverse temporary pavement markings will be
measured by the linear foot of material actually placed. Temporary buzz strips will be
measured by the linear foot for each 8 in. strip placed, without regard to the number
of passes required to attain the specified height.
950
Removal, when necessary, of any type of non-removable temporary pavement
markings will be measured in accordance with 808.12. Removal of removable
temporary pavement markings will not be measured for payment.

Where temporary pavement markings are to be placed on a pavement which has

existing markings, removal of existing markings which conflict with the temporary
markings will be measured in accordance with 808.12. Where conflicting markings
are covered with black temporary tape Type I, the black temporary tape will be
measured by the linear foot of markings covered.
960
The removal and replacement of prismatic reflectors on existing snowplowable
raised pavement markers will be measured in accordance with 808.12.
831
 801.18

Compacted aggregate No. 73 used for shoulder material will be measured in

accordance with 303.09. Excavation of the existing earth shoulder will not be
measured for payment.

Cones and tubular markers will not be measured for payment. Permanent tubular
markers will be measured per each.
970
Temporary illumination, fixed temporary signals, portable signals, and
maintaining traffic will not be measured for payment.

801.18 Basis of Payment

The accepted quantities of construction signs, detour route marker assemblies,
detour route marker assemblies-multiple routes, temporary worksite speed limit sign
assemblies, road closure sign assemblies, permanent road closure sign assemblies and
temporary raised pavement markers will be paid for at the contract unit price per each.
Payment for temporary worksite speed limit assemblies, PCMS, and Aries Field
980 Processors will be made for the maximum number of such assemblies in place at any
one time during the life of the contract. Type III-A, type III-B, and permanent type III
barricades will be paid for at the contract unit price per linear foot.

Temporary traffic barrier and anchored temporary traffic barrier will be paid for
at the contract unit price per linear foot per the type specified. Payment will be made
only once, regardless of the number of times the barrier is moved to accommodate
different phases of traffic maintenance or construction operations as shown in the
contract. End treatments used on a type 2 or type 4 temporary traffic barrier will be
paid for on a linear basis as part of the barrier.
990
Construction zone energy absorbing terminal, CZ, when used with type 1 or type
3 temporary traffic barriers will be paid for at the contract unit price per each for
energy absorbing terminal, CZ, of the test level placed. Each unit will be paid for only
once regardless of how many times it is moved. Construction zone energy absorbing
terminal, CZ, when used with type 2 or type 4 temporary traffic barriers will be paid
for at the contract unit price per linear foot of type 2 or type 4 temporary traffic barrier.
Back-up units will be paid for as energy absorbing terminal, CZ, of the test level
placed, if they are placed in service due to non-repairable damage to the units already
in service.
1000
The accepted quantities of temporary crossovers will be paid for at the contract
unit price per each for the type specified. The accepted quantities of refurbishing
existing temporary crossovers will be paid for at the contract unit price per each for
the type specified. The accepted quantities of HMA for temporary crossovers will be
paid for as HMA for temporary pavement at the contract unit price per ton in
accordance with 402.20. Temporary drainage pipe for temporary crossovers will be
paid for at the contract unit price per linear foot. Sodding and seeding for temporary
crossovers will be paid for in accordance with 621.14. Removal and subsequent

832
 801.18

replacement of permanent pavement markings and snowplowable raised pavement

1010 markers for temporary crossovers will be paid for in accordance with 808.13. Removal
and resetting of guardrail, if required for temporary crossovers, will be paid for in
accordance with 601.14.

If more than one construction sign is mounted on a common support with the
messages facing opposite directions, the largest sign will be paid for at the contract
unit price of the sign, and each additional sign will be paid for at half the unit price of
the sign if it had been erected independently.

Temporary panel signs will be paid for at the contract unit price per square foot
1020 as shown on the plans. Temporary panel sign supports will be paid for at the contract
unit price per linear foot, complete and in place.

A temporary worksite speed limit sign assembly for continuous use includes two
signs; each will be paid for at the contract unit price for construction sign.

Flashing arrow signs and patrollers will be paid for at the contract unit price per
day per each.

Temporary pavement message markings placed will be paid for at the contract
1030 unit price per each, for the message specified. Longitudinal and transverse temporary
pavement markings and temporary buzz strips, will be paid for at the contract unit
price per linear foot of material, complete in place.

Removal, when necessary, of non-removable temporary pavement lines and

message markings will be paid for in accordance with 808.13. The cost of removal of
removable temporary pavement markings shall be included in the cost of the pay item
for placement of the markings.

Where temporary pavement markings are to be placed on a pavement which has

1040 existing markings, removal of the existing markings which conflict with the temporary
markings will be paid for in accordance with 808.13. Where conflicting markings are
covered with black temporary tape Type I, the specified width of black temporary tape
will be paid for at the contract unit price per linear foot of temporary pavement
marking, removable.

Permanent tubular markers and permanent drums will be paid for at the contract
unit price per each.

Compacted aggregate used for shoulder material will be paid for as compacted
1050 aggregate No. 73 in accordance with 303.10.

The removal and replacement of reflectors on existing snowplowable raised

pavement markers will be paid for in accordance with 808.13.

833
 801.18

Temporary illumination will be paid for at the contract lump sum price.

All temporary traffic control devices which are specified as separate pay items
and used for maintenance of traffic will be paid for as set out in the Schedule of Pay
Items. The furnishing, placing, moving, removal, and maintenance of all other
1060 temporary traffic control devices will be paid for at the contract lump sum price for
maintaining traffic.

The accepted fixed temporary and portable signals, complete in place and later
removed as specified, will be paid for at the contract lump sum price.

Payment will be made under:

Pay Item Pay Unit Symbol

1070 Aries Field Processor for PCMS ............................................... EACH

Barricade, _____ ....................................................................... LFT
type
Barricade, III, Permanent .......................................................... LFT
Barrier, Direction Indicator ....................................................... EACH
Construction Sign, _____ .......................................................... EACH
type
Detour Route Marker Assembly ................................................ EACH
Detour Route Marker Assembly, Multiple Routes .................... EACH
Drum, Permanent....................................................................... EACH
1080 Energy Absorbing Terminal, CZ, TL - _____ ........................... EACH
test level
Fixed Temporary Signal ............................................................ LS
Flashing Arrow Sign.................................................................. DAY
Maintaining Traffic ................................................................... LS
Patroller ..................................................................................... DAY
Portable Changeable Message Sign ........................................... EACH
Portable Signal .......................................................................... LS
Road Closure Sign Assembly .................................................... EACH
Road Closure Sign Assembly, Permanent ................................. EACH
1090 Temporary Buzz Strips .............................................................. LFT
Temporary Crossover Drainage Pipe......................................... LFT
Temporary Crossover, _____ .................................................... EACH
type
Temporary Crossover, _____, Refurbish................................... EACH
type
Temporary Illumination............................................................. LS
Temporary Panel Sign Supports ................................................ LFT
Temporary Panel Signs.............................................................. SFT
Temporary Pavement Marking, _____ in. ................................. LFT
1100 width

834
 801.18

Temporary Pavement Marking, Removable, _____ in. ............. LFT

width
Temporary Pavement Message Marking, _____ ....................... EACH
description
Temporary Pavement Message Marking,
Removable, _____ .............................................................. EACH
description
Temporary Raised Pavement Marker, _____ ............................ EACH
grade
1110 Temporary Traffic Barrier, _____ ............................................. LFT
type
Temporary Traffic Barrier, Anchored, _____ ........................... LFT
type
Temporary Transverse Pavement Marking, _____ in................ LFT
width
Temporary Transverse Pavement Marking,
Removable, _____ in. ......................................................... LFT
width
Temporary Worksite Speed Limit Sign Assembly .................... EACH
1120 Tubular Marker, Permanent ....................................................... EACH

The cost of delineation of temporary traffic barrier shall be included in the cost of
temporary traffic barrier.

Damage done to pavement by removal of temporary traffic barriers and anchors

shall be repaired with no additional payment.

The cost of all materials, equipment, labor, and incidentals necessary to install,
maintain, repair, and to remove the unit shall be included in the cost of energy
1130 absorbing terminal, CZ. The cost of stockpiling standby terminals and terminal
materials, whether incorporated into the work or not, shall be included in the cost of
energy absorbing terminal, CZ. All units shall remain the property of the Contractor
upon completion of the contract.

The cost of the excavation required for placement of compacted aggregate

shoulders No. 73 will be included in the pay item maintaining traffic.

The cost of installation, maintenance, and removal or closure of the temporary

crossover, including excavation, compaction, subgrade preparation, and reshaping
1140 damaged median area shall be included in the cost of temporary crossover.

The cost of removal of earth cover, removal of drums, reshaping damaged median
areas, and closure or removal of temporary crossover shall be included in the cost of
temporary crossover, refurbish.

The cost of furnishing, installing, maintaining, and subsequent removal of

835
 801.18

temporary raised pavement marker shall be included in the cost of temporary raised
pavement marker.

1150 The cost of placement, maintenance and replacement of temporary pavement

markings shall be included in the cost of the markings.

The cost of cleaning existing pavement and removal of buzz strips shall be
included in the cost of buzz strips. Damage to the pavement caused by removal of buzz
strips and temporary pavement markings shall be repaired as directed with no
additional payment.

No payment will be made for temporary pavement markings which are in the
standard pavement marking pattern, and which are to be in service from December 1
1160 through the following March 31 due to the Contractor’s failure to complete the work
as scheduled. However, payment will be made for these markings if the failure to
complete the work as scheduled is due to conditions beyond the Contractor’s control.

The cost of the second application of paint and beads for painted temporary
markings shall be included in the cost of the first application of painted temporary
pavement markings.

The cost of furnishing, installing, maintaining, and subsequent removal of the

detour marker, route marker, or street or road name sign, cardinal directional marker,
1170 directional arrow marker, posts which support the assembly, and all necessary
hardware shall be included in the cost of detour route marker assembly or detour route
marker assembly, multiple routes.

The cost of installing, maintaining, and subsequent removal of signs, construction

warning lights, assembly supports, and all necessary hardware shall be included in the
cost of road closure sign assembly.

The cost of furnishing all materials, erection, maintenance, removal, and

necessary incidentals shall be included in the cost of barricades.
1180
Each construction sign, barricade, temporary worksite speed limit sign assembly,
road closure sign assembly, or flashing arrow sign will be paid for only once regardless
of how many times each is moved, replaced, or how many times each is altered to
change the sign message. Payment will not be made for signs or barricades used for
the convenience of the Contractor.

Additional materials necessary to place the portable changeable message sign in

a secure and level manner for site conditions shall be included in the cost of the pay
item. All costs to furnish, install, program, activate, deactivate, change messages,
1190 move, replace, and maintain the PCMS shall be included in the cost of the pay item.
The cost of IP cellular phone service shall be included in the cost of the pay item.

836
 802.01

If a temporary worksite speed limit sign assembly, for intermittent use is not
flashing when required beginning 2 h after work begins, or if such assembly is flashing
when no work has been taking place for 2 h or longer, $200.00 will be deducted from
payment for such work for each 4 h period or part thereof, beginning after the 2 h grace
period.

If the Contractor elects to use more than two simultaneous operations during the
1200 installation of snowplowable pavement markers or reflectors, the cost of required
traffic protection devices for additional operations shall be included in the cost of
maintaining traffic.

The cost of necessary flaggers; automated flagger assistance devices; protection

of traffic at structure foundations; and furnishing, erecting, placing, maintaining,
relocating, and removing lights, cones, flexible channelizers, tubular markers, drums,
delineators, or other devices as directed shall be included in the cost of maintaining
traffic.

1210 Temporary mounted construction signs will not be paid for.

Replacement of snowplowable raised pavement marker castings damaged due to

removing reflectors will not be paid for.

The cost of furnishing and placing cones or tubular markers in accordance with
801.08 and drums in accordance with 801.09, the watcher in accordance with 107.12,
repair or replacement of damaged or inoperative traffic control devices, and traffic
maintenance in accordance with 104.04 shall be included in the cost of maintaining
traffic.
1220
If the compacted aggregate No. 73 required for shoulders is removed, the cost of
such removal shall be included in the cost of the compacted aggregate.

The cost of the vehicle detection, solar panel, battery cabinet, program timing
module, signal heads, wiring, trailer, and all hardware required shall be included in the
cost of the portable signal.

Electric energy necessary to power luminaires and fixed temporary signals will
not be paid for.

SECTION 802 – SIGNS

802.01 Description
This work shall consist of furnishing the material for and erecting traffic signs in
accordance with 105.03. Signs shall be installed as required unless written approval is
obtained from the District Traffic Engineer to make modifications at specific locations.

837
 802.02

Signs shall be stored in such a manner that they do not come in contact with
surface run-off water. Signs shall be stored so that moisture accumulation or heat
10 build-up does not occur.

All signs shall be marked for identification as shown on the plans. The marking
shall consist of a type II sheeting material, with a class I adhesive, shown on the
Department’s list of approved Sign Sheeting Materials. It shall be applied to the back
of the sign on the lower corner closest to the nearest edge of pavement and shall not
be covered by the sign’s supports.

MATERIALS

20 802.02 Materials
Materials shall be in accordance with the following:

Concrete ...................................................................... 702 or 901.08

Fasteners ...................................................................... 919.01(d)
Overhead Sign Structure.............................................. 910.19
Reinforcing Bars.......................................................... 910.01
Sign Posts .................................................................... 910.14
Traffic Signs ................................................................ 919.01

30 Materials used for temporary construction signs, temporary traffic signs, and
temporary panel signs shall meet the requirements herein. The basis for use of the
materials will be by visual inspection with no additional testing, evaluation, or
documentation.

CONSTRUCTION REQUIREMENTS

802.03 Location of Signs and Sign Structures

Sign and sign structure locations shall be staked, and the Engineer will either
approve the locations or give written notice of necessary changes. The provisions of
40 109.03 will not apply to posts ordered prior to approval of staked locations.

Two days notice shall be provided for inspection and approval of staked locations.

All signs shall be adjusted to eliminate specular reflection.

802.04 Working Drawings

Working drawings shall be submitted in accordance with 105.02 for all strain
poles and structural frames, except breakaway posts. Roadway cross sections and
bridge dimensions shall be checked, as applicable, in the field prior to preparation of
50 working drawings. If the no-load camber is not shown on the plans, the Contractor
shall furnish this information on the working drawings.

838
 802.07

802.05 Excavation and Backfill

The finished pavement or shoulder section shall not be damaged during
excavation.

The Engineer shall be notified in writing of class X material in accordance with

206.02 encountered within the limits of the traffic sign supports foundation
excavation. The Engineer will determine the design for the installation of the
60 foundations. Excavation of class X material shall be in accordance with 206.

The excavation for sign posts shall be made as nearly as possible to neat lines.
Sign post encasement shall not be formed except in sandy soil, or as directed.

802.06 Placing Concrete

Placing concrete shall be in accordance with 702, except that foundations
incorporated into sections of concrete barrier wall shall receive a finish in accordance
with 702.21. Exposed concrete shall have a smooth surface and beveled edges.

70 Anchor bolt alignment shall be maintained during concrete placement. Temporary

positioning place and associated nuts shall be removed upon completion of the
foundation. The threads shall be protected during concrete placement. Any damage to
galvanized coating shall be repaired prior to assembly.

Conduit and grounding shall be in accordance with 807.

802.07 Installing Supports

(a) Posts
80 Posts shall be vertical after installation. All damaged posts shall be removed and
replaced with an acceptable post.

Square sign post foundations shall be reinforced anchor base or unreinforced

anchor base as shown on the plans. If sign post type A or sign post type B is specified,
square sign posts may be used. Splicing of square steel sign posts will not be allowed.

In locations where class X excavation is encountered if the total length of the

anchor bolts cannot be used, they shall be cut off. A steel plate measuring 6 by 6 by
1/2 in. shall be welded to the bottom of the bolts. The plate shall have a hole cut which
90 allows the bolt to pass through it and the plate and bolt shall be completely welded
together around the circumference of the bolt on both sides of the plate. No butt
welding is allowed. The length of the bolts shall allow the plate to be covered by 3 to
4 in. of concrete at the bottom of the foundation.

Base plate bolts for panel sign post installations shall be tightened in accordance
with 711.65(d). Bolts at the fuse or hinge plate joint shall be tightened in accordance
with 711.65(d) or by the direct tension indicator, DTI, method.

839
 802.07

(b) Overhead Sign Structures

100 When erection of the structure has been started, it shall be completed the same
day. The structure shall be loaded, to prevent vibration, by attaching signs or lighting
supports the same day.

An oxidation inhibitor in accordance with 802.07(b)4 shall be applied to all

surfaces that mate with a dissimilar material.

Fasteners for chord splice connections shall be high-strength bolts conforming to

ASTM F 3125, grade A 325 with matching lock nuts having steel inserts. Installation
shall be in accordance with 711.65. Other bolts and hardware shall conform to the
110 requirements of 910.19.

Fasteners shall be tightened by turn-of-nut tightening, calibrated wrench

tightening, or direct tension indicator tightening. The calibrated wrench shall be
calibrated by an acceptable tension measuring device such as a Skidmore-Wilhelm.

The base plate bolt tightening shall be as follows:

a. Lower nuts and washers shall be in full contact with the

base plate,
120
b. The top nuts shall be tightened to 1/6 turn beyond snug fit,

c. The lower nuts shall be retightened to assure that full

contact with the base plate has been maintained.

Damage that is detrimental to the structural integrity of the frame or aesthetic

appearance shall be repaired.

No field welding will be allowed.

130
The grounding connection shall be located 12 in. from the bottom of the support
and shall be easily accessible from the structure manhole.

Traffic shall be maintained in accordance with 801.16 during installation.

1. Trusses
When placed on blocks to produce the required camber, the truss sections shall fit
together at the flange connections with a minimum gap of 1/16 in. on any flange
assembly. The total of the gaps in any one connection shall not exceed 1/8 in. Gaps
140 shall be shimmed with tapered shims before tightening the flange bolts.

Vertical truss members and vertical diagonals shall be machined to provide a snug
tube-to-tube fit to the chord along the entire edge before welding. Horizontal truss

840
 802.08

members and horizontal diagonals shall be slotted for the dimensions shown on the
plans and welded to the gusset plates. They shall be sealed against water penetration.

Chord flanges shall be machined from solid rounds. Mating surfaces shall be flat
within 1/64 in. Flanges shall be given an additional finish if necessary to ensure contact
between plates.
150
The cap bolts used to attach the top caps of end-support columns shall be located
so as to miss the J hook.

The camber shown on the plans is for fabrication only. It shall be measured with
the truss fully supported. The allowable camber tolerance is 25% of the specified
camber value.

All signs and walkway brackets shall be placed as close to the brace points as
possible. The Contractor shall verify that the dimensions are suitable for the type of
160 fixture to be supplied.

2. Monotube
The required camber shall be achieved in accordance with the manufacturer’s
recommendations as detailed on the working drawings.

3. Cantilever Arms
Cantilever arms shall fit together at the flange connections between sections with
a minimum gap of 1/16 in. on any flange assembly. The total of the gaps in any one
connection shall not exceed 1/8 in. Double arm chords are octagonal tubular shape
170 with 0.14 in./ft taper. Quadri-chord arms are circular shape with constant diameter.

4. Bridge Brackets
The location of the sign bracket may be shifted to avoid joints or stiffeners on the
bridge. Before placing aluminum in contact with concrete, both the concrete and
aluminum surfaces shall be coated with an aluminum-impregnated caulking
compound. Where aluminum surfaces are to be placed in contact with steel, the steel
surface shall be given one coat of zinc chromate paint and the aluminum surfaces shall
be coated with an aluminum-impregnated caulking compound before placement. After
the bolts have been tightened, the excess caulking compound shall be removed. All
180 openings around the flanges shall be fully painted and shall be flush with the caulking
compound.

802.08 Installing Signs

If new signs are to be installed on existing overhead sign structures, the existing
mounting hardware, if applicable, may be reused. Bolts, nuts, and washers shall not be
reused. Additional new hardware may be required to complete the mounting. All such
sign hangers protruding above the new signs shall be cut off flush to the top of the
signs. Splicing or overlapping of sign hangers will not be allowed. All unused sign
hangers and hardware shall be removed.

841
 802.09

190
A minimum of two sign support bracket assemblies will be required for all signs
having a width greater than 30 in. Signs 7 ft or less in height shall have sign support
bracket assemblies mounted at a maximum spacing of 7 ft. Signs greater than 7 ft in
height shall have sign support bracket assemblies mounted at a maximum spacing of
5 ft. Sign overhang beyond the end bracket assembly shall be not more than half the
spacing of the bracket assemblies.

(a) Sheet Signs

Sheet signs shall be fastened to the post as shown on the plans. Rivets shall be
200 used to fasten sheet signs mounted to panel or other sheet signs. Steel and plastic
washers shall be placed as shown on the plans. Lock-nuts shall be tightened
sufficiently so that the sign is held firmly against the post. If the sign sheeting is twisted
or damaged, the sign shall be replaced.

Lock-nuts for cable span mounted signs shall be tightened so that the sign is held
firmly against the cable. There shall be no deformation or twisting of aluminum
sheeting, or damage to the reflective sheeting.

(b) Panel Signs

210 Panel signs shall be mounted as follows:

1. Up to and including 24 ft of sign width, clips shall be

placed on both sides of each post at the top and bottom of
the sign. Intermediate clips shall be placed one on each
panel on each post and shall alternate left and right on each
post.

2. Over 24 ft of sign width, double clips shall be used, one on

the right side and one on the left side on each post per panel
220 width, plus the sets necessary to attach the top and bottom
of the sign.

3. Lock-nuts shall be torqued two full turns beyond snug fit.

Panels shall be bolted together on 24 in. centers with an allowable gap of no more
than 1/16 in. between units. Panels shall be temporarily braced in accordance with the
panel manufacturer’s recommendations.

802.09 Removal or Relocation of Signs or Support Assemblies

230 Signs to be relocated shall be installed in accordance with the MUTCD and on
new posts.

Signs or support assemblies to be removed shall be removed within five work

days after the required replacement signs or support assemblies are installed. Concrete
foundations shall be removed to a minimum depth of 1 ft below the ground surface.

842
 802.11

After concrete foundations have been removed, the area shall be backfilled and seeded
or sodded in accordance with 621, or treated with a material which matches that in the
surrounding area.

240 802.10 Roadway and Bridge Reference Signs

If existing roadway and bridge reference signs interfere with the prosecution of
other work, such signs and posts shall be removed, stored, and then reinstalled within
25 ft of their original longitudinal location or as directed.

802.11 Method of Measurement

Sheet signs and panel signs will be measured by the square foot. Sheet signs will
be measured as the smallest dimensions of a square or rectangle large enough to make
the sign. However, triangular or trapezoidal signs will be measured as the smallest
triangle or trapezoid required to make the sign.
250
If the pay unit for sheet signs is shown in the Schedule of Pay Items as each, the
number of sheet signs specified, including posts, hardware, and erection, will be
measured by the number of units installed.

Sign posts will be measured by the linear foot. Square sign posts will be measured
from the top of the post to the termination of the post in the anchor base.

Traffic sign support foundations will be measured by the number of units of each
type installed. No reduction will be made in a unit if class X material is encountered
260 during foundation excavation.

If class X material is encountered during foundation excavation, the quantity to

be measured will be that authorized and removed and in accordance with 206.10.

Structural steel, breakaway, will be measured by the pound. Such measurement

will include the weight of breakaway sections such as stubs, stiffeners, base plates,
and fuse plates. For rigid sections, the weight of the base plate will be included.

Reference posts, including post, sign, and hardware, will be measured by the
270 number of units installed.

Backfill of traffic sign support foundations will be measured in accordance with

211.09.

Overhead sign structures will be measured by the number of units of each type
installed.

Overhead sign structures to be removed will be measured by the number of

structures removed.
280

843
 802.12

802.12 Basis of Payment

The accepted quantities of sheet signs and panel signs will be paid for at the
contract unit price per square feet, of the type and thickness specified, with legend,
complete in place.

Sign post will be paid for at the contract unit price per linear foot for the type
specified.

Structural steel, breakaway, will be paid for at the contract unit price per pound.
290
Ground mounted sign support foundations will be paid for at the contract unit
price per each type specified.

Reference posts will be paid for at the contract unit price per each, complete in
place.

Payment for class X material encountered during a foundation excavation will be

made in accordance with 206.11.

300 Payment for backfill of support foundations will be made in accordance with
211.10.

The removal of signs, overhead structures, and sign assemblies, will be paid for
at the contract unit price per each.

Payment will be made under:

Pay Item Pay Unit Symbol

310 Box Truss Sign Structure Foundation, _____............................ EACH

type
Cable Span Sign Structure Foundation, _____ .......................... EACH
type
Cantilever Sign Support Foundation, _____ ............................. EACH
type
Overhead Butterfly Cantilever
Sign Structure Foundation, _____ ...................................... EACH
type
Overhead Sign Structure, _____, Remove ................................ EACH
320 type
Overhead Sign Structure, Box Truss, _____ ............................. EACH
type
Overhead Sign Structure, Bridge Bracket Assembly................. EACH
Overhead Sign Structure, Butterfly Cantilever .......................... EACH
Overhead Sign Structure, Cantilever, _____ ............................. EACH
type

844
 802.12

Overhead Sign Structure, Monotube ......................................... EACH

Overhead Sign Structure, Tri-Chord, _____.............................. EACH
type
330 Reference Post ........................................................................... EACH
Sign and Supports, Wide Flange, Remove ................................ EACH
Sign Post, _____ ........................................................................ LFT
type
Sign Post, Square, _____, Reinforced Anchor Base.................. LFT
type
Sign Post, Square, _____, Unreinforced Anchor Base .............. LFT
type
Sign, Double Faced, Sheet, With Legend, _____ ...................... SFT
thickness
340 Sign, Overhead, Remove ........................................................... EACH
Sign, Panel, Relocate ................................................................. EACH
Sign, Panel, Remove.................................................................. EACH
Sign, Panel, With Legend .......................................................... SFT
Sign, Sheet Assembly, Relocate ................................................ EACH
Sign, Sheet, and Supports, Remove ........................................... EACH
Sign, Sheet, Relocate ................................................................. EACH
Sign, Sheet, Remove.................................................................. EACH
Sign, Sheet, With Legend .......................................................... EACH
Sign, Sheet, With Legend, _____ .............................................. SFT
350 thickness
Structural Steel, Breakaway ...................................................... LBS
Tri-Chord Sign Structure Foundation, ______ .......................... EACH
type
Wide Flange Sign Post Support Foundation, _____ .................. EACH
type

The cost of staking sign and sign structure locations, including materials and
labor, shall be included in the cost of the pay items in this section.

360 The cost of all hardware necessary to assemble and attach the sign to its structural
supports, all legend, and adjustments necessary to eliminate specular reflection shall
be included in the cost of sheet sign or panel sign.

The cost of all hardware to attach the sign to its structural supports, the reflective
sheeting on both faces, and all legend shall be included in the cost of double-faced
sheet signs.

The cost of all necessary hardware including sign hangers, clips, and U bolts
required for the mounting of signs to existing or new overhead sign structures shall be
370 included in the cost of the sign.

845
 802.12

The cost of modifying existing hardware to mount a new sign shall be included in
the cost of the new sign.

The cost of the reinforced anchor base or unreinforced anchor base, angle bolts,
and rivets shall be included in the cost of sign post, square.

The cost of identification markings for signs shall be included in the cost of the
sign.
380
The cost of sign removal, existing post removal, and all mounting hardware
necessary to attach the existing sign to new posts, shall be included in the cost of the
sign relocation.

The cost of roadway and bridge reference signs and posts to be removed, stored,
and reinstalled shall be included in the cost of other pay items, unless otherwise
specified. Roadway and bridge reference signs which are damaged by the Contractor
shall be replaced with no additional payment.

390 The cost of furnishing and applying aluminum-impregnated caulking compound

and zinc chromate paint as required in 802.07, shall be included in the cost of the pay
items in this section.

The cost of removal of signs, sign assemblies, sign lighting circuitry, supports,
concrete foundations, backfill material, sodding, seeding, and necessary incidentals
shall be included in the cost of overhead sign structure, remove.

The replacement of posts damaged by the Contractor’s activities shall be without

additional payment.
400
The cost of concrete, reinforcement, stub, anchor bolts, conduit, and all necessary
hardware shall be included in the cost of the support foundation.

The cost of cutting the reinforcing bars and anchor bolts, furnishing the steel plate
and welding the plate to the ends of the anchor bolts when class X excavation is
encountered shall be included in the cost of the pay items in this section.

No additional payment will be made if square sign posts are used in lieu of type
A or type B posts.
410
The cost of excavation, except for class X material, and necessary incidentals shall
be included in the cost of the pay items in this section.

The cost of walkway assembly, where applicable, shall be included in the cost of
overhead sign structure.

846
 803.03

SECTION 803 – WELDING ALUMINUM ALLOYS

803.01 Description
This work shall consist of welding aluminum alloys for highway structures. The
welding terms used shall be in accordance with definitions included in the AWS
Definitions “MD” Welding and Cutting, AWS A3.0. Special conditions shall be fully
explained by means of added notes or details.

The aluminum alloys to be welded under these specifications may be any of the
10 following ASTM alloy designations:

(a) wrought non-heat-treatable alloys 3003, 3004,

5052, 5083, 5086, 5456;

(b) wrought heat-treatable alloys 6061, 6063; or

(c) cast heat-treatable alloy 356.0.

803.02 Materials
20 Materials shall be in accordance with the following:

Electrodes .................................................................... 924.01

Filler Material .............................................................. 924.01
Shielding Gases ........................................................... 924.01
Welding Rods .............................................................. 924.01

Material used for permanent backing shall be at least equivalent in weldability to

the base metal being welded.

30 803.03 Welding Processes

The welding process shall be by the gas metal-arc process or the gas tungsten-arc
process. Other processes may be used if prior approval is given.

(a) Preparation of Materials

Joint details shall be in accordance with design requirements and detail drawings.
The location of joints shall not be changed without approval.

Edge preparation shall be by sawing, machining, clipping, or shearing. Gas

tungsten-arc or gas metal-arc cutting may also be used. Cut surfaces shall meet the
40 ANSI surface roughness rating value of 1000. Oxygen cutting shall not be used.

Surfaces and edges to be welded shall be free from fins, tears, and other defects
which would adversely affect the quality of the weld. Dirt, grease, forming or
machining lubricants, and organic materials shall be removed from the areas to be
welded by cleaning with a suitable solvent or by vapor degreasing.

847
 803.03

The oxide shall be removed from all edges and surfaces to be welded by wire
brushing or by other mechanical methods such as rubbing with steel wool or abrasive
cloth, scraping, filing, rotary planing, or sanding just prior to welding. If wire brushing
50 is used, the brushes shall be made of stainless steel. Hand or power driven wire brushes
which have been used on other materials shall not be used. Where mechanical methods
of oxide removal are found to be inadequate, a standard chemical method shall be
used. Welding shall be done within 24 h after chemical treatment. When gas tungsten-
arc welding with direct current straight-polarity is being used, all edges and surfaces
to be welded shall have the oxide removed by a standard chemical method.

Welding shall not be done on anodically treated aluminum unless the condition is
removed from the joint area to be welded.

60 (b) Welding Procedure

All butt welds requiring 100% penetration, except those produced with the aid of
backing, shall have the root of the initial weld chipped or machined out to sound metal
before welding is started from the second side. Butt welds made with the use of
backing shall have the weld metal fused with the backing. Where accessible, backing
for welds that are subject to computed stress or which are exposed to view on the
completed structure and which are not otherwise parts of the structure, shall be
removed and the joints ground or machined smooth. In tubular members, butt welds
subjected to computed stresses shall be made with the aid of permanent backing rings
or strips.
70
The procedure used for production welding of any particular joint shall be the
same as used in the procedure qualification for that joint.

All welding operations, either shop or field, shall be protected from air currents
or drafts so as to prevent any loss of gas shielding during welding. Adequate gas
shielding shall be provided to protect the molten metal during solidification. The work
shall be positioned for flat position welding whenever practicable. All weld joints shall
be dry at the time of welding.

80 The size of the electrode, voltage and amperage, welding speed, gas or gas
mixture, and gas flow rate shall be suitable for the thickness of the material, design of
joint, welding position, and other circumstances attending the work. Gas metal-arc
welding shall be done with direct current, reverse polarity. Gas tungsten-arc welding
shall be done with alternating current or with direct current, straight polarity.

When the joint to be welded requires specific root penetration, the Contractor shall
make a sample joint and a macro etched cross section of the weld to demonstrate that
the joint welding procedure to be used is attaining the required root penetration. The
sample joint shall have a length of at least 1 ft and shall be welded with the electrode,
90 polarity, amperage, voltage, speed, gas mixture, and gas flow rate that are proposed to
be used in production welding. Evidence on record may be accepted in lieu of the
receding test.

848
 803.03

Where preheat is needed, the temperature of preheat shall not exceed 350°F for
heat-treated alloys and 600°F for non-heat-treated alloys. The temperature shall be
measured by temperature indicating crayons or by pyrometric equipment. Heat-treated
alloys shall not be held at the maximum preheat temperature or at temperatures near
the maximum for more than 30 minutes.

100 (c) Weld Quality

Welds will not be accepted if they contain cracks in the welds or in the adjacent
base metal, copper inclusions, or porosity in excess of that allowed by the AWS D1.2
Structural Welding Code.

Lack of fusion, incomplete penetration, or tungsten or oxide inclusions will be

acceptable only if small and well dispersed.

Undercut shall be no more than 0.01 in. deep when its direction is transverse to
the primary stress in the part that is undercut. Undercut shall be no more than 1/32 in.
110 deep when its direction is parallel to the primary stress in the part that is undercut.
Overlap shall not be allowed. All craters shall be filled to the full cross section of the
welds. Welds having defects greater than the levels of acceptance specified herein
shall be considered as rejected unless corrected in accordance with 803.03(e).

(d) Inspection
All welds shall be inspected visually to determine compliance with 803.03(c). In
addition, all welds subjected to computed stress shall be inspected by the dye penetrant
method except as specified below. For highway sign structures, the dye penetrant
method shall be used on butt welds in columns and main chord members; on fillet
120 welds connecting columns to bases and main chord members, including the associated
flanges, gussets, or main load carrying brackets or members; and on fillet welds
connecting flanges to the main truss chord members. The dye penetrant tests shall be
performed in accordance with ASTM E 165, method B, procedures B-2 or B-3. Dye
penetrant inspection may be omitted provided that the inspector examines each layer
of weld metal with a magnifier of 3X minimum before the next successive layer is
deposited.

(e) Corrections
In lieu of rejection of an entire piece or member containing welding which is
130 unacceptable, the corrective measures listed below may be allowed if approval is
obtained prior to making each repair. Defective welds shall be corrected by removing
and replacing the entire weld, or as follows:

1. Cracks in Welds or Base Metal

The full extent of cracks shall be determined by dye penetrant method or other
positive means. The cracks shall be removed throughout their length and depth, and
rewelded.

849
 803.04

2. Excessive Porosity and Lack of Fusion

140 All defective portions shall be removed and rewelded.

3. Copper or Tungsten Inclusions

All defective portions shall be removed and rewelded.

4. Excessive Concavity of Crater, Undercut and Undersize Weld

The weld shall be cleaned and additional weld metal shall be deposited.

5. Overlap
Overlap shall be reduced by removal of the excess weld metal.
150
The defective areas shall be removed by chipping or machining. Oxygen cutting
shall not be used. Before rewelding, the joint shall be inspected to ensure all the
defective weld has been removed. If dye penetrant has been used to inspect the weld,
all traces of penetrant solutions shall be removed with solvent, water, heat, or other
suitable means before rewelding.

803.04 Qualification of Procedures, Welders, and Welding Operators

Joint welding procedures shall be qualified previously by tests prescribed in the
AWS D1.2 Structural Welding Code. Evidence of previous qualification of the joint
160 welding procedures to be employed may be accepted.

All welders and welding operators shall be previously qualified by tests in

accordance with the AWS D1.2 Structural Welding Code. Evidence of previous
qualification of the welders and welding operators to be employed may be accepted.
The same process and type of equipment that is required for execution of the contract
work shall be used in qualifying welders and welding operators.

SECTION 804 – DELINEATORS

804.01 Description
This work shall consist of furnishing and erecting delineators in accordance with
105.03 and 107.12. Delineators shall be installed as required unless approval is
obtained from the District Traffic Engineer to make modifications.

MATERIALS

10 804.02 Materials
Materials shall be in accordance with the following:

Delineator Posts ........................................................... 910.15

Delineators................................................................... 926.02
Flexible Delineator Posts ............................................. 926.01

850
 804.07

The types of delineators shall be:

(a) D1 – single
20 (b) D2 – double
(c) D3 – triple.

Hardware for mounting delineators on posts shall be aluminum alloy in

accordance with 919.01(d)2; stainless steel or galvanized steel in accordance with
919.01(d)1; or aluminum pull-through blind rivets. Bolts and lock-nuts or rivets shall
be 3/16 in. diameter.

The types of flexible delineator posts shall be:

30 (a) type I - ground mounted

(b) type II - surface mounted.

CONSTRUCTION REQUIREMENTS

804.03 Delineator Visibility

Delineator reflector units shall be positioned so as to be visible for a distance of
1,000 ft on tangent sections or at maximum visibility distances on curves. These
locations shall be established under normal weather and atmospheric conditions when
illuminated by the upper beam of standard automobile headlights.
40
804.04 Posts
Posts shall be installed in accordance with 802.07.

804.05 Flexible Delineator Posts

These posts shall be installed according to the manufacturer’s recommendations
and shall be set so that the top is no more than 1/2 in. from any vertical plane through
the bottom.

804.06 Method of Measurement

50 Delineators with posts, delineator posts, and flexible delineator posts will be
measured by the number of units of the type specified.

804.07 Basis of Payment

The accepted quantities of delineators, delineators with post, delineator post, and
flexible delineator post, if set out as a separate pay item, will be paid for at the contract
unit price per each for the type specified, complete in place.

Payment will be made under:

60 Pay Item Pay Unit Symbol

Delineator Post .......................................................................... EACH

851
 805.01

Delineator Post, Flexible, ______ ............................................. EACH

type
Delineator with Post, _____ ...................................................... EACH
type
Delineator .................................................................................. EACH

Where new delineator posts are installed to replace existing delineator posts, the
70 cost of the removal of the existing post shall be included in the cost of the new post.

SECTION 805 – TRAFFIC SIGNALS

805.01 Description
This work shall consist of furnishing miscellaneous materials, not furnished by
the Department, and installing traffic signals in accordance with these specifications
and in reasonably close conformance with the lines, grades, and locations shown on
the plans or as directed.

MATERIALS
10
805.02 Materials
Materials shall be in accordance with the following:

Castings for Handhole ................................................ 910.05(b)

Coarse Aggregate, Class E or Higher,
Size No. 8 ............................................................ 904
Concrete, Class A, B, or C ......................................... 702
Loop Detector Sealant ................................................ 906.02(a)
Reinforced Concrete Pipe ........................................... 907.02
20 Reinforcing Bars.......................................................... 910.01
Traffic Signal Materials and Equipment ..................... 922
Treated Lumber .......................................................... 911.02

The proposed work shall be examined in order to determine what materials not
furnished by the Department are required to complete the contract. The Department
will furnish only the materials specified on the Department Furnished Materials
special provision. If materials to be furnished by the Contractor are listed, the list is
only a guide for estimating purposes. All additional materials required to complete an
operating installation as specified shall be furnished.
30
Signal handholes shall be Type I or Type II as shown on the plans.

Pedestrian push buttons shall be the type designated in the contract documents,
APS or Non-APS.

852
 805.03

Joint sealant material shall be compatible with the roadway materials. If

polyethylene duct loop wire is used, only sealant in accordance with 906.02(a)1 shall
be used.

40 Timber poles to be furnished shall be in accordance with the current ANSI

specifications and dimensions. They shall be of the length and class specified, be fully
treated in accordance with 922.10(b), and dry. Minimum circumference at the top and
at a point 6 ft from the butt shall be in accordance with ANSI specifications.

Steel strain poles greater than 24 ft in length shall be in accordance with 922.10(a).

The battery cabinet and program timing module for solar powered flashing
beacons shall be from the Department’s Approved List of Traffic Signal and ITS
Control Equipment.
50
CONSTRUCTION REQUIREMENTS

805.03 General Requirements

The Contractor shall maintain existing traffic signals in operation until the
Engineer determines that the progress of the work necessitates their removal. The new
installation shall not interfere with the operation of the existing signal. The work shall
proceed in such a manner that the signals are not out of service at any two adjacent
intersections at any time. When the operation of an existing traffic signal needs to be
interrupted before the new signal is placed in operation, the traffic shall be controlled
60 at all times. The work shall be scheduled so that the interruption is limited to a
minimum amount of time and at off peak hours. The new span and catenary installation
shall not interfere with the operation of the existing traffic signal. Traffic shall be
controlled at all times during the changeover when the existing traffic signal is turned
off and the new signal is turned on. This changeover shall take place such that the
interruption is limited to a minimum amount of time.

When directed, temporary stop signs shall be erected at the intersection. When no
work is in progress, the intersection shall have at least two operating signal faces for
each approach. When the new installations are completed, all existing signal
70 equipment and materials including timber poles, steel poles, and cast-iron handhole
rings and covers which have not been used in the new installation shall be carefully
removed. Regardless of the right to materials found on the project, as set out in other
sections of these specifications, items designated in the contract documents, and field
identified by the Department, as traffic signal equipment to be salvaged by the
Department or local unit of government shall be stored at a secure site until such time
as it is transported to the designated location, when designated as a pay item, or
salvaged by the Department or local unit of government. The Contractor shall verify
that the field identification placed by the Department has not been removed by
vandalism or natural causes. If the Contractor has reason to believe field identifications
80 have been removed, it shall contact the Department. The Contractor shall be
responsible for all damage or loss of this equipment and shall repair or replace the

853
 805.03

damaged or lost equipment as directed. All signal equipment removed and not
designated to be salvaged shall become the property of the Contractor and shall be
disposed of in accordance with 202.

All existing painted metallic signal equipment to be reused, such as pedestals,

bases, controller cabinets, signal weatherheads, pipe arms, shall be cleaned and painted
with two coats of highway yellow enamel in accordance with 909.02(c). Existing
metallic signal heads to be reused shall be painted with two coats of black or highway
90 yellow enamel as directed by the Engineer and in accordance with 909.02(c).
Aluminum poles and signal support structures shall not be painted.

Existing concrete foundations, which have not been used in the new installation,
shall be removed to a minimum of 4 in. below the adjacent grade. The openings shall
be filled with concrete and the surface finished and broomed, if they are located in
sidewalk areas. Otherwise, they shall be filled with acceptable material conforming
with the surrounding area.

Existing signal handholes to be removed, shall be filled after removing rings and
100 covers, with B borrow with a minimum of 4 in. of concrete on top to bring it up to
grade in a sidewalk area. Surfaces shall be finished and broomed. Otherwise, they shall
be filled with acceptable material conforming with the surrounding area.

The signal controller timings will be provided and the Engineer shall be present
when the signal intersection is to be placed in operation.

All electrical wiring terminations and splices; controller and cabinet set-up; and
testing, review, and turn-on of all operational apparatus at each location shall be done
by or in the presence of and under the responsible charge of an employee of the
110 Contractor who holds an IMSA Traffic Signal Construction Technician Level II
certification or an IMSA Traffic Signal Field Technician Level II certification.
Installation inspections, troubleshooting, maintenance and repair of these systems
shall be accomplished by or in the presence of and under the responsible charge of an
employee of the Contractor who holds an IMSA Traffic Signal Construction
Technician Level II certification. Supervision of non-electrical, traffic signal related
construction work and traffic control shall be done by a person holding, at a minimum,
an IMSA Work Zone Temporary Traffic Control Technician certification or an
equivalent certification approved by the Department.

120 Before starting work, the Contractor shall provide the names of the Level II
Traffic Signal Construction Technicians, the Level II Traffic Signal Field Technicians
and Work Zone Temporary Traffic Control Technicians who have been assigned to
perform signal related work, and a photocopy of each such person’s certification card.
If the Level II Traffic Signal Construction or Field Technicians or Work Zone
Temporary Traffic Control Technicians are dismissed from the work, all signal related
work requiring such certified personnel on the project site shall cease until the names

854
 805.04

and photocopies of certification cards for replacement personnel are provided to the
Engineer.

130 Electrical work shall be executed in accordance with the requirements of the
National Board of Fire Underwriters, the State Fire Marshal, and the power company
which will furnish the electric service. The work shall be in accordance with any local
regulations that may apply. The Department will arrange and provide for power
service which the power company will bring to the point designated on the plans. Prior
to the start of construction, the schedule of activities shall be coordinated with the
power company and they shall be contacted again at least 14 days prior to the time the
service work is to be completed.

The Department will obtain permits from local officials, companies, or

140 individuals for the use of poles, right-of-way, or other property incidental to the
installation of traffic signal. Although entering into the contract implies permission
and authority to cut into and push under pavement, sidewalks, and alleys, any damage
to underground utilities or interruption of such service shall be the responsibility of
the Contractor. The Contractor shall be in accordance with local regulations as well as
107.08. Protective devices shall be in accordance with 107.12 and 801.

The location of signal heads, controllers, signal poles, signal cantilever structures,
detector housing, disconnect hangers, and other installation items will be shown on the
plans. However, a change in the location of an item may be ordered during the progress
150 of the work. The work shall be completed as shown on the plans except for those
changes specifically authorized in writing.

Flashing beacons shall flash at a rate for each beacon of 50 to 60 times per minute
with the illuminated period from 1/2 to 2/3 of the total cycle. Second beacons, if
specified, shall flash alternately with the exception of intersection control beacons
which shall flash simultaneously.

805.04 Pole Installation

Working drawings for strain poles or cantilever structures shall be provided in
160 accordance with 105.02. Metal poles shall be erected on concrete foundations and shall
be reasonably plumb after installation of signal heads. The handhole side of the pole
shall be at right angles to the direction of the signal cantilever arm or span, catenary,
and tether. Signal cables shall be brought up inside the poles. Any steel pole, signal
cantilever arm, or hardware not galvanized shall be painted with structural steel
coating system in accordance with 619.09(a). The surface shall be prepared in
accordance with 619.08(a), 619.08(b) and 619.08(d). Paint shall be applied in
accordance with 619. All rust, scale, and dirt shall be cleaned from the metal surface
so that paint adheres to the surface.

170 The construction of concrete foundations shall be in accordance with 805.13.

Timber poles shall be set a minimum of 7 ft in the ground and raked 12 in.

855
 805.05

805.05 Placing Signal Heads

Signal cantilever arm and span mounted signal heads shall have 17.5 ft minimum
and 22.5 ft maximum clearance over the roadway unless there are visual obstructions
which require lowering the signal head. A signal head over the roadway shall not have
a clearance of less than 15 ft. Such signal heads shall be located over the intersection
as shown on the plans. Such signal heads shall have a uniform clearance, which will
be determined. Signal heads not mounted over a paved roadway, on the top or side of
180 a pole, shall not be less than 10 ft or more than 15 ft above the sidewalk or, if none,
above the pavement grade at the center of the roadway. Signal faces shall be directed
to the proper approach lane in each direction. Flasher signal faces that supplement
signs shall be mounted with the bottom of the housing at not less than 3 ft or more
than 13 ft above the edge of pavement. Flasher signal faces that supplement signs shall
be directed towards oncoming traffic. Pedestrian signal faces shall be mounted with
the bottom of the housing at not less than 7 ft or more than 10 ft above the sidewalk.
The pedestrian signal shall be in line with the pedestrian’s vision at the appropriate
crosswalk being used. Pedestrian push-buttons shall be mounted at a height of 3 1/2 to
4 ft above the sidewalk as shown on the plans. A pedestrian actuated signal sign shall
190 be mounted immediately above the push-button.

Signal heads shall be assembled and wired with one conductor, type THW,
stranded wire. Where splices are made, a 2 ft minimum length of cable or wire in
excess of that required for a continuous run shall be provided. Splices shall be twisted
together and soldered or approved type connectors used. Each splice shall be
completely insulated by wrapping with an approved tape and sealed with an approved
electrical coating material. Splices shall be made in such manner that the connections
are moisture proof. The cables coming out of the signal weatherhead shall be looped
to form a drip loop. The drip loop shall be made so that the cables coming out of the
200 weatherhead loop down below the elevation of the weatherhead to prevent water from
following the cable into the weatherhead. If used, the splice indicated above shall be
located in the top of the coils of cable forming the drip loop.

Except for signal heads installed on existing traffic signal cantilever structures, all
overhead signal heads shall have backplates, unless otherwise indicated on the plans.
Backplates shall not be cut or altered upon installation.

Signal heads shall not be installed until all other work has been completed. If it
becomes necessary to mount signal heads for more than 2 h before the lights are to be
210 turned on, the signal heads shall be hooded by placing sacks or similar cover over them
so as to conceal them from traffic. Hooded signal heads are not allowed to be in place
for more than five days. No signal head shall be left over night with the lights out
unless it is hooded. Signal heads shall be securely mounted. The polycarbonate signal
face shall be used only when securely supported on both ends of the assembly. In a
span cable installation, a tether cable would satisfy this requirement.

856
 805.07

When installing push buttons with accessible pedestrian signals, APS, features the
Contractor shall verify that the audible tone is discernible from the mid-point of the
crosswalk.
220
805.06 Grounding
All signal supports, signal controller supports, and entrance switches shall be
grounded in accordance with the applicable requirements of 807.12.

805.07 Wire and Cable Installations

All cable runs attached to utility poles shall have code clearance relative to utility
cables. They shall be no less than 18 ft above the ground level except over railroad
tracks when a minimum of 27 ft clearance shall be maintained. All cable runs shall be
installed in continuous lengths without splices between terminals except when
230 necessary at handholes, junction boxes, pole signal bases, and pedestal bases. The type
of cable and the number of conductors as well as the gage shall be as shown on plans
unless otherwise specified.

Cable rings shall be used to support the signal cable on the signal span cable. They
shall be spaced 12 in. on center. Cable shall be pulled through the conduit to the
terminal panel in the controller cabinet. Caution shall be used to prevent damage to
the cable when it is being pulled through conduit.

Coded cable conductors shall be used throughout the installation. Cable

240 conductors shall be tagged at all detector housings, handholes, signal pole bases, and
controller cabinets. At the ends of each cable, the tag shall be placed between 4 and 8
in. from the end of the wire and on the outer jacket. At all other locations, the tag shall
be placed in the middle of the length of cable stored at the location. The tag shall be
1/2 in. wide, thermal printed black on yellow or black on white, polyester or nylon
tape with permanent adhesive and shall be water, chemical and scratch resistant. The
font shall be arial, size 10px. Tags shall be installed flag style around the cable with
the backs of the tag ends placed together. Tags shall identify the cables by their use.
The following are the uses which shall be indicated by the tags:

250 1. Power
2. Pedestrian Signal
3. Pedestrian Actuation
4. Signal
5. Detection Loop Identification
6. Interconnect.

Signal cables shall be tagged to identify the direction of travel. Detector lead-in
cables shall be tagged throughout the installation with the corresponding loop tag
information.
260
The tagging material and fastening shall be approved prior to proceeding with this
work. The color coded wires shall be connected properly. The white wire shall be the

857
 805.08

common or ground. Wire used for all identical indications of any individual phase
shall be color coded and, where possible, shall use red wire to connect red lenses,
orange wire to connect yellow lenses, and green wire to connect green lenses. Signal
heads shall be assembled and wired before being installed. The testing of the loops
shall be documented in the Loop Testing Table provided by the State.

805.08 Controller Cabinet, Signal Service, and Detector Housing

270 Installation
Three document packets shall be prepared in accordance with 922.02(b) for each
cabinet. Each packet shall be labeled with the name of the contract number, the
intersection, the commission number of the signal, and the date of installation. One
paper packet shall be placed in the cabinet, one paper packet shall be submitted to the
Engineer, and one electronic packet shall be submitted to the Electronic Technician
Supervisor at the Department’s Logistical Support Center within two days after the
signal is turned on. Information in the packets shall include all approved changes to
the signal installation. All detector loop lead-in tags and detector rack labels shall
reflect all approved changes to the signal installation.
280
Additional detector loop amplifier units and detector racks shall be supplied as
directed by the Engineer. Additional detector racks shall include all cables or harnesses
including, but not limited to a SDLC cable for each added rack, interface panels and a
BIU to provide a complete and functional installation. Additional auxiliary BIU panels
shall include all cables or harnesses including, but not limited to a SDLC cable for
each additional auxiliary BIU panel, terminal strip on BIU panel and BIU to provide
a complete and functional installation.

For signal cabinets installed by the Contractor, where no detector loop or lead-in
290 work is included in the contract, the Contractor shall perform detector loop tagging,
testing and vehicle simulator testing in accordance with 805.09, only to the extent of
documenting the test readings and confirming that all existing detector loops are
connected correctly and all detector related equipment in the cabinet is operating
correctly.

The controller cabinet shall be mounted securely on a pole, pedestal, or concrete

foundation. All cabinets on concrete foundations shall be installed with the anchor
bolts inside. Controller cabinets on poles or pedestals shall be mounted at a height of
38 in. ±2 in. Pole mounted controller cabinets shall be fastened with two stainless steel
300 bands as shown in the plans. Signal cables and lead-in cable shall be run in conduit
from the controller cabinet to the signal support base and to detector housing as
indicated on the plans. Galvanized steel elbows shall be used on the detector housing
as shown on the plans.

The Contractor shall wire the entrance switch and bring service cable up the riser
and out the weatherhead and leave 4 ft of cable outside the weatherhead. The utility
company, at their option, may bring the service cables to the load side of the entrance
switch. Meter bases, if required, shall be obtained from the power company.

858
 805.09

310 A minimum of 12 in. and a maximum of 18 in. of loop wire duct will be allowed
in the detector housing for each loop lead. Concrete used in the installation of detector
housings shall be in accordance with 506, except 506.05 will not apply. A CMDS in
accordance with 502.03 shall be submitted, however, utilization of the Department
provided spreadsheet is not required. Where a portion of the road is closed or where
there is no vehicular traffic, then class A concrete in accordance with 702 may be used.
The concrete shall be placed flush with existing surface and shall be covered with a
steel plate during the setting time.

805.09 Loop Wire Detector Installation

320 This work shall consist of placement and testing of loop wire detectors in
accordance with the installation details shown on the plans.

(a) Layout
The number, size, arrangement, and locations of loops shall be as shown on the
plans except that loop spacing shall be adjusted to avoid PCCP joints. Loops shall be
of a regular octagon shape with sides of 2 1/2 ft in length or a circular shape with a
diameter of 6 ft. Loops placed longitudinally adjacent in the same lane shall be spaced
15 ft from the center of one loop to the center of the next loop. Loops shall be arranged
so that no loop wire will be bent at an angle less than 120°. Regardless of
330 configuration, the loop installation shall match the intention of the loop tagging table.

Prior to installation, loop layout shall be approved in writing by the District

Traffic Engineer. The Contractor shall notify the District Traffic Engineer a minimum
of two business days prior to the date that loop layout approval is required. All
roadway centerlines, edge-lines and stop-bars pertinent to loop layout shall be
accurately and clearly identified at the time loop layouts are reviewed for approval.
An outline shall be painted where the loops are to be placed. The Contractor shall
ensure that the final installed location of each loop matches the intention and
functionality of the approved layout for loop spacing, lane width and geometry.
340
(b) Installation
All loops and lead-in cables shall be tagged according to the plans and 805.07.

The slots shall be saw-cut as shown on the plans. A diamond cutting blade shall
be used for sawing all loops. All saw-cut loops shall have individual saw cuts to the
detector housing. Joints shall be overlapped such that the saw cut at the corner is full
depth. Prior to installing roadway loop wire in the roadway saw cuts, the saw cuts shall
be cleaned in accordance with the manufacturer’s requirements for the joint sealant to
be used. After proper cleaning, the loop wire shall be installed. All loops shall be wired
350 clockwise as viewed from above. Loops shall be wired with four turns or as specified
then gently tamped with a blunt non-metallic tool. Backer rod 2 to 4 in. in length shall
be spaced every 12 in. around the saw cut above the wire and gently tamped to hold
the loop wire snug in the bottom of the saw cut. Backer rod shall not be continuous
around the saw cut. After installation of the loop wire, the saw cut shall be sealed with

859
 805.09

a joint sealant material. The sealant shall be poured into the saw cut making a water
tight seal. The joint sealant material shall be installed in accordance with the
manufacturer’s recommendations and 906.02. However, the joint configuration shall
not apply. A copy of the sealant manufacturer’s written application instructions shall
be submitted to the Engineer prior to any sealant operations. If the Contractor elects
360 to use a sealant complying with 906.02(a)2, the sealant material shall be heated in a
kettle or melter constructed as a double boiler with the space between the inner and
outer shells filled with oil or other heat-transfer medium. This melter shall have a
positive temperature control and a mechanical agitator. A backer rod shall be used for
both cold applied sealants and hot poured sealants. The sealant material shall fill the
saw cut as shown on the plans. All excess joint sealant on the pavement surfaces shall
be promptly removed.

The black lead-in wire shall be spliced to the loop wire which goes back to the
field. Such wire shall be tagged as “Out/Loop (No.)”. The white lead-in wire shall be
370 spliced to the loop wire which comes in from the field. Such wire shall be tagged as
“In/Loop (No.)”.

(c) Splices
For each loop cable and lead-in cable entering a handhole, there shall be 6 ft of
cable jacket remaining on each wire after the splice is complete. For each loop cable
and lead-in cable entering a detector housing, there shall be 2 ft of cable jacket
remaining on each wire after the splice is complete. For all loop splices, there shall be
a maximum of 1/2 in. of non-jacketed wire measured from the end of each cable jacket
to the edge of the splice waterproofing material. The splice of the loop wire and lead-
380 in cable shall be soldered and waterproofed at the detector housing or handhole.
Waterproofing shall consist of the use of heat shrink tubing which has an internal
coating sealant material. The heat shrink tubing shall not be heated by means of a
direct flame tool.

(d) Testing and Acceptance

All testing and acceptance procedures performed by the Contractor shall be
performed in the presence of the Department personnel assigned by the Engineer. The
Contractor shall notify the Engineer a minimum of two business days prior to the date
testing is to be performed.
390
The Contractor shall meter all new loop wire detectors or a new bank of loop wire
detectors by means of instruments capable of measuring electrical values for installed
loop wires and lead-in cables. The instruments shall measure inductance in
microhenries, resistance in ohms, induced AC voltage in volts, and leakage resistance
in megohms. All measuring tests shall be performed at the detector housing before the
loop wire is spliced to the lead-in cable, and at the cabinet after the loop wire is spliced
to the lead-in cable.

860
 805.09

1. Electrical Testing
400
a. Megohm Test Before Splice is Made at Detector Housing for
Loop Wire
One of the megohm probes shall be connected to ground and the other probe shall
be connected to the “in” or “out” loop wire. The remaining loop wire shall be isolated.
The test shall then be performed.

b. Megohm Test Before Splice is Made at Detector Housing for

Lead-in Cable
The two wires and shield of the lead-in cable at the cabinet shall be isolated and
410 taped. The test shall consist of recording four readings taken at the detector housing or
handhole as follows:

(1) Connect the first megohm probe to ground and the

second probe to the shield. Record the reading.

(2) Connect the first megohm probe to the first lead-in

wire and the second probe to the shield. Record the
reading.

420 (3) Connect the first megohm probe to the second

lead-in wire and the second probe to the shield.
Record the reading.

(4) Connect the first megohm probe to the first lead-in

wire and the second probe to the second lead-in
wire. Record the reading.

The lowest of the four readings taken above shall be recorded on the testing
document for acceptance.
430
c. Megohm Test After Splice is Completed at Cabinet
This test shall be performed after the splice at the detector housing is completed.
A water solution of one tablespoon of baking soda per pint of water shall be placed in
a metal container. The metal container shall be grounded and the splice shall be fully
submerged in the solution for 2 minutes. With the splice submerged, the shield of the
lead-in shall be connected to ground at the cabinet. One megohm probe shall then be
connected to ground and the other probe connected to one of the lead-in wires and the
reading recorded.

440 2. Delay Amplifier Settings and Vehicle Simulator Test

After all detector loop testing is complete, the detector amplifiers shall be installed
and settings adjusted for proper operation at the intersection.

861
 805.09

The frequency setting shall be adjusted using the amplifier’s display so that
adjacent loops in the roadway that are connected to different loop amplifiers have a
minimum difference of 5 kHz. This operating frequency setting does not apply to loops
that are adjacent to each other in the roadway but are connected to the same loop
amplifier.

450 The sensitivity setting shall be adjusted using the amplifier’s display. With an
average size front wheel drive vehicle with the front axle centered over the back loop
of a series of loops, the sensitivity shall be adjusted in accordance with the
manufacturer’s recommendations.

The count output shall be enabled for all loops designated as counting loops. The
number of loops setting shall be set for loops designated for counting purposes and
shall be set to the number of loops connected to that loop amplifier.

This test shall be performed by dragging a test vehicle across the loops using a
460 non-conducting string. The test vehicle shall be fabricated with an 8 ft length of No. 6
bare copper wire formed into a 2 1/2 ft diameter circle. The two ends shall then be
electrically spliced. The test shall be started with all detector amplifiers turned ‘Off’
except for one approach. All amplifiers for that approach shall be turned ‘On’ and
adjusted to the proper settings. All traffic for the approach being tested shall be stopped
and not allowed to cross any loops during the test procedure for that approach. The
simulator shall be dragged slowly across each loop system in the same direction as to
simulate a vehicle driving through the loop system. As the simulator crosses each loop
an IMSA level II certified Signal Technician shall verify that a call is displayed
exclusively on the corresponding loop amplifier, controller detector input and
470 controller phases. After completely verifying the loops on the first approach the
amplifiers shall be left ‘On’, and the amplifiers for the next approach to be tested shall
be turned ‘On’ and adjusted to the proper settings. The same procedure shall be
followed for each remaining approach. With large intersections, as the test proceeds,
it may become difficult to verify that the calls are going to the correct detector inputs.
In this case, traffic control shall be used to stop vehicles before reaching the loops for
as many approaches as needed to accurately complete the testing to the inspector’s
approval. Testing may be paused between lanes to allow traffic to clear.

3. Acceptance Criteria
480 The Contractor shall record all test readings, in triplicate, on tabular forms
provided by the Department or by copying the one included elsewhere herein. The
Contractor shall complete, sign, and date the forms before submitting them to the
District Traffic Engineer. The District Traffic Engineer will use these forms for
recording the Department’s readings on the corresponding space provided.

In order for the loop detector installation to be accepted, the electrical values shall
be as follows:

862
 805.11

a. Inductance shall be between 80 and 800 μH. Inductance

490 shall be determined by means of digital readout meter
which drives the field loop system.

b. Resistance shall be less than or equal to 8 ohms.

c. Induced AC voltage shall be less than or equal to 3 volt.

d. Leakage resistance shall be greater than 100 megohms.

Loop wire or lead-in cable failing to meet this requirement shall be replaced at no
500 cost to the Department.

805.10 Other Vehicle Detection Systems

When required, the Contractor shall furnish and install an alternative vehicle
detection system from the Department’s list of approved Traffic Signal and ITS
Control Equipment.

805.11 Steel Conduit

Conduit shall be installed to a depth of no less than 2 ft or more than 5 ft below
the finished grade unless otherwise specified or approved. Pockets or traps where
510 moisture might accumulate shall be avoided. Conduit shall be placed under existing
pavement by approved jacking or drilling methods. Pavement shall not be disturbed
unless otherwise specified. If specified, cuts in pavement areas shall be no greater than
24 in. wide. All cuts in the pavement and sidewalk areas shall be sawed. Sidewalk
removal and replacement shall be to the nearest tooled joint. Jacking and drilling pits
shall be kept at least 2 ft clear of the edge of any type of pavement or paved shoulder.
Excessive use of water that may cause undermining of the pavement shall be avoided.
Continuous conduit runs shall not exceed 200 ft in length, unless otherwise shown on
the plans.

520 Expansion fittings as detailed on structure plans shall be installed where conduit
crosses an expansion joint in the structure. Where it is deemed inadvisable to install
expansion fittings in closely confined areas, the installation of approved flexible tubing
may be allowed. Such expansion joints or tubing shall be the same size as the conduit.
Any existing underground conduit to be incorporated into a new signal installation
shall be cleaned with a mandrel and blown out with compressed air before cable is
drawn into pipe. All new conduit runs shall be cleaned and swabbed before cables are
installed. All conduit ends shall be capped and shall remain capped until the Contractor
is ready to pull cable into the conduit, at which time the caps shall be removed and
conduit bushings placed on each end to protect the cable. The inside surface of the
530 conduit shall be kept clean. Conduit to be installed, indicated on the plans for future
use of signal cables, shall be left in place with a pull cord on its entire length.

Larger size conduit may be used with no additional payment, but when it is used,
it shall be for the entire length of the run from outlet to outlet. Conduit runs as shown

863
 805.12

on the plans are for bidding purposes only and may be changed, with permission, to
avoid underground obstructions. A change order may be authorized if the conduit runs
can be made on the opposite side of the street to that shown on the plans in order to
avoid obstruction and traffic inconvenience or to avoid unnecessary tearing up of
existing pavement.
540
805.12 PVC, HDPE, and Fiberglass Conduit
The method of installing PVC, HDPE and rigid fiberglass conduit underground
shall be the same as for steel conduit where applicable except trenches for the conduit
in areas with class X material as described in 206.02 shall be backfilled with 2 in. of
natural sand before the conduit is placed in the trench. Materials excavated may be
used for backfill, if approved. If the Engineer deems it necessary, approved B borrow
shall be placed over the conduit to a depth of 12 in. and the remainder of the trench
shall be filled with excavated material.

550 Schedule 40 or 80 PVC, Schedule 40 HDPE, or rigid fiberglass conduit may be

used for conduit placed in trenches with expansion fittings used every 200 ft unless
otherwise indicated on the plans. Schedule 80 HDPE, or steel shall be used for conduit
that is jacked or bored. Schedule 80 PVC or rigid fiberglass shall be used for conduit
on bridges or other structures. A No. 6 AWG copper or No. 14 AWG aluminum ground
wire shall be included in all PVC, HDPE, and rigid fiberglass conduit.

805.13 Foundations
Foundations for traffic signal structures, cabinets, and pedestals of the type
specified shall be constructed, or existing M foundations shall be modified, as shown
560 on the plans or as directed. Pedestal bases shall be plumb and firmly attached to the
anchor bolts either by using leveling nuts or shims if top of the foundation is not level.
Grouting shall be used when necessary to fill any gap between pedestal base and
foundation. Pipe pedestals shall be screwed tightly into the bases and secured with a
stainless steel pin. Power and signal cables shall then be pulled from the base into the
cabinet. Curing of concrete shall be in accordance with 702.22.

The foundation concrete for traffic signal cantilever structures shall be placed
monolithically and shall have no construction joint. Structure bases shall be plumb and
attached to the anchor bolts using leveling nuts. A tooled line or other type of
570 permanent marking shall be provided on the top of the foundation to indicate the
direction of the conduits.

During excavation of the foundation, all material shall be removed to the full
depth as shown on the plans, except if class X material is encountered, the work shall
be performed in accordance with 206.02(b).

805.14 Final Clean-Up

When the installation is completed, all disturbed portions of sidewalk, pavement,
shoulders, driveways, and sod, shall be cleaned and any excess excavation or other
580 materials shall be disposed. All cutting in the sidewalk and pavement areas shall be

864
 805.16

done with a saw. Sidewalk removal and replacement shall be to the nearest tool joint.
Unless otherwise directed, cuts in pavement areas shall be no greater than 12 in. in
width.

805.15 Method of Measurement

Controller and cabinet; controller cabinet foundation; disconnect hanger;
handhole, signal; loop detector delay amplifier; loop detector rack; pedestrian push
button; pedestrian signal head; signal cantilever structure, combination arm; signal
cantilever structure, drilled shaft foundation type; signal cantilever structure, dual arm;
590 signal cantilever structure, single arm; signal cantilever structure, single arm,
combination arm; signal cantilever structure, spread footing foundation type; signal
detector housing; signal pole; signal pole foundation; signal service; span catenary and
tether; traffic signal head; and traffic signal head, retrofit; will be measured by the
number of units installed.

The pay length for a signal cantilever arm or combination arm will be the length
shown in the Schedule of Pay Items.

Conduit of the type specified will be measured by the linear foot from outside to
600 outside of foundations. All signal cable will be measured by the linear foot.

Saw cut for roadway loop detector and sealant will be measured by the linear foot
for the full depth of slot cut in the pavement as shown on the plans or as directed.

If class X material is encountered during foundation excavation, measurement

will be made in accordance with 206.10.

Traffic signal installation, flasher installation, miscellaneous equipment for traffic

signals, and final cleanup in accordance with 805.14 will not be measured for payment.
610 Reinforcing bars will not be measured for payment.

Traffic signal equipment removal will be measured per each installation to be

removed. Transportation of salvageable signal equipment will not be measured.

805.16 Basis of Payment

Traffic signal installation and flasher installation, all of the type, new or
modernized, and the location number specified, will be paid for at a contract lump sum
price.

620 If specified as pay items, controller and cabinet; controller cabinet foundation;
disconnect hanger; handhole, signal; loop detector delay amplifier; loop detector rack;
pedestrian push button; pedestrian signal head; signal cantilever structure, single arm;
signal cantilever structure, combination arm; signal cantilever structure, single arm,
combination arm; signal cantilever structure, dual arm; signal cantilever structure,
drilled shaft foundation type; signal cantilever structure, spread footing foundation
type; signal detector housing; signal pole; signal pole foundation; signal service; span

865
 805.16

catenary and tether; traffic signal head; and traffic signal head, retrofit; will be paid
for at the contract unit price per each.

630 Conduit of the type specified will be paid for at the contract unit price per linear
foot. The cost of any backfill, ground wire, or expansion fittings shall be included in
the cost of conduit.

Saw cut for roadway loop detector and sealant, and signal cable will be paid for
at the contract unit price per linear foot.

The removal of existing traffic signal equipment designated to be removed will

be paid for at the contract unit price per each for traffic signal equipment, remove for
each location removed. When designated as a pay item, the transportation of
640 salvageable signal equipment will be paid for at the contract lump sum price for
transportation of salvageable signal equipment.

Class X excavation will be paid for in accordance with 206.11.

Miscellaneous equipment for traffic signals will be paid for at a contract lump
sum price.

Payment will be made under:

650 Pay Item Pay Unit Symbol

Conduit, ____ ............................................................................ LFT

type
Controller and Cabinet, _____................................................... EACH
type
Controller Cabinet Foundation, _____ ...................................... EACH
type
Disconnect Hanger .................................................................... EACH
Flasher Installation, ______, Location No. _____..................... LS
660 type
Handhole, Signal, _______ ....................................................... EACH
type
Loop Detector Delay Amplifier, ______,_____ Channel .......... EACH
type no.
Loop Detector Rack................................................................... EACH
Miscellaneous Equipment for Traffic Signals ........................... LS
Pedestrian Push Button, _____ .................................................. EACH
type
Pedestrian Signal Head, _____, ________ ............................... EACH
670 type lens size
Saw Cut for Roadway Loop Detector and Sealant .................... LFT

866
 805.16

Signal Cable, _____, Copper, _____ C/ _____ ......................... LFT

type conductors/size
Signal Cantilever Structure, Combination Arm _____ ft .......... EACH
length
Signal Cantilever Structure, Drilled Shaft Foundation, ______ EACH
type
Signal Cantilever Structure, Dual Arm ___ ft, ___ ft ................ EACH
length length
680 Signal Cantilever Structure, Single Arm _______ ft ................. EACH
length
Signal Cantilever Structure, Single Arm ___ ft,
length
Combination Arm ___ ft..................................................... EACH
length
Signal Cantilever Structure, Spread Footing
Foundation, _______ .......................................................... EACH
type
Signal Detector Housing............................................................ EACH
690 Signal Pole,______, _____ ft .................................................... EACH
type length
Signal Service ............................................................................ EACH
Signal Pole Foundation, _____ in. x _____ in. x _____ in........ EACH
Span, Catenary, and Tether ....................................................... EACH
Traffic Signal Equipment, Remove ........................................... EACH
Traffic Signal Head, _____, Section, __________ .................... EACH
no. lens size
Traffic Signal Head, _____ Section, Retrofit ........................... EACH
no.
700 Traffic Signal Installation, _____, Location No. _____ ........... LS
type
Transportation of Salvageable Signal Equipment ..................... LS

The cost of the controller and cabinet, conduit, foundations, vehicle detection,
pedestrian signals, signal heads, signal poles, signal service, signal cable and all
equipment or materials required to complete the installation shall be included in the
cost of traffic signal installation.

The cost of the controller and cabinet, conduit, foundations, signal heads, signal
710 poles, signal service, signal cable and all equipment or materials required to complete
the installation shall be included in the cost of flasher installation. For a solar powered
flasher, the cost of the solar panel, battery cabinet, program timing module, signal
heads, wiring, and all hardware required to complete the installation shall be included
in the cost of flasher installation.

The cost of the controller assembly, standard loop detector racks, all wiring,
hardware, and associated equipment required to operate the intersection shall be
included in the cost of controller and cabinet.
867
 805.16

720 The cost of concrete, conduits, grounding bushings, ground rod, ground wire,
drainage, anchor bolts, and all hardware required to complete the installation shall be
included in the cost of controller cabinet foundation.

The cost of all work and hardware required to properly install loop detector delay
amplifier, counting or non-counting, as shown on the plans or as directed shall be
included in the cost of loop detector delay amplifier.

The cost of concrete reinforcing pipe and ring or polymer concrete box, cover and
attachment hardware, handhole bottom if required, and aggregate as shown on the
730 plans shall be included in the cost of handhole, signal.

The cost of any supplementary loop detector rack, all wiring, hardware, detector
panel, BIU, and associated equipment shall be included in the cost of the loop detector
rack.

The cost of the push button, pedestrian actuated signal sign, any accessible
pedestrian signal components, and all hardware required to complete the installation
shall be included in the cost of pedestrian push button.

740 The cost of signal face hook-up wire, pole plates and arms for side mounts, pipe
arms, signal brackets, bulbs, weatherhead, and all additional hardware required to
assemble a combination of pedestrian signal indications as shown on the plans shall
be included in the cost of pedestrian signal head.

The cost of the slot cut on the pavement, backer rod, loop sealant, and all testing
in accordance with 805.09 shall be included in the cost of saw cut for roadway loop
and sealant.

The cost of all work and hardware required to properly install overhead or
750 underground signal cable, signal, fiber optic, or interconnect, as shown on the plans or
as directed shall be included in the cost of signal cable.

The cost of signal pole section 2 and combination arm, all hardware including the
metal skirt base plate, where necessary, to complete the installation as shown on the
plans shall be included in the cost of the signal cantilever structure, combination arm.

The cost of concrete, reinforcing bars, conduits, ground rod, ground wire,
grounding bushings, anchor rods, and all hardware required to complete the
installation of the drilled shaft or spread footing foundation for signals shall be
760 included in the cost of signal cantilever structure, drilled shaft or spread footing
foundation.

The cost of signal pole and dual arms, all hardware including the metal skirt base
plate, where necessary, to complete the installation as shown on the plans shall be
included in the cost of the signal cantilever structure, dual arm.
868
 805.16

The cost of signal pole section 1 and single arm, all hardware including the metal
skirt base plate, where necessary, to complete the installation as shown on the plans
shall be included in the cost of the signal cantilever structure, single arm.
770
The cost of signal pole section 1, 2 and single arm, combination arm, all hardware
including the metal skirt base plate, where necessary, to complete the installation as
shown on the plans shall be included in the cost of the signal cantilever structure, single
arm, combination arm, when structure with single arm and combination arm is
required in the same contract.

The cost of aluminum casting, enclosure concrete, conduit and elbow, and all
hardware required to complete the installation shall be included in the cost of signal
detector housing.
780
For a steel signal pole, the cost of the base plate, metal skirt base plate, handhole
and cover grounding lug, 2 in. pipe cable entrance, J hook, and top cover as shown on
the plans shall be included in the cost of signal pole.

For a timber signal pole, the cost of downguys, anchor rods, downguy guards, and
hub-eyes as shown on the plans, and all hardware required to complete the installation
shall be included in the cost of signal pole.

For a signal pedestal, the cost of the pedestal metal base, pedestal pole, pole cap,
790 and all hardware required to complete the installation shall be included in the cost of
signal pole.

The cost of concrete, reinforcing bars, conduits, ground rod, ground wire,
grounding bushings, anchor rods, and all hardware required to complete the
installation of the signal pole foundation shall be included in the cost of signal pole
foundation.

The cost of weatherhead, 1 in. conduit riser, entrance switch, 1 to 2 in. conduit
reducer, ground rod, ground wire, and all hardware required to complete the
800 installation, including the meter base when required and supplied by the utility
company shall be included in the cost of signal service.

The cost of steel pole bands or straight eye bolts, span, catenary, and tether of wire
rope cables, cable rings, type A support cable, wire rope clips, safety cable, thimble,
service sleeve, and all hardware required to complete the installation as shown on the
plans shall be included in the cost of span, catenary, and tether.

The cost of signal face hook-up wire, pole plates and arms for side mounts, mid-
mast arm mount, pipe arms, signal brackets, visors, louvers, bulbs, span hanger,
810 backplates, balance adjuster, weatherhead, and all additional hardware required to

869
 807.01

assemble a combination of signal faces as shown on the plans shall be included in the
cost of traffic signal head.

The cost of removing the existing traffic signal head, salvaging the existing LED
indicators, replacing the existing signal head with a new housing and backplate, and
reinstalling shall be included in the cost of traffic signal head, retrofit.

The cost to repair or replace damaged or lost salvageable traffic signal equipment
shall be at no additional cost to the Department.
820
The cost of excavation, backfill, final cleanup in accordance with 805.14, the cost
of re-painting existing metallic equipment to be re-used and necessary incidentals shall
be included in the cost of the pay items in this section.

SECTION 806 – BLANK

SECTION 807 – HIGHWAY ILLUMINATION

807.01 Description
This work shall consist of installing wire, cable, conduit, lighting standards,
luminaires, lamps, and incidental materials in accordance with 105.03.

Lighting installations shall be in accordance with the National Electrical Code and
the National Safety Code.

10 MATERIALS

807.02 Materials
Materials shall be in accordance with the following:

Casting for Handholes ................................................. 922.17(a)

Coarse Aggregate, Class D or Higher,
Size No. 53 ........................................................... 904
Concrete, Class A ........................................................ 702
Conduit ........................................................................ 922.19
20 Highway Illumination Materials .................................. 920.01
Line Hardware ............................................................. 922.10(e)1
Paint ............................................................................. 909
Reinforced Concrete Pipe ............................................ 907.02
Reinforcing Bars.......................................................... 910.01

Manufacturers’ descriptive and technical literature for major items shall be

submitted for approval. Where it is normal trade practice to furnish a warranty, a
warranty shall be furnished on all major items such as luminaires, lamps, poles,

870
 807.03

brackets, cable-duct, wire and cable, fuse connectors, and ballasts. The effective date
30 of the warranty shall commence on the date of final acceptance. These items shall bear
the seal of approval of the UL.

All flexible conduit shall be galvanized steel, polyvinyl jacketed, and watertight.

Reinforcing bars shall be epoxy coated.

CONSTRUCTION REQUIREMENTS

Existing highway illumination shall be maintained on all projects unless

40 discontinuance of the highway illumination is specifically allowed.

807.03 Working Drawings

Working drawings shall be submitted in accordance with 105.02 for lighting-
standard assemblies, luminaires, and external drive assemblies.

Working drawings for each luminaire model submitted shall include the luminaire
specifications and data sheets.

For contracts not utilizing the approved materials list for solid state luminaires,
50 working drawings for luminaires shall also include the Illumination Engineering
Society of North America, IESNA, photometric distribution file if the file number
varies from what is shown on the plans. The IESNA photometric distribution file shall
be in either Visual, developed by Acuity Brands Lighting, or AGi32 from Lighting
Analysis, Inc.

Working drawings for conventional lighting standards shall show the outside shaft
diameter, height, wall thickness, arm length and rise, size, handhole details, grinding
details, materials required, and complete anchor-bolt details including bolt circle-
projection and hardware. If a breakaway base is required, its details shall be shown.
60
When requested, sufficient design data shall be furnished with the drawings to
verify that conventional lighting standards are in accordance with wind load,
deflection, vibration, and breakaway requirements. All of the above shall be based on
the lighting-standards details shown on the plans. After approval, the Engineer shall
be advised of where changes to the Installation Summary sheets are being made
because of existing roadside conditions. Where necessary, additional lighting standard
working drawings shall be submitted for approval.

If a lighting standard is designed to support a larger luminaire than that specified,

70 such information shall be shown on the working drawings. A Type C certification from
the manufacturer shall be furnished with the working drawings stating that the
breakaway devices are in accordance with the breakaway criteria of the AASHTO
Standard Specifications for Structural Supports for Highway Signs, Luminaires, and
Traffic Signals.

871
 807.04

Working drawings for high mast standards shall show the pole height, number of
sections, the pole shaft data for each section, luminaire lowering ring assembly,
handhole details, materials required, and complete anchor bolt details including bolt
circle-projection and hardware.
80
Unless calculations are on file with the Department, the following design
calculations and data shall be submitted for approval prior to the fabrication of a high-
mast pole.

(a) general dimensions of all component parts;

(b) the maximum moments, the section modulus required, and the
section modulus furnished at the base of the pole, at all splices,
at the connection of the ring, and at least every 20 ft;
90
(c) calculation of stresses in the base plate, connection attachment,
and anchor bolts;

(d) maximum deflection at the top of the structure under the

specified loading; and

(e) the dimensions and wiring diagrams of the external drive

system connection to the pole in accordance with 920.01(b)7.

100 The working drawings shall include the dimensions and wiring diagram of the
standard connections of the external drive system.

807.04 Excavation
All excavation for the roadway lighting installation shall be performed in
accordance with the dimensions, elevations, and grades shown on the plans or as
directed. If class X material is encountered, foundation excavation shall be completed
in accordance with 206.

(a) Trench Excavation

110 Excavation may be accomplished either manually or with mechanical trenching
equipment. The blades of road patrols or graders shall not be used to excavate the
trenches. The depth of trenches shall be a minimum of 2 ft. Walls of trenches for cable-
duct or conduit shall be essentially vertical. The bottoms of trenches shall be smooth
and free from aggregate larger than 1/2 in. Bracing, shoring, and sheathing shall be
provided as necessary. If the excavation, through accident or otherwise, is below the
required level, the excess excavated area shall be refilled in a satisfactory manner with
no additional payment. The accumulation of water in excavated areas shall be
prevented by the use of pumps or other approved means. When rocks or other materials
which might damage the cable-duct or conduit are encountered, the excavation shall
120 be extended to a depth of at least 27 in. and backfilled with a 3 in. compacted layer of

872
 807.06

sand or earth containing no particles that would be retained on a 1/4 in. sieve. No extra
payment will be made for this additional excavation or backfill.

(b) Foundation Excavation

If possible, excavation for concrete foundations shall be accomplished by means
of drilling with an auger of sufficient size to admit the width of the foundation. Work
shall be so scheduled that all open excavations are poured with concrete during the
work day they are dug. No excavations shall remain open over night or over a weekend
or holiday. Accumulated water shall be removed from the excavation before concrete
130 is poured. If class X material is encountered, foundation excavation shall be completed
in accordance with 206.02(b).

(c) Landscape Replacement

Where roadside shrub plantings interfere with the location of illumination
installations, the plantings shall be reset at other locations and at such times as directed,
all in accordance with 622. The cost of this work will not be paid for directly, but shall
be included in the cost of other pay items.

All slopes for foundation grading shall be sodded. Sod shall be placed in
140 accordance with 621.

807.05 Backfilling
Wherever practicable, all suitable materials removed from the excavated areas
shall be used in refilling cable-duct and conduit trenches. No excavated materials shall
be wasted without authorization. Materials authorized to be wasted shall be disposed
of as approved. Backfill for trenches shall be placed in layers not to exceed 6 in., loose
measurement. The first layer shall be sand or earth containing no particles or lumps
that would be retained on a 1/4 in. sieve. The second layer shall contain no particles
or lumps that would be retained on a 1 in. sieve. Subsequent layers shall contain no
150 particles or lumps that would be retained on a 3 in. sieve. The second layer and each
subsequent layer shall be compacted with pneumatic hand tamps to the satisfaction of
the Engineer to prevent any future settlement of the backfilled area. Backfilling of
cable-duct and conduit trenches around lighting standard foundations, handholes,
manholes, and other structures shall be in accordance with the applicable provisions
of 211. Finish grading of earthwork shall be accomplished in a satisfactory manner.

807.06 Placing Conduit

Conduit shall be placed as shown on the plans and in accordance with applicable
provisions of 805.11. Conduit shall be of a size to readily enable the passage of the
160 cable-duct being used.

Conduit installed under pavement shall extend a minimum of 2 ft beyond the edge
of the paved surface or improved shoulder. The ends of such conduit shall terminate a
nominal 2 ft below the ground surface. The ends shall be pitched so as to provide a
positive drain to the surrounding soil. The ends shall be protected by threaded cap

873
 807.07

fittings until the time of installation of cable or cable-duct. Threaded bushing fittings
shall be used on all ends before cable installation.

Conduits installed in bridge railing concrete sections shall terminate a minimum

170 of 2 ft beyond the end of the bridge railing outside of the paved surface and a minimum
of 2 ft under the ground surface. Existing conduit shall be extended as necessary to
satisfy these requirements.

Hot dipped galvanized, malleable pipe straps and spacers shall be used to attach
conduit to bridge structures. Galvanized steel conduit hangers or pipe clamps will not
be allowed. Pipe straps of the proper size shall be installed 4 ft center to center along
the conduit. When fastening pipe straps to concrete, a 3/8 in. by 2 1/2 in. galvanized
steel lag screw, with an approved sleeve, shall be used; however, other approved
expansion anchors may be used. The pipe strap and spacer shall be bolted to the steel
180 beams.

Conduit for service supply shall be mounted on a service pole, either company or
State owned, near the right-of-way line. For simple supply circuits, one straight,
continuous, conduit riser shall be used. The top end shall terminate with a weatherhead
device, and the lower end shall terminate at least 2 ft below ground level with a
threaded grounding bushing fitting. Unless otherwise directed, the weatherhead shall
be 24 ft above the ground. However, the actual elevation of the weatherhead shall meet
the requirements of the utility concerned.

190 807.07 Connections in Base of Lighting Standards

Conductors shall be electrically bonded to each other, as required to satisfy circuit
requirements, by means of compression type fittings of the style and type shown on
the plans. Inhibitor compound shall be used on each compression connection.
Conductor identification shall be maintained by connecting like color connectors.

A multiple conductor compression fitting shall be used to connect supply

conductors and an insulating link used to provide an extension as shown on the plans.
These fittings shall be covered with snap-on fiber or plastic covers designed to protect
them from electrical contact. Taping will not be allowed. The bare extension of the
200 supply conductor from the multiple fitting to the insulation link shall be no longer than
necessary to admit the application of the snap-on cover for the multiple fitting.

The pole circuits shall be connected by means of easily separated, single

conductor connector kits. The connector kit on the “hot” side of the pole circuit shall
be fused. The connector kit for the neutral side shall not be fused. Fuses shall be of the
“KTK” series with a rated capacity three times the operating amperage of the
luminaire. If the required capacity is not a standard size, the next larger size fuse shall
be used.

210 The connector kit on the “hot” side of the pole circuit shall have the following
features:

874
 807.07

(a) a line side and load side housing made of plastic or water
resisting synthetic rubber suitable for direct burial in the ground
or installation in sunlight;

(b) a water seal between the two housings;

(c) each housing permanently marked “Line Side” or “Load Side”;

220
(d) a spring loaded, 90% minimum conductivity, contact suitable
for gripping the “KTK” cartridge fuse in each housing. These
contacts shall be fully annealed;

(e) an interior arrangement for each housing that will adequately

receive and rigidly maintain the fuse contacts;

(f) a terminal on each housing designed for a crimp type connection

to the conductor that securely retains the conductor in the proper
230 position;

(g) a water seal between the conductor and the housing;

(h) a disconnecting means that shall retain the fuse on the load side
when disconnected and keep the conductive parts of the line
side inaccessible; and

(i) sufficient silicone compound provided and used to lubricate the

metal parts and the rubber housings or boots for easy assembly.
240
The neutral side connector kit shall be similar in all respects to that described for
the hot side except that a dummy fuse shall be used for the purpose of completing the
electrical circuit. The bayonet disconnect feature of the connector kits shall be part of
the load side of both the neutral side and the hot side conductors. The line side shall
have a socket to receive the bayonet. These kits shall be installed in the pole circuit
between the luminaire terminals and the compression connection to the underground
distribution circuit as shown on the plans. A separate insulated conductor shall be used
to connect the neutral of the underground distribution circuit and the neutral of the
pole circuit to the ground lug in the pole base from the point at which both neutrals are
250 connected together by a compression connection. The bayonet disconnect features
from the neutral side and the hot side connector kits as cited above shall be included
in the sign structure circuitry when luminaires are installed on the sign structures.
Consecutive roadway luminaires in a circuit shall be alternately connected to opposite
load conductors R or B as specified in the plans to balance the load. Sign luminaires
on individual structures shall be similarly connected.

875
 807.08

807.08 Placing Wire and Cable

(a) Underground Through Cable-duct

260 All underground distribution conductors shall be continuous runs between splice
points. Unless otherwise authorized, splice points shall be inside the bases of lighting
standards, inside handholes, in service distribution boxes, at point of connection to
power supply in switch boxes, or in junction boxes. All splices shall be made with the
proper connector in accordance with 807.07.

1. Cable-duct
Cable-duct shall be placed either in a trench or plowed into place. Cable-duct shall
be installed without sharp bends or kinks and in straight runs so as to enable
withdrawal of a conductor and the installation of new conductor without additional
270 excavation or backfill.

Plowed cable-duct shall be installed at a minimum depth of 2 ft in a single cavity

gored into the earth by a vibrating plow blade. The equipment used for plowing the
cable-duct shall be designed specifically for that purpose with the power and versatility
to easily and accurately bury the various sizes of cable-duct under all normal soil
conditions. This equipment shall place the cable-duct without twisting, kinking, or
damaging it in any way. Dragging or pulling the cable-duct from the start of the
trenching operation will not be allowed. Where two ducts are to be installed parallel
to each other, the distance between them shall be no less than 12 in. and no more than
280 24 in.

The plastic duct of the cable-duct shall be terminated 4 in. above the top of
foundations or 4 in. inside handholes with sufficient excess conductors as directed. All
terminations of this plastic duct shall be beveled free from any sharp edges or burrs.
Insulation of the electrical conductor shall not be damaged when cutting the duct.

2. Cable Markers
The location of underground conduits or cable-ducts shall be marked with cable
markers. The marker shall be placed at all changes in direction, where the underground
290 distribution circuit is split, and at a maximum of 400 ft intervals on straight runs. Cable
markers shall be a slab of concrete 2 ft square by 4 in. thick, with the word “Cable”
die impressed into the surface of the marker, a minimum depth of 3/8 in. with letters a
minimum of 2 in. high. Arrows showing the direction of the cable shall be die
impressed or saw cut a minimum depth of 3/8 in. into the marker surface.

Curing of the concrete shall be in accordance with 702.22. The cable marker shall
have a smooth metal trowel finish without scaling.

(b) Underground Through Conduit

300 The underground distribution circuit shall be protected by galvanized steel
conduit when installed under pavement, in road shoulders, or elsewhere as shown on
the plans or as directed.

876
 807.09

1. Cable-duct
Cable-duct shall be pulled through the entire length of galvanized steel conduit if
at all possible. If this is not possible, written authorization shall be obtained to allow
the duct to be cut away and the conductors installed in the conduit with a minimum of
2 ft of duct extended into the conduit. Where so authorized, the plastic duct shall be
terminated in the proper transition fitting attached to the end of the conduit and each
310 conductor of the cable-duct assembly shall continue undamaged and uninterrupted
through the galvanized steel conduit to the other end of the conduit where a transition
to the cable-duct shall be used again and the cable-duct shall continue uninterrupted
to the next designated splice point. All transitions from galvanized steel conduit to
cable-duct shall be accomplished with the proper adapter. This adapter shall provide a
durable, watertight transition that has a smooth uniform interior.

2. Cable Markers
Cable markers shall be in accordance with 807.08(a)2.

320 (c) In Conduit Risers

Cable-duct shall enter the bottom of the conduit riser with a sweeping radius bend
and continue up the riser to within 3 in. of the top of the conduit riser. At this point the
plastic duct shall be terminated and the conductors shall continue uninterrupted and
undamaged into the service cabinet, underpass switchbox, or through the weatherhead
with sufficient excess to make the required connections.

(d) Through Conduit in Bridge Coping

Where a cable-duct underground distribution circuit is run through conduit
installed in bridge coping, the duct shall be cut away and the conductors shall be
330 installed in the conduit with at least 2 ft of duct extended into the conduit. The
conductors, through this transition, shall be continuous between authorized splice
points. Where more than one lighting standard is to be installed on the same side of
the bridge structure and connected to the same distribution circuit, the cables pulled
between these lighting standards shall be of the same type and size used in the cable-
duct underground distribution circuit.

(e) Aerial Cable

Aerial cable for overhead distribution circuits shall be supported and terminated
as shown on the plans. The aerial cable shall have a sag of no more than 5% of the
340 distance between lighting poles except where slack spans are indicated on the plans.
Aerial cables shall have a minimum vertical clearance of 18 ft.

807.09 Lighting Handholes

Handholes shall not be placed in areas subject to flowing or ponding water.
Handholes shall be installed with the top flush with adjoining surfaces. Precast
handholes with integral bottoms will be considered acceptable.

877
 807.10

Multiple compression fittings and insulating links installed in handholes shall be

taped and waterproofed by application of an approved waterproofing device. The
350 insulation around the area to be waterproofed shall be cleaned before applying the
waterproofing device. These waterproofing devices shall be designed for insulating
multi-conductor cables with a minimum voltage carrying capacity of 600 volts.

Heavy weave fiberglass reinforced polymer concrete service boxes will be

allowed as an acceptable substitute for a street and alley handhole providing that they
can be placed at a location which meets both of the following conditions:

(a) there is no evidence of vehicles traveling over the area where

the handhole is to be located; and
360
(b) it is located a minimum of 15 ft from the edge of pavement,
unless it is protected by guardrail, unmountable curb, a
structure, or an untraversable ditch.

The handhole shall be backfilled with sand or earth containing no particles that
would be retained on a 1/4 in. (6.3 mm) sieve. The backfill shall be placed as shown
on the plans. No additional payment will be allowed for this backfill.

807.10 Concrete Foundations For Lighting Standards

370 Foundations shall be class A concrete in accordance with 702. Footings may be
either round or square in shape as shown on the plans.

Anchor bolt circle dimensions shall be furnished and the anchor bolts shall be in
accordance with 920.01(a)7. A rigid template shall be used to center the anchor bolts
in the foundation. Unless otherwise specified, the template shall be oriented so that the
mast arm of the lighting standard is perpendicular to the center line of the roadway.

Each foundation installation shall have provisions for grounding the lighting
standard in accordance with 807.12. The tops of the concrete foundations shall be
380 constructed level and only shims used to rake the lighting standard will be allowed.
Shims shall not be used with break-away couplings. Each foundation shall have an
imprinted arrow or arrows on the top of the foundation to indicate the direction of the
cable duct run.

Foundations for high mast towers shall be constructed prior to constructing

foundations for conventional roadway lighting.

(a) Cast-in-Place Foundations

If the sidewalls of the excavated areas remain firm and stable, concrete may be
390 poured directly against the dirt below the level of the top 6 in. form. Otherwise, the
concrete foundation shall be fully formed by means of a paper preformed liner or other
approved means. However, the foundation shall be formed to the proper size for the
top 6 in. before concrete is poured. If a paper liner is used, it may be withdrawn as the

878
 807.11

concrete is placed or it may be left in place permanently. If the liner is left in place, all
voids between the excavation walls and the form shall be filled and compacted using
coarse aggregate No. 53. If the liner is withdrawn, the top 12 in. of the foundation shall
remain formed until the concrete has obtained initial set.

(b) Precast Foundations

400 Precast foundations shall be complete with reinforcing bars, tie bars, anchor bolts,
and entry sleeves located to provide a level mounting for the lighting standard after
installation. The grounding coil, as shown on the plans, may be used for grounding
lighting standards set on precast foundations. Foundation backfill shall consist of
coarse aggregate No. 53.

(c) Grading of Foundations

Foundation projection above the finished grade shall be as shown on the plans.
The excavated material may be used for this grading if it is not granular in nature and
will readily stabilize and support the growth of sod. If the excavated material is
410 unsuitable, it shall be properly disposed of and approved materials used. The area shall
be sodded. Sodding will be in accordance with 621.

807.11 Placing Lighting Standards

(a) Lighting Standards Under 80 ft in Height

The lighting standard assembly shall consist of a metal pole, a shoe base, a
frangible breakaway base or coupling where shown on the plans, and a metal mast arm
for attaching the luminaire. The unit shall be assembled on the ground. Pole circuit
wiring shall be installed and the luminaire shall be attached prior to erection. The
420 factory finish of the pole assembly shall be protected from mars, blemishes, scratches,
or other damage. Slings and chokers for lifting purposes shall be of nylon or other
approved material. Chains, metal rope, or other abrasive materials shall not be used
for lifting devices. If damage to the factory finish occurs, repair or replacement shall
be as directed.

The base plate shall be designed to carry the pole assembly. The plate assembly
shall be supported by a transformer base, which shall be in accordance with the
breakaway requirements in the AASHTO Standard Specifications for Structure
Supports for Highway Signs, Luminaires, and Traffic Signals.
430
After erection and attachment to the foundation, the pole assembly shall be plumb.
The luminaires shall be level in both horizontal areas. Shims shall not be used with
breakaway couplings. Shimming will be allowed on other types of installations to rake
the pole assembly to obtain the desired attitude of the luminaire where the combined
weight of the pole and mast arm requires it and the luminaire saddle will not allow the
adjustment. The mast arm shall be perpendicular to the axis of roadway travel unless
special orientation is noted on the plans. Unless otherwise specified, the lighting
system shall consist of metal pole supports for the luminaires with an underground
electrical supply system.

879
 807.12

440
(b) High Mast Lighting Standards of 80 ft Height and Over
High mast light pole sections shall be mechanically fitted in the field using factory
supplied hydraulic jack or hoist puller that shall produce a minimum force of 10,000
lb per side. Field assembly procedures and assembly apparatus requirements shall be
submitted for approval. Field welds will not be allowed except where shipping
limitations prevent permanent factory assembly. Prior approval for field welds is
required.

The pole shall be erected on the lower set of the anchor bolt nuts and secured with
450 the top nuts. The adjustments to plumb the pole shall be made prior to the final
tightening of the top nuts.

The pole shall be plumbed under no wind conditions before sun-up, after
sun-down, or on an overcast day. The deviation from vertical shall not exceed 1/4 in.
within any 10 ft of height.

When installing the high mast power cable, one end of the power cable shall be
securely connected to the luminaire ring. The other end of the power cable shall be
secured to the support and terminated 3 ft below this support with a heavy duty three-
460 wire electrical plug. Adjustments of the three support cable lengths shall be made prior
to lowering the ring for the first time. After the support cables have been adjusted and
the luminaires installed on the ring, at least one complete cycle operation of the ring
shall be conducted on each structure.

807.12 Grounding
Ground wire shall be No. 6 solid bare copper. Ground rods shall be 1/2 in.
diameter by 8 ft long copper weld ground electrodes except where larger sizes are
specified. The top of the ground rod shall be driven at least 6 in. below grade. Ground
rods shall not be installed within the lighting standard, sign structure, or high mast
470 tower foundations.

The ground wire shall be connected to the top or side of the ground rod. The
ground rod, ground wire connection shall be made by a thermo weld process. The wire
and ground rod shall be free of oxidized materials, moisture, and other contaminates
prior to inserting the wire and the ground rod into the properly sized mold. The welding
material shall sufficiently cover and secure the conductor to the rod. The completed
connection shall be non-porous.

As an acceptable substitute to this process, a mechanical ground grid connection

480 of an approved type may be used. Tap type clamps, parallel type clamps, U-bolt flat
clamps, and crossover clamps will not be accepted.

Luminaire standards shall be grounded by connecting the free end of the ground
wire to the grounding lug in the transformer base or pole. The free end of the ground
wire shall enter the pole base through the entry sleeve installed in the foundation.

880
 807.13

The neutral conductor of the underground distribution circuit shall be connected

to the ground lug in the transformer base or pole. This connection shall include a
quick-disconnect type connector kit so that in the event of a pole knockdown the
490 connection will readily break without damage to the buried conductor.

The breaker boxes for the sign and underpass circuits shall be grounded by
connecting the free end of the ground wire to the neutral grounding terminal in the
breaker box and connecting this terminal to a grounding lug securely fastened to the
metal interior of the breaker box. The conduit terminating in the breaker box and the
sign or underpass luminaire housing shall have a good, clean, tight connection and act
as a grounding conductor for these luminaires. The neutral conductors of the feed and
distribution circuits for underpass and sign illumination shall be connected to the
neutral grounding terminal in the switch box or breaker box. The neutral conductor of
500 the distribution circuit for underpass and sign illumination shall be grounded in each
luminaire by connecting a jumper from the neutral terminal of the luminaire to a
ground lug fastened to the metal housing of the luminaire.

Sign structures shall be grounded at one sign column by connecting the free end
of the grounding wire at that column to the grounding lug in the column base.

A type I service for supply of electrical energy shall consist of a conduit riser to a
weatherhead. This conduit shall be grounded at the lower end by means of a standard
strap grounding connection to the ground wire and ground rod. A type II service shall
510 consist of a multiple number of conduits from underground to the bottom of the service
cabinet and a single conduit to a weatherhead from the top of the service cabinet. All
of these conduits shall be connected by a single ground wire from the grounding
terminal to a grounding bushing for each conduit within the interior of the service
cabinet. In addition a ground wire from the grounding terminal of the service cabinet
shall be connected through a conduit to a ground rod.

Bridge railing conduits shall be grounded at each end of the bridge railing by
means of a standard grounding strap connected to a ground wire and ground rod. The
ends of the conduits terminating in a bridge anchor location shall provide ground
520 continuity by means of a grounding bushing on each conduit end and the connection
of the bushing to a ground wire.

All equipment used in the highway lighting system shall be grounded. If

necessary, additional grounding shall be installed as directed.

807.13 Luminaires

(a) Installation
Luminaire installation shall consist of the physical placing of the luminaire. Each
530 installation shall include the furnishing and placing of the light source as designated.
Luminaires shall be compatible with other lighting materials as specified in 920.01.

881
 807.13

1. Roadway Luminaires
Each luminaire shall be leveled in both directions in the horizontal plane after the
light standard has been erected and adjusted. Rotary adjustment of the mast arm and
vertical adjustment of roadway luminaires to obtain an installed level position in both
directions shall be accomplished by means of the bolted saddle arrangement used to
attach the luminaires to the mast arm. Lamp socket positions may be shown on the
plans by type of Illuminating Engineering Society of North American, IES, and light
540 pattern. The specified lamp socket position or comparable arrangement of LEDs shall
be used to obtain the desired light pattern delivery. Proper connections shall be made
to provide operation at the voltage being supplied. Replacements needed because of
faulty or incorrect voltage connections shall be made with no additional payment. All
roadway luminaires provided for an intersection, interchange, or contiguous highway
segment shall be the same model.

2. Sign Luminaires
Connections in which plain and galvanized steel are in contact shall be protected
such that aluminum surfaces shall receive one coat of zinc chromate primer. Steel
550 surfaces shall be prepared in accordance with 619.08(a), 619.08(b) and 619.08(d) and
painted with a structural steel system in accordance with 619.09(a). All paint shall be
allowed to cure before assembly. Conduit fittings, if required, shall be watertight.
Required conduit shall be either rigid or flexible as necessary. Conduit shall not be
clamped to a sign panel.

Sign luminaires shall be mounted on overhead sign structures on two metal

channels located at the extremity of the sign walkway support brackets. The distance
between lighting unit support channels shall be 7 in. These channels shall be located
in such a manner that they readily receive the mounting bolts from the rear of the sign
560 luminaire. The installation of the sign luminaire shall consist of the physical placement
of the luminaire on the channels.

Sign luminaires shall be connected to a phase conductor and a neutral conductor.

The luminaires shall be alternately connected to opposite phase conductors to balance
the load. The connections in the base of the sign structure shall be in accordance with
807.06. Conductor splicing shall be in junction boxes, in-ground handholes, inside
handholes of sign structures, and circuit breaker enclosures. All sign luminaires
provided for an interchange or contiguous highway segment shall be the same model.

570 3. Underpass Luminaires

Underpass luminaires shall be mounted on the vertical side surfaces of bridge bent
structures or suspended by means of pendants supported by angle-iron struts or clips
fastened to the structural beam members of the bridge. All parts of the pendent pipe
assembly shall be hot-dipped galvanized after threads are cut. Silicone caulking
compound shall be applied to the threads during assembly of the pendent. Underpass
luminaires may require separately mounted ballasts which shall be installed in close
proximity to the luminaires.

882
 807.14

Underpass luminaires shall be connected to a phase conductor and a neutral

580 conductor. The luminaires shall be alternately connected to opposite phase conductors
to balance the load. Conductor splicing will only be allowed in junction boxes, in-
ground handholes, and circuit breaker enclosures. All underpass luminaires provided
for an interchange shall be the same model.

4. High Mast Luminaires

The aiming of the luminaires shall be as shown on the plans. When the aiming
process is being done the luminaire shall be oriented to conform to its raised position
and the ring properly tethered to prevent rotation during the aiming adjustment. The
long axis of the luminaire shall be parallel to the aiming direction indicated on the
590 plans. All high mast luminaires provided for an interchange shall be the same model.

(b) Warranty
A non-prorated manufacturer’s written warranty, against loss of performance,
defects in materials and defects in workmanship, shall be provided to and in favor of
the Department. For roadway, underpass, and high mast luminaires, the warranty shall
cover a period of 10 years from the date of installation of the luminaire; for sign
luminaires the period shall be five years. The warranty shall cover all components of
the luminaire, including but not limited to ballast, driver, and light source. Loss of
performance is defined to include, but is not limited to, the luminaire or any of its
600 components falling out of compliance with the specification in place at the time of
installation, which includes but is not limited to the following: there is no light output
from 10% or more of the LEDs, LED junction temperature exceeds 158F under any
circumstance, the luminaire is operating below the lumen maintenance curve, or the
color temperature shifts more than 500K outside of the specified color temperature
range. The warranty shall stipulate that replacement luminaires shall be shipped to the
appropriate Department District Office, at no cost to the Department, within 30 days
after the manufacturer’s receipt of failed luminaires. Warranty documents shall
include the manufacturer’s name, address to which failed luminaires are to be shipped
for replacement, contact person and contact person’s telephone number and e-mail
610 address. Warranty documents shall be submitted to the Engineer with the type C
certification. Warranty documents shall provide the estimated life cycle of the lamp,
LEDs, plasma emitter and power driver.

807.14 Sign, Underpass, Roadway, High Mast Lighting Location, and

Luminaire Identification
All high mast towers, roadway light standards, underpass lighting installations,
and sign lighting installations shall have an identification code number as shown on
the plans. In addition, each luminaire at a sign or underpass installation shall be
individually identified with a single capital letter.
620
The code number shall be displayed on the light standard, sign structure column,
and high mast tower as shown on the plans. The underpass code number shall be
displayed near the breaker box at a location as directed.

883
 807.15

The code number for the lighting standard and sign structure column shall be
applied to the pole, as specified by the manufacturer, by using individual, pressure
sensitive, adhesive backed tags. The code number for the high mast tower shall be
applied to an aluminum plate which is mounted with spacers away from the structure
as shown on the plans.
630
A luminaire identification sticker shall be provided on each luminaire and on the
light pole or tower that supports the luminaire. The sticker shall be titled
“LUMINAIRE” and contain the following information: light source type,
manufacturer, model, wattage, date of installation, and warranty period. The
pole/tower sticker shall be attached underneath the light pole ID tag, shall face the
roadway, and shall have 3/4 in. lettering, and be no greater than 8 in. by 8 in.

807.15 Service Point Power Entry

The utility’s requirements for service locations shall be coordinated. Unless
640 otherwise specified, a pole shall be furnished for the service point. If the utility requires
metering of the lighting system, a meter socket shall be obtained from and installed in
accordance with the requirements of the utility. Grounding shall be in accordance with
807.12 and shall be a part of the service installation.

Energy shall be provided with 120/240 V service or 240/480 V service with the
proper KW capacity on poles located immediately inside the right-of-way at locations
designated on the plans. Electrical materials incorporated in the work shall be
compatible with the service voltages supplied by the local utility.

650 The service voltages supplied by the local utility shall be checked for compliance
with the planned voltages. If a discrepancy exists, it will be resolved as directed before
work is started or any electrical equipment is purchased.

(a) Types of Service Points

Service point installations shall be of two types as shown on the plans.

1. Type I Service Point

This service point installation shall consist of class 5 timber pole, 2 3/4 in.
galvanized steel conduits, weatherhead, photo cell and multiple relay switch. The
660 conduit riser shall be fastened and supported on the pole by means of galvanized hook
pipe straps and secured to the pole by means of a galvanized lag screw all of the proper
size for the conduit being installed. Cable-duct shall be installed in the conduit riser in
accordance with 807.08(c). The conductors shall extend beyond the weatherhead a
minimum of 4 ft. The conductors outside of the weatherhead shall be ringed to prevent
moisture from entering the conduit enclosure.

2. Type II Service Point

This service point installation shall consist of a service cabinet with a single
galvanized steel or aluminum conduit riser to the weatherhead. A multiple number of

884
 807.16

670 galvanized steel conduits shall extend from the bottom of the service cabinet in
accordance with 807.06. Underground cable-duct shall be installed in accordance with
807.07(c). Connections, connectors, and fixtures shall be as shown on the plans.

The service cabinet shall be secured to the pole by means of a galvanized steel
channel post or other approved device.

(b) Sign and Underpass Circuits

The illumination circuits for sign structures with an overhead power supply shall
be protected by circuit breakers mounted on the end support.
680
Circuits for adjustable end support sign structures, bridge bracket signs, or
underpasses shall be protected by circuit breakers mounted on the bridge or sign
structure and connected to the underground distribution circuit in a handhole.

Circuits for sign structures with an underground power supply shall be protected
by fuse connector kits in the base of the sign support. The fuse connector kits shall
include bayonet disconnect features for the “neutral” side and “hot” side.

(c) Multiple Relay Switches

690 Unless otherwise specified, timber pole, multiple relay switches, service cabinet,
photocells, photocell receptacles, weatherhead, conduit, and other miscellaneous items
shall be furnished and installed as a part of the service point.

807.16 Testing of Highway Lighting System

(a) Testing Lighting Circuitry

All necessary equipment and apparatus properly calibrated for testing the lighting
circuits shall be furnished. The supplying utility shall be given advance notice of the
test scheduling so their representative may witness the testing procedures if desired.
700 Each main lighting circuit, including its branches, shall be tested for insulation
resistance and continuity after it is completely installed but before the pole circuits,
underpass circuits, sign circuits, and grounding circuits are connected. The insulation
resistance test shall be made with a megohm meter and the resistance to ground shall
be no less than 50 megohms in all lighting circuit power cables. The meter shall be set
for the voltage rating of the insulation. The continuity test shall be made with an
ohmmeter properly scaled for measuring the resistance of the power cables. This test
shall verify the following:

1. That each power cable is continuous to its termination

710 points.

2. That the cable coding at junction and termination points

is consistent with cable coding at the supply point.

885
 807.17

3. That power cables are not crossed with the neutral

or each other.

4. That the main circuit through each of its branches

does not have unusual resistance values.
720
The entire completed installation shall be tested by circuit or by such portions as
may be selected and at night if directed. Tests shall demonstrate the following:

1. That all power, lighting, and control circuits are

continuous, free from short circuits, and free from
unspecified grounds.

2. That all circuits are properly connected in accordance

with applicable wiring diagrams.
730
3. That all circuits are operable which shall be demonstrated
by continuous operation of each lighting circuit for at
least 1 h.

4. That voltage at the ends of each lighting circuit and at inter

points is within allowable limits. A maximum of 10%
voltage drop will be allowed for each complete circuit.

(b) Testing and Inspecting Luminaires

740 The lighting system from the service point through the last luminaire shall be
subjected to 14 days of normal operation prior to final acceptance. This testing
procedure may be conducted separately on each circuit or on the entire system.

Normal operation is defined as the luminaires being on during the darkness hours
and off during the daylight hours as controlled by the service point photocells and
relay switches. Malfunctioning equipment shall be replaced or repaired before final
inspection. The pattern of light delivered to the pavement by roadway and high mast
luminaires will be inspected at night. At this inspection, the proper tools, equipment,
and personnel shall be available to make all adjustments. These items shall specifically
750 include a bucket truck capable of reaching all luminaires in the system, safety
equipment, and a level to determine the proper luminaire position.

807.17 Pay Item and Installation Summary Sheets

Prior to final inspection, two sets each of installation summary and pay item
summary, each marked Final Record, shall be furnished for the lighting standards as
installed. The installation summary shall show the effective mounting height, arm
length, foundation elevation, pay item, type of base, and catalog number or drawing
for each lighting standard furnished. The pay item summary shall indicate the pay
item, quantity, effective mounting height, arm length, and type of base for each type
760 of lighting standard furnished.

886
 807.19

807.18 Method of Measurement

Luminaire, light standard with mast arm, high mast standard, identification
number, connector kit, multiple compression fitting, insulating link, foundation,
handhole, service point, and cable marker will be measured by the number of units
installed. Pole circuit conductor and circuit conductor in conduit will be measured by
the linear foot. Pole circuit conductor will be measured from the base of the lighting
standard to the terminal block of the luminaire. Pole line extension will be measured
in a straight line between each pole.
770
Conductor in bridge conduit will be measured by the linear foot from end to end
of conduit or from the end of conduit to the last bridge light pole foundation entry. An
allowance of 5 lft will be made for each foundation entry. An allowance of 2 lft will
be made for each junction box.

Removal of existing light structure, which shall include the pole, mast arm, and
foundation, will be measured by the number of units removed.

Cable-duct and conductor in underground duct or conduit will be measured by the

780 linear foot as follows:

(a) From the face of the concrete foundation to the center of the
handhole or face of the next concrete foundation. An allowance
of 5 lft will be made for each entry at foundations. An allowance
of 2 lft will be made at handholes for connection purposes.

(b) From lighting standard bases or handholes to switch boxes at

underpasses. An allowance of 4 lft will be made at the switch
box for electrical connections.
790
(c) From end to end of the conduit when the cable is in conduit
under a roadway surface or shoulder. No measurement will be
made of cable-duct in conduit where it is part of a service point,
sign installation, or underpass lighting system.

807.19 Basis of Payment

Luminaire will be paid for at the contract unit price per each for the type and
wattage specified. Service point will be paid for at the contract unit price per each for
the type specified. Light pole will be paid for at the contract unit price per each for the
800 estimated mounting height, length of mast arm, and base type specified.

Lighting foundation, concrete, with grounding will be paid for at the contract unit
price per each for the size specified. If class X material is encountered during lighting
foundation excavation, payment will be made for such excavation in accordance with
206. Partial payment for lighting foundation in the amount of 80% will be made if all
such work is complete except for finish grading and sodding. The remaining

887
 807.19

percentage of payment will be made upon completion of the finish grading and
sodding.

810 Connector kit will be paid for at the contract unit price per each for fused or
unfused, as specified. Multiple compression fitting and insulation link will be paid for
at the contract unit price per each for waterproofed or non-waterproofed, as specified.
Cable-duct marker, high mast tower winch drive, and handhole, lighting will be paid
for at the contract unit price per each. Sign, underpass, and roadway lighting location
identification will be paid for at the contract unit price per each. Circuit installation
will be paid for at the contract unit price per each for the type, structure number, and
number of luminaires specified. Light structure, remove and portable tower lighting
drive system will be paid for at the contract unit price per each.

820 Wire will be paid for at the contract unit price per linear foot for the designation,
copper gage, housing, and number of conductors specified. Pole circuit cable, type
THWN, stranded will be paid for at the contract unit price per linear foot for the copper
gage and number of conductors specified. Conduit, steel, galvanized, 2 in. diameter
will be paid for at the contract unit price per linear foot.

Payment will be made under:

Pay Item Pay Unit Symbol

830 Cable, Pole Circuit, THWN, No. _____ Copper,

Stranded, _____ _____/C ............................................... LFT
Cable-Duct Marker .................................................................... EACH
Circuit Installation, Str. No. _____, _____ Luminaires............. EACH
no.
Conduit, Steel, Galvanized, 2 in. ............................................... LFT
Connector Kit, Fused ................................................................. EACH
Connector Kit, Unfused ............................................................. EACH
Handhole, Lighting .................................................................... EACH
High Mast Tower Winch Drive ................................................. EACH
840 Insulation Link, Non-Waterproofed .......................................... EACH
Insulation Link, Waterproofed .................................................. EACH
Light Pole, High Mast, _____ ft E.M.H. ................................... EACH
Light Pole, Roadway, _____ ft E.M.H.,
_____ ft Mast Arm, _____ Base ......................................... EACH
Light Structure, Remove ........................................................... EACH
Lighting Foundation, Concrete, with Grounding,
_____ in. x _____ in. x _____ in. ....................................... EACH
Luminaire, High Mast ............................................................... EACH
Luminaire, High Lumen Roadway ............................................ EACH
850 Luminaire, Low Lumen Roadway ............................................. EACH
Luminaire, Low Lumen-Low Mounting Height Roadway ........ EACH
Luminaire, Sign ......................................................................... EACH

888
 807.19

Luminaire, Underpass................................................................ EACH

Multiple Compression Fitting, Non-Waterproofed ................... EACH
Multiple Compression Fitting, Waterproofed............................ EACH
Portable Tower Lighting Drive System ..................................... EACH
Service Point, _____.................................................................. EACH
type
Sign, Underpass, and Roadway Lighting
860 Location Identification ....................................................... EACH
Wire, ______, No. _____ Copper, in _____, _____ ____ /C .... LFT
designation housing

The cost of lamps, LED arrays, plasma emitters, drivers, optical systems,
weatherproof housings, surge protection devices, and electrical connections shall be
included in the cost of luminaire.

The cost of the mast arm, J-support hook for pole circuit, handhole with cover,
shoe base, transformer base or frangible coupling if required, installation on the
870 foundation with the pole circuit, and luminaire installation shall be included in the cost
of light pole.

The cost of the pole; lowering system including winch assembly, power cable,
and support cable; concrete pad; luminaire ring; anchor bolts and nuts; lightning rod
assembly; grounding system; and all incidental materials necessary to complete the
installation shall be included in the cost of light pole, high mast. The cost of
excavation, concrete, sleeves for cable-duct, non-metal pipe, reinforcing bars, backfill,
finish grading, and sodding shall be included in the cost of lighting foundation.

880 The cost of aerial distribution service, drops to sign structures branching off from
the pole line extension, weatherheads and risers required to connect the line extension
to the underground electrical distribution circuit, all anchorage guy wires, hardware,
aerial cable, electrical connections, timber poles, and incidentals required to complete
the pole line extension shall be included in the cost of cable, pole circuit.

The cost of snap-on covering in light pole base and waterproof covering in
underground handhole shall be included in the cost of multiple compression fitting.

The cost of circuit breakers; breaker enclosures; conduit; flexible conduit; conduit
890 fittings; grounding; weatherhead; aerial cable termination; and incidentals required
from the last luminaire to the point of attachment by the utility, the bottom of the riser
at the structure base, or the connector kits in the base of the sign supports shall be
included in the cost of circuit installation.

The cost of maintaining highway illumination during the life of the contract shall
be included in the cost of other pay items.

889
 808.01

SECTION 808 – PAVEMENT TRAFFIC MARKINGS

808.01 Description
This work shall consist of furnishing and installing, or removing, pavement traffic
markings and snowplowable raised pavement markers in accordance with the
MUTCD, these specifications and as shown on the plans. Markings shall be installed
as required unless written approval is obtained from the District Traffic Engineer to
make modifications at specific locations.

10 MATERIALS

808.02 Materials
Materials shall be in accordance with the following:

Beads ........................................................................... 921.02(e)

Cones ........................................................................... 801.08
Multi-Component ........................................................ 921.02(c)
Preformed Plastic ........................................................ 921.02(b)
Snowplowable Raised Pavement Markers................... 921.02(d)1
20 Thermoplastic .............................................................. 921.02(a)

A certification which shows the paint meets all IDEM and EPA regulatory
requirements for VOC levels and lead, chromium or other heavy metals from the paint
manufacturer shall be provided.

CONSTRUCTION REQUIREMENTS

808.03 General Requirements

Permanent pavement markings shall be placed on the surface course in a standard
30 pavement marking pattern. Center lines shall be placed on two-way two-lane roads,
lane lines shall be placed on multi-lane divided roads, and both center lines and lane
lines shall be placed on multi-lane undivided roads.

The pavement shall be cleaned of all dirt, oil, grease, excess sealing material,
excess pavement marking material and all other foreign material prior to applying new
pavement traffic markings. New paint pavement markings may be placed over sound
existing markings of the same color. New thermoplastic, preformed plastic, or multi-
component markings may be applied over sound existing markings of a compatible
type if allowed by manufacturer’s recommendations, a copy of which shall be supplied
40 to the Engineer prior to placement; otherwise, existing markings shall be removed in
accordance with 808.10 prior to placement of the new markings. Removal of pavement
marking material shall be in accordance with 808.10. The pavement surface shall be
dry prior to applying pavement traffic markings.

890
 808.04

Control points required as a guide for pavement traffic markings shall be spotted
with paint for the full length of the road to be marked. Control points along tangent
sections shall be spaced at a maximum interval of 100 ft. Control points along curve
sections shall be spaced so as to ensure the accurate location of the pavement traffic
markings. The location of control points shall be approved prior to the pavement traffic
50 marking application.

808.04 Longitudinal Markings and Milled Corrugations

All longitudinal lines shall be clearly and sharply delineated, straight and true on
tangent, and form a smooth curve where required. Lines shall be square at both ends,
without mist, drip or spatter.

A solid line shall be continuous. A broken line shall consist of 10 ft line segments
with 30 ft gaps. A dotted line shall consist of 3 ft line segments with 9 ft gaps unless
otherwise indicated on the plans.
60
All lines shall be gapped at intersections unless otherwise specified or directed.

The actual repainting limits for no-passing zone markings will be determined by
the Engineer.

A new broken line placed over an existing broken line shall laterally match the
existing broken line, and the new line segments shall not extend longitudinally more
than 10% beyond either end of the existing line segments. A new dotted line placed
over an existing dotted line shall laterally match the existing dotted line, and the new
70 line segments shall not extend longitudinally more than 6 in. beyond either end of the
existing line segments.

(a) Center Lines

Center lines shall be used to separate lanes of traffic moving in opposite
directions. All center line markings shall be yellow in color and 4 in. in width. They
shall be placed such that the edge of the marking, nearest to the geometric centerline
of the roadway, shall be offset 4 in. from the geometric centerline.

The center line of a multi-lane roadway shall be marked with a double solid line.
80 The two lines forming the double solid line shall be spaced 8 in. apart and shall be
equally offset on opposite sides of the geometric centerline.

The center line of a two-lane, two-way roadway, where passing is allowed in both
directions, shall be marked with a broken line.

The center line of a two-lane, two-way roadway, where passing is allowed in one
direction only, shall be marked with a double line, consisting of a broken line and a
solid line. The broken line and the solid line shall be spaced 8 in. apart and shall be
equally offset on opposite sides of the geometric centerline. The solid line shall be

891
 808.04

90 offset toward the lane where passing is prohibited. The broken line shall be offset
toward the lane where passing is allowed.

The center line shall be placed within the milled corrugation when center line
rumble stripes are specified. Placement of the center line marking in the milled
corrugation does not alter the pavement marking performance requirements of 808.07.

(b) Lane Lines

Lane lines shall be used to separate lanes of traffic moving in the same direction.
Normal width lane line markings shall be white in color and shall be 5 in. wide on
100 interstates and freeways, and 4 in. wide on all other roads. They shall be offset 4 in. to
the right of longitudinal pavement joints or divisions between traffic lanes. Wide lane
lines for lane drops, route splits, or auxiliary lanes shall be white in color and shall be
8 in. wide. White solid lines shall be used to mark lane lines only when specified or
directed.

(c) Edge Lines

Edge lines shall be used to outline and separate the edge of pavement from the
shoulder. Edge line markings shall be 4 in. in width and shall be placed such that the
edge of the marking nearest the edge of the pavement shall be offset 4 in. from the
110 edge of the pavement except as otherwise directed. Right edge lines shall be marked
with a white solid line and left edge lines shall be marked with a yellow solid line.

The edge line shall be placed in the milled corrugation when edge line rumble
stripes are specified. Placement of the edge line marking in the milled corrugation does
not alter the pavement marking performance requirements of 808.07.

(d) Barrier Lines

Barrier lines shall be used as specified or directed. Barrier line markings shall be
solid lines of the size and color specified or as directed.
120
(e) Markings in Retrofitted Corrugations
In sections where corrugations are being placed in the existing surface, all existing
pavement markings shall be removed in accordance with 808.10 and any existing
sealants shall be routed or grinded out. Temporary pavement markings placed in
accordance with 801.12 shall be offset a sufficient distance from the longitudinal joint
so as to not to obstruct the installation of the corrugations or the application of the
liquid asphalt sealant.

The Contractor shall make a record of the existing pavement marking locations
130 so that such markings may be replicated later with the appropriate adjustments for
edge line rumble stripes. This record shall show longitudinal and transverse
dimensions. The record shall be submitted to, and approved by, the District Traffic
Engineer prior to the removal of existing pavement markings. The District Traffic
Section shall be notified two weeks prior to applying pavement markings to allow the
District Traffic Section time to verify the pavement marking plan.

892
 808.07

808.05 Transverse Markings and Pavement Message Markings

(a) Transverse Markings

140 Transverse marking lines shall be used as specified or directed to delineate
channelizing lines, stop lines, crosswalk lines, and parking lines. Parking lines for
ADA accessible parking spaces shall be 4 in. wide and blue in color. Unless otherwise
specified or directed, all other parking lines shall be 4 in. wide and white in color. All
other transverse markings shall consist of all necessary lines, of the width specified or
directed and shall be in accordance with the MUTCD.

(b) Pavement Message Markings

Pavement message markings shall be used as specified or directed for railroad
crossing approaches, intersection approaches, crosswalk approaches, ADA accessible
150 parking space symbols, and other messages applied to the pavement with pavement
marking material. The markings shall consist of all necessary lines, words, and
symbols as specified or directed, and shall be in accordance with the MUTCD.

808.06 Curb Markings

Curb markings shall consist of reflectorized paint which shall cover the face and
top of the curb. The existing curb and gutter area shall be cleaned of dirt, dust, oil,
grease, moisture, curing compound, and unsound layers of other materials before paint
is applied to the curb surface.

160 808.07 Pavement Marking Material Application, Equipment, and

Performance Requirements
All double line markings, such as a no passing zone or the center line of an
undivided multi-lane roadway, shall be applied in one pass. When a hand-propelled
machine is used, the single pass application of double line markings will not be
required and control points shall be spaced at a maximum of 10 ft longitudinally.

For contracts with completion dates when conditions do not enable application of
the specified marking materials, or grooving for durable marking materials, other
materials may be substituted with an appropriate unit price adjustment if approved by
170 the Engineer.

Markings shall be installed in accordance with the manufacturer’s

recommendations, except that the minimum requirements stated herein shall also
apply. Products specifically designed for application temperatures below the stated
minimums herein are not required but may be used if approved by the Engineer. When
directed, the Contractor shall provide the Department with original copies of all
necessary current manufacturer’s installation manuals prior to beginning installation
work, and no installation work shall begin prior to the Department’s receipt of these
manuals. These manuals shall become the property of the Department.
180
The markings shall be protected from traffic until dry to eliminate tracking.

893
 808.07

The markings shall meet or exceed the following performance criteria:

1. Color. The daytime and nighttime color of the applied

markings shall be in accordance with ASTM D 6628 when
determined in accordance with ASTM E 811 and E 1349.

2. Durability. The pavement markings shall have a minimum

190 resistance to wear of 97% in accordance with ASTM D
913.

3. Retro-reflectivity. Contracts with 50,000 ft or more of

longitudinal paint line or 10,000 ft or more for each type of
longitudinal durable marking line applied shall have retro-
reflectivity measured, except markings placed on seal coat
pavements placed in accordance with 404. Longitudinal
lines shall meet required minimum initial and retained
average retro-reflectivity measurements.
200
All other contracts and markings, except parking lines,
shall meet the required longitudinal line minimum
measurements and will be measured by the Department at
the discretion of the Engineer, except that quality
adjustments will not apply. Retained retro-reflectivity is
the value at the time of the warranty expiration in
accordance with 808.09 and will be measured by the
Department at the discretion of the Engineer.

210 Retro-reflectivity testing equipment shall be furnished, calibrated, and operated

in accordance with ITM 931. The markings shall be tested in a period of not less than
14 days to not more than 30 days after the materials are applied. The retro-reflectivity
equipment shall remain the property of the Contractor. The measurement of retro-
reflectivity shall be supervised or performed at all times by an operator trained and
certified by the unit’s manufacturer. A report as described in the ITM and including
the specified test results and calculations shall be prepared and provided to the
Engineer within three days of each day of testing.

Quality adjustments will be applied to the payment of markings as indicated in

220 the table below. The required minimum initial and retained average retro-reflectivity
values for longitudinal line measured in mcd/m²/lx are as follows:

894
 808.07

Quality Retained Retained

Material Type White Yellow
Adjustment* White Yellow
Paint ≥ 250 ≥ 175 1.00 n/a n/a
Required Minimum 150 to 249 125 to 174 0.70
see see
Thermoplastic ≥ 300 ≥ 200 1.00
808.09 808.09
Required Minimum 250 to 299 150 to 199 0.70
see see
Multi-Component ≥ 300 ≥ 200 1.00
808.09 808.09
Required Minimum 250 to 299 150 to 199 0.70
see see
Preformed Plastic ≥ 650 ≥ 450 1.00
808.09 808.09
Required Minimum 550 to 649 350 to 449 0.70
* Quality Adjustments do not apply to the retained retro-reflectivity values

(a) Traffic Paint

1. Application
Traffic paint shall be applied only when the ambient air and pavement temperature
is 40ºF or higher and will remain 40ºF or higher for 2 h after application.

230 The markings shall be protected from traffic until dry to eliminate tracking.

The wet film thickness of the traffic paint shall be a minimum of 15 mils. Painted
lines and markings shall be immediately reflectorized by applying beads at a uniform
minimum rate of 6 lb/gal. of traffic paint. Only standard or modified standard beads
shall be used for paint markings.

2. Equipment
Traffic paint shall be applied with a spray type machine capable of applying the
traffic paint under pressure through a nozzle directly onto the pavement. The truck-
240 mounted machine shall be equipped with the following:

a. air blast device for cleaning the pavement ahead

of the application;

b. guide pointer to keep the machine on an accurate line;

c. spray guns which can be operated individually or

simultaneously;

250 d. agitator or recirculation system as appropriate;

e. control device to maintain uniform flow and

application;

895
 808.07

f. capability of heating the material to application

temperatures;

g. automatic device which will provide a line of the

required pattern; and
260
h. automatic bead dispenser which is synchronized
with the marking application.

A hand-propelled machine may be used to apply markings. A brush may be used

if approved to apply some markings.

3. Performance Requirements
The color and durability requirements shall be met for a minimum of 90 days after
application.
270
Pavement marking segments which are found to have an average retro-reflectivity
reading below the minimum required shall be re-striped with no additional payment.
Pavement markings segments which have more than five of 20 individual readings
below the minimum required shall be re-striped with no additional payment. The re-
striping shall begin within 14 calendar days of the completion of the retro-reflectivity
measurement. Line segments may be re-striped with no additional payment. Following
each re-striping, additional retro-reflectivity measurements shall be made with no
additional payment. Quality adjustments will be based on the final retro-reflectivity
measurements. The alignment of all re-striped pavement markings shall be placed
280 within ±1/4 in. in width and ±2 in. in length of the original placed markings. Re-
striping will not be allowed more than two times, after which removal and replacement
of the markings will be required.

(b) Durable Pavement Marking Material

Durable pavement marking material consists of thermoplastic, preformed plastic
or multi-component markings. Durable pavement marking materials used for center
lines, lane lines, or edge lines shall be installed within a groove in the pavement unless
otherwise shown on the plans. Durable pavement marking materials used for barrier
lines, pavement message, and transverse markings shall be surface applied unless
290 otherwise indicated on the plans.

1. Grooving for Durable Pavement Markings

a. Application
The pavement shall be grooved prior to the placement of longitudinal durable
pavement markings, excluding bridge decks and approach slabs. The groove or recess
shall be installed in a single pass using dry cut equipment that utilizes diamond cutting
blades and that is approved by the pavement marking manufacturer. If there are no
markings on the pavement, a guide line shall be placed using paint without glass beads
300 as a template for the grooving operation. The groove shall be at least 1 in. and no more

896
 808.07

than 2 in. wider than the pavement marking to be placed. The Contractor may leave a
gap in the grooving for longitudinal lines that delineate the radii of lane usage
transitions, driveways, intersections, or adjacent to curb that does not have a curb
offset to the marking of at least 12 in.

The depth of the groove shall be in accordance with the manufacturer’s

recommendations and shall be at minimum 5 mils greater than the thickness of the
marking material including exposed glass beads, up to maximum allowable depth of
150 mils. A continuous groove shall not be allowed for broken or dotted lane lines.
310 The groove may extend up to 3 in. at either end of a lane line. Grooves shall be no
closer than 2 in. to the edge of a longitudinal joint.

b. Groove Finish and Cleaning

The grooved surface shall be cleaned with vacuuming equipment immediately
following the grooving operation. The surface shall be clean and dry prior to pavement
marking installation. The finished groove surface shall have a fine corduroy-like
appearance with a maximum variation in depth of 10 mils.

2. Thermoplastic
320
a. Application
Thermoplastic marking shall be applied in molten form by conventional extrusion
when the pavement and ambient air temperatures are a minimum of 50°F and rising;
or by ribbon type extrusion or spray when the pavement and ambient air temperatures
are 50°F and rising. Heat bonded preformed thermoplastic may be used for transverse
or message markings. The average final thickness of each 36 in. length of
thermoplastic marking shall be no less than 90 mils and no more than 125 mils.
Immediately following the application of the thermoplastic markings, additional retro-
reflectorization shall be provided by applying beads to the surface of the molten
330 material at a uniform minimum rate of 8 lb/100 sq ft of marking. Individual passes of
markings shall not overlap or be separated by gaps greater than 1/4 in. longitudinally.

b. Equipment
The equipment used for the application of thermoplastic markings shall consist of
a kettle for melting the material and an applicator for applying the markings. All of the
equipment required for melting and applying the material shall maintain a uniform
material temperature within the manufacturer specified limits, without scorching,
discoloring or overheating any portion of the material.

340 A truck-mounted machine shall be equipped with the following: an air blast
device for cleaning the pavement ahead of the marking operation; a guide pointer to
keep the machine on an accurate line; at least two spray guns which can be operated
individually or simultaneously; agitators; a control device to maintain uniform flow
and application; an automatic device which will provide a broken line of the required
length; and an automatic bead dispenser which is synchronized with the marking
application.

897
 808.07

A hand-propelled machine may be used to apply markings.

350 The equipment for applying heat bonded preformed plastic shall be in accordance
with the manufacturer’s recommendations. An open flame shall not come into direct
contact with the pavement.

c. Performance Requirements
When the initial average retro-reflectivity measurement is below the required
minimum the segment of line shall be removed and replaced with no additional
payment. Pavement markings segments which have more than five of 20 individual
readings below the minimum required shall be removed and replaced with no
additional payment.
360
3. Preformed Plastic

a. Application
The markings shall be applied when the air temperature is a minimum of 40°F
and rising. A primer is required if the ambient air temperature is below 50°F. The
pavement surface shall be primed with a binder material in accordance with the
manufacturer’s recommendations.

If there is a dispute regarding installation, the manufacturer shall provide a trained

370 representative to ensure that the installation is properly performed.

b. Performance Requirements
When the initial average retro-reflectivity measurement is below the required
minimum the segment of line shall be removed and replaced with no additional
payment. Pavement markings segments which have more than five of 20 individual
readings below the minimum required shall be removed and replaced with no
additional payment.

4. Multi-Component
380
a. Application
This material shall be applied only when the pavement and ambient air
temperatures are 40°F and rising. The wet film thickness of the marking material shall
be a minimum of 20 mils. Immediately following the application of the markings,
additional reflectorization shall be provided by applying beads to the surface of the
wet marking at a uniform minimum rate of 20 lb/gal. of marking.

b. Equipment
The machine used to apply the marking material shall precisely meter each
390 component, and produce and maintain the necessary mixing head temperature within
the required tolerances. The machine shall be equipped in accordance with 808.07(a)2.

898
 808.08

c. Performance Requirements
Pavement marking segments which are found to have an average retro-reflectivity
reading below the required minimum shall be re-striped with no additional payment.
Pavement markings segments which have more than five of 20 individual readings
below the minimum required shall be re-striped with no additional payment. The re-
striping shall begin within 14 calendar days of the completion of the retro-reflectivity
measurement. Line segments may be re-striped with no additional payment. Following
400 each re-striping, additional retro-reflectivity measurements shall be made with no
additional payment. Quality adjustments will be based on the final retro-reflectivity
measurements. The alignment of all re-striped markings shall be placed within ±1/4
in. in width and ±2.0 in. in length of the original placed markings. Re-striping will not
be allowed more than two times, after which removal and replacement of the markings
will be required.

808.08 Marking Protection and Maintenance of Traffic

Protection of the traveling public, of the pavement marking crews, and of the
pavement markings shall be provided during the marking operation through the use of
410 proper equipment, traffic control devices, safety devices and proper procedures.
Traffic control devices shall be placed in accordance with 107.12. Flaggers shall be
provided for traffic control as directed.

(a) Vehicle Signs

Each vehicle in the marking operation shall display the slow moving vehicle
emblem when operating at speeds of 25 mph or less. The slow moving emblems shall
be removed when the vehicles are operating at speeds greater than 25 mph. The paint
crew signs shall be 24 in. high by 96 in. wide, with 12 in. series C black letters on an
orange encapsulated lens reflective background. Type A and C flashing arrow signs
420 shall be in accordance with 923.04.

(b) Vehicle Warning Lights

All amber flashing warning lights and amber strobe lights mounted on vehicles
used in the marking operation shall be in accordance with 801.14(d). All vehicles used
in the marking operation shall have a minimum of one flashing amber warning light
or amber strobe light which is visible in all directions.

(c) Cones
Cones shall be used to protect marking material which requires more than 60 s
430 drying time. Cones shall remain in place until the marking material is dry or firm
enough not to track or deform under traffic. Cones shall be removed as soon as possible
and shall never be left in place overnight. Edge lines shall not require protection with
cones.

The maximum spacing of cones shall be as follows:

40 mph or less over 40 mph

Broken Lines every line segment every fifth line segment
Solid Lines 20 ft to 30 ft
899
 808.09

(d) Front Escort Vehicles

A front escort vehicle shall be used if the marking vehicle extends across the
440 center line while operating. This front escort vehicle shall be equipped with a forward
facing paint crew sign, a rear facing slow moving vehicle emblem, and a red flag
mounted at least 10 ft above the pavement.

(e) Marking Application Vehicles

Marking application vehicles such as edgeliner or centerliner trucks shall have a
rear facing type A or type C flashing arrow sign, an amber flashing warning light
mounted near the center of the truck bed and an amber strobe light mounted on each
rear corner of the truck bed. The amber flashing warning light and the amber strobe
lights shall be mounted on retractable supports and shall be operated at a height of
450 12 ft above the pavement unless otherwise directed.

(f) Rear Escort Vehicles

If cones are not required, a rear escort vehicle shall follow a marking application
vehicle at a distance of 100 to 500 ft. If an additional rear escort vehicle is required
due to drying time or heavy traffic volume, it shall follow the first rear escort vehicle
at a maximum distance of 1,000 ft, and may operate in the travel lane or on the paved
shoulder.

If cones are required, the cone setting truck shall follow the marking application
460 vehicle and shall be followed by a rear escort vehicle. The cone pick up truck shall be
followed by another rear escort vehicle.

All rear escort vehicles shall be equipped with a rear facing type C flashing arrow
sign mounted above a rear facing paint crew sign. On two-lane two-way roads, this
type C flashing arrow sign shall be operated with the arrowhead turned off. The supply
truck may be used as a rear escort vehicle providing it is empty and is equipped with
the required traffic control devices.

808.09 Warranty for Durable Pavement Marking Material

470 Durable pavement marking material shall be warranted against failure resulting
from material defects or method of application, or the result of snowplowing and
deicing activities. The material shall be warranted to retain its color, adherence to the
pavement, and shall be free of other obvious defects or failures. Grooved durable
pavement markings shall also be warranted to retain retroreflectivity as specified
below.

All pavement traffic markings which have failed to meet the warranted conditions
shall be replaced with no additional payment.

480 For the terms of the warranty a unit shall be defined as a 1,000 ft section of line
of specified width in any combination or pattern.

900
 808.10

(a) Surface Applied Durable Pavement Marking Warranty

The warranty period for surface applied durable markings shall be 180 days
beginning with the substantial completion date for the contract as defined in 101.60,
but not prior to November 1 of the calendar year in which the last pavement markings
were installed. If more than 3% of a unit or 3% of the total of any one intersection or
set of transverse markings fails, the failed portion shall be replaced. All pavement
markings required to be replaced under the terms of this warranty shall be replaced
490 within 60 days of the notification of failure.

(b) Grooved Durable Pavement Marking Warranty

The warranty period for durable markings placed in a groove shall be two years
beginning with the substantial completion date for the contract as defined in 101.60,
but not prior to November 1 of the calendar year in which the last pavement markings
were installed. The retained retro-reflectivity, mcd/m2/lx, as determined by ITM 931
shall meet or exceed the minimum values at all times during the warranty period as
follows:

Material Year White Yellow

1 225 150
Thermoplastic
2 175 125
1 225 150
Multi-Component
2 175 125
1 400 300
Preformed Plastic
2 300 200
500
If more than 5% of a unit or 5% of the total fails, the failed portion shall be
replaced. All pavement markings required to be replaced under the terms of this
warranty shall be replaced within 60 days of the notification of failure.

808.10 Removal of Pavement Markings

Pavement markings which conflict with revised traffic patterns and may confuse
motorists shall be removed immediately before, or immediately following, any change
in traffic patterns as directed or approved.

510 Removal of pavement markings shall be to the fullest extent possible without
materially damaging the pavement surface. Pavement marking removal methods shall
be sandblasting, steel shot blasting, waterblasting, grinding or other approved
mechanical means. Grooving will not be allowed. Grinding will only be allowed under
the following conditions:

(a) when removing durable pavement markings, or

(b) when removing non-durable markings where another course

of material is to be placed on the existing course.
520
Painting over existing pavement markings to obliterate them will not be allowed.

901
 808.11

When a blast method is used to remove pavement markings, the residue, including
sand, dust and marking material, shall be vacuumed concurrently with the blasting
operation or removed by other approved methods. Accumulation of sand, dust or other
residual material, which might interfere with drainage or constitute a traffic hazard,
will not be allowed.

All damage to the pavement caused by pavement marking removal shall be

530 repaired by approved methods with no additional payment.

808.11 Snowplowable Raised Pavement Markers

Snowplowable raised pavement markers shall be used as supplemental
delineation at the locations shown on the plans or as directed.

(a) Surface Preparation

The pavement or bridge deck surface shall be cleaned of dirt, dust, oil, grease,
moisture, curing compound, and loose or unsound layers of all materials which would
interfere with the proper bonding of the marker to the pavement or bridge deck.
540
(b) Location
Marker locations shall be accurately laid out and approved prior to the installation
operation. Markers shall not be located on surfaces that show visible evidence of
cracking, checking, spalling or failure of underlying materials. Markers shall not be
located within the intersection of a public road. Any marker location, which falls on
any of the restricted areas, shall be moved a longitudinal distance not to exceed 10%
of the required marker spacing. If this adjusted location still falls within a restricted
area, then that marker location shall be deleted. Marker locations shall be as shown on
the plans.
550
(c) Reflector Color
The color combinations of the reflectors shall be as shown on the plans unless
otherwise directed. When replacement prismatic reflectors are specified, such
reflectors shall not be ordered until the quantity and color combinations have been
determined and approved.

(d) Installation
Marker installation shall be in accordance with the manufacturer’s
recommendations. The pavement surface temperature and the ambient air temperature
560 shall be at least 50°F. The pavement surface shall be dry at the time of marker
installation. The installation slot shall be clean and dry before the adhesive is applied.
The slot shall be filled with sufficient adhesive to provide a water tight seal between
the marker base and the pavement, and to fill all voids between the marker base and
the surfaces of the slot. The marker shall be placed in the slot so that the tips of the
snowplow deflecting surfaces are below the pavement surface.

If the pavement surface is newly placed HMA, the pavement shall be allowed to
cure for two days prior to installing the markers.
902
 808.12

570 Installation of markers on new concrete pavement or bridge decks or on newly

overlaid bridge decks shall not be done until after the pavement or bridge deck is ready
to be opened to traffic as specified elsewhere herein.

The number of slots cut in one day shall not exceed the number of markers which
will be installed in that day. No slots shall be left open overnight.

(e) Removal of Markers

Markers designated for removal shall be as located on the plans or as otherwise
specified or directed. If the pavement surface or bridge deck surface is to be removed,
580 the markers shall be removed prior to any surface removal operation.

The markers shall be removed with a jackhammer or other approved equipment.

The area of the pavement or bridge deck disturbed by the marker removal shall not
exceed 3 in. in depth or extend more than 3 in. out from any side of the marker base.
The marker removal operation shall stop if it is determined that excessive damage is
occurring to the pavement, or bridge deck.

The resulting holes shall be filled with the appropriate patching material as
described herein or as otherwise directed. Concrete pavement which is to be overlaid
590 as part of the contract and HMA pavement shall be patched with HMA intermediate
materials. Concrete pavement which is not to be overlaid as part of the contract and
concrete bridge decks shall be patched with concrete patching material from the
Department's approved list for Rapid Setting Patch Materials. Overlaid bridge decks
and bridge decks which are to be overlaid as part of the contract shall be patched with
patching material which is compatible with the deck overlay material. All patching
material shall be placed in accordance with the appropriate specifications for the
patching material.

Removed markers shall become the property of the Contractor and removed from
600 the jobsite prior to the completion of the work.

(f) Replacement of Prismatic Reflectors

Reflectors designated for replacement shall be as shown on the plans or as
otherwise directed. Prior to placement of the new reflector, the castings shall be
cleaned of all remaining butyl pad materials. All loose or foreign material shall be
satisfactorily removed by sandblasting, wire brush, or other approved mechanical
means. Removed reflectors shall be disposed of properly off the project site.

808.12 Method of Measurement

610 Broken or dotted lines, placed or removed, will be measured by counting the
number of broken or dotted lines placed and multiplying the number of counted lines
by the length of the broken or dotted line. Solid lines will be measured as the total
distance in linear feet of solid lines placed or removed. The material, type, color, or

903
 808.13

width of broken, dotted, or solid lines to be removed will not be considered when
measuring such lines for payment.

Except as otherwise specified, transverse marking lines will be measured as the

total distance in linear feet of lines placed or removed. Transverse marking yield lines
will be measured transversely including the entire extent of the marking line and gaps.
620 Curb markings will be measured by the linear feet along the front face of the curb.
Grooving for pavement markings will be measured as the total distance of grooving
for each pavement marking line in linear feet. Pavement message markings will be
measured by the total number of each type placed. A railroad crossing pavement
message marking shall include the two R’s, the X, and the three stop lines per traffic
lane. Railroad crossing pavement message markings will be measured by the total
number of each marking place. Lane indication arrow pavement message markings
will be measured by the number of lane indication arrowheads placed. Removal of
pavement message markings will be measured in square yards using areas shown in
the following table. The material will not be considered when measuring such
630 markings for pavement.

Pavement Message Markings

Description Area
“Ahead” 3.1 SYS
Combo Arrow 3.1 SYS
“Exit” 2.5 SYS
“Left” 2.5 SYS
“Only” 2.5 SYS
Railroad “R” 0.6 SYS
“Right” 3.2 SYS
“RXR” 7.7 SYS
“School” 3.9 SYS
“Stop” 2.6 SYS
Straight Arrow 1.4 SYS
“Turn” 2.6 SYS
Turn Arrow 1.7 SYS
“XING” 2.5 SYS

Snowplowable raised pavement markers will be measured by the number placed

or removed. Prismatic reflectors will be measured by the number furnished and
installed. Each two-way prismatic reflector will be measured as one reflector. No
measurement will be made of the adhesive or the hole patching material used in the
placement or removal of snowplowable raised pavement markers.

808.13 Basis of Payment

640 Lines and transverse markings placed will be paid for at the contract unit price per
linear foot for the material, type, color, and width specified. Grooving for pavement
markings will be paid for at the contract unit price per linear foot. Curb markings will
be paid for at the contract unit price per linear foot for curb painting, of the color

904
 808.13

specified. Pavement message markings placed will be paid for at the contract unit price
per each, for the material and message specified. Lines and transverse markings
removed will be paid for at the contract unit price per linear foot. Pavement message
markings removed will be paid for at the contract unit price per square yard.

Snowplowable raised pavement markers, furnished and installed, or removed will

650 be paid for at the contract unit price per each. Prismatic reflectors will be paid for at
the contract unit price per each. Each two-way prismatic reflector will be paid for as
one reflector.

Payment for furnishing, calibrating, and operating retro-reflectivity testing

equipment will be paid for at the contract price for lump sum. The cost of report
preparation shall be included in the cost of retro-reflectivity testing. Adjustments to
the contract payment with respect to retro-reflectivity of performance based pavement
markings will be included in a quality adjustment in accordance with 109.05.1. The
Engineer may waive retro-reflectivity testing due to weather limitations. Retro-
660 reflectivity testing will be waived for markings applied after October 31 and before
April 1. If retro-reflectivity testing is waived, no payment will be made for retro-
reflectivity testing. If retro-reflectivity testing is not waived by the Engineer due to
weather or waived by the seasonal time restriction and retro-reflectivity testing is not
performed, no payment will be made for retro-reflectivity testing and payment for the
marking items will be made at 70% of the unit price.

Payment will be made under:

Pay Item Pay Unit Symbol

670
Curb Painting, _____ ................................................................. LFT
color
Grooving for Pavement Markings ............................................. LFT
Line, _____, _____, _____, _____ in. ....................................... LFT
material type color width
Line, Remove ............................................................................ LFT
Pavement Message Marking, ________, ________ .................. EACH
material message
Pavement Message Marking, Remove ...................................... SYS
680 Prismatic Reflector .................................................................... EACH
Retro-Reflectivity Testing ......................................................... LS
Snowplowable Raised Pavement Marker .................................. EACH
Snowplowable Raised Pavement Marker, Remove ................... EACH
Transverse Marking, _____, ____, _____, _____ in. ................ LFT
material type color width
Transverse Marking, Remove.................................................... LFT

No additional payment will be made for the removal and or replacement of

markings that fail to meet the performance or warranty conditions of 808.07 and
690 808.09.
905
 809.01

The cost of removal of existing prismatic reflectors shall be included in the cost
of prismatic reflectors.

Beads, binder material for thermoplastic and preformed plastic, adhesive for
snowplowable markers, patching material for snowplowable marker removal, guide
lines for grooving operations, pavement cleaning and surface preparation, and all
necessary incidentals shall be included in the cost of the pay items.

SECTION 809 – ITS CONTROLLER CABINETS AND FOUNDATIONS

809.01 Description
This work shall consist of furnishing and installing ITS cabinets and foundations
in accordance with 105.03.

MATERIALS

809.02 Materials
10 Materials shall be in accordance with the following:

ITS Controller Cabinet ................................................ 925

Padlock ........................................................................ 925.04(aa)

Materials for ITS cabinet foundations shall be in accordance with 805.02.

CONSTRUCTION REQUIREMENTS

809.03 General
20 ITS cabinet foundations shall be installed in accordance with 805.13.

A seal of silicone caulking compound shall be placed between each controller

cabinet and the concrete foundation after the cabinet placement.

A rubber duct seal shall be used to seal all conduits that enter the bottom of the
cabinet.

The input power source to the cabinets shall be 240 volts AC and 60 amps.

30 One laminated 11 by 17 in. site drawing shall be included in the data pocket of
each cabinet.

809.04 Grounding
All ITS controller cabinets and foundations shall be grounded in accordance with
the ITS grounding specification.

906
 809.07

809.05 Cabinet Wiring

Wiring within ITS cabinets shall be neatly arranged and ty-wrapped, or enclosed
in expandable braided polyester sleeving. All cabinet wiring harnesses shall be neat,
40 firm, routed, and mechanically supported to minimize crosstalk, electrical
interference, and to prevent inadvertent pulling. AC power cables shall be routed and
bundled separately from shielded control cables which include, but are not limited to,
logic voltage, video cables, and RF cables.

All conductors, except for the equipment-grounding conductors, shall be

individually labeled at each termination with a unique identifier. All terminal blocks
shall be labeled in accordance with the appropriate standard schematic drawings on
the plans.

50 Conductors used in cabinet wiring shall terminate with properly sized captive
terminals, spade type terminals, or shall be soldered. All crimp-style connectors shall
be applied with a proper tool that prevents opening of the handles until the crimp is
completed.

No more than three conductors shall be brought to any one terminal. Two flat
metal jumpers, straight or U-shaped, may also be placed under a terminal screw. At
least two full threads of all terminal screws shall be fully engaged when the screw is
tightened. No live parts shall extend beyond the barrier.

60 Connectors, or devices plugging into connectors, shall be provided with positive

means to prevent any individual circuit from being broken due to vibration, pull on
connecting cable, or some similar disruptive force.

809.06 Field Testing

Cabinets and ITS components shall be field tested in accordance with the field
test procedure furnished by the Department and the test results shall be submitted to
the ITS Electronics Technician of the Operations Support Division. The Contractor
shall record all test readings, in triplicate, on the field test procedure form. The
Contractor shall complete, sign, and date the forms before submitting them to the ITS
70 Electronics Technician. All necessary equipment and personnel shall be provided to
ensure the tests are safely conducted. The Electronics Technician shall be present to
witness the tests. A cabinet shall pass every test to be accepted. If the cabinet fails, the
problem shall be corrected and a new test shall be arranged.

The technician shall be given at least 36 h advance notice of the test.

809.07 Clean-Up
When the installation is completed, all disturbed portions of the construction area
shall be cleaned and all excess excavation or other materials shall be disposed of in
80 accordance with 104.05 and 203.10. The site shall be restored to its original condition.

907
 809.08

809.08 Method of Measurement

ITS controller cabinet foundations will be measured per each installed, complete
and in place. ITS controller cabinets will be measured by the number of units installed,
complete and in place.

809.09 Basis of Payment

ITS controller cabinet foundations will be paid for at the contract price per each.
ITS controller cabinets, complete, in place, will be paid for at the contract unit price
90 per each.

Payment will be made under:

Pay Item Pay Unit Symbol

ITS Controller Cabinet Foundation ........................................... EACH

ITS Controller Cabinet .............................................................. EACH

The cost of all cabinet accessories, mounting hardware, anchor bolts, handles,
100 setup and wiring shall be included in the cost of the ITS controller cabinet.

The cost of all grading necessary for installation of the foundations and the final
clean-up of the area shall be included in the cost of the ITS controller cabinet
foundation.

The cost of padlocks shall be included in the cost of the ITS controller cabinet.

908
 901.01

DIVISION 900 – MATERIALS DETAILS

SECTION 901 – PCC MATERIALS

901.01 Hydraulic Cement

(a) General
At the time cement is incorporated into the work, it shall meet the quality
requirements of these specifications.

Cement which has been in storage may be tested prior to use, and if tests show
10 that it does not meet the requirements specified, it will be rejected.

A means for storing and protecting the cement against dampness shall be
provided. Cement which has become partially set or which contains lumps or caked
cement will be rejected. Cement salvaged from discarded or used sacks shall not be
used.

Different kinds or brands of cement, or cement of the same brand from different
mills, even if tested and approved, shall not be mixed during use unless allowed, and
then only as directed. They shall not be used alternately in any one pour for any
20 structure, unless otherwise approved.

(b) Portland Cement

Portland cement shall conform to the requirements of the following cited
specifications except as noted.

1. Requirements

Cement Specifications
Air-Entraining Portland Blast-Furnace Slag Cement AASHTO M 240, Type IS-A
Air-Entraining Portland Cement AASHTO M 85, Type IA or IIIA
Air-Entraining Portland-Pozzolan Cement AASHTO M 240, Type IP-A
Portland Blast-Furnace Slag Cement AASHTO M 240, Type IS
Portland Cement AASHTO M 85, Type I, II, or III
Portland-Limestone Cement AASHTO M 240, Type IL
Portland-Pozzolan Cement AASHTO M 240, Type IP

The exceptions to AASHTO M 240 are as follows:

30
a. The amount of pozzolan shall be limited to 20% ±5%
by weight of the portland-pozzolan cement for the types
IP and IP-A.

b. The pozzolan in the portland-pozzolan cements, types

909
 901.01

IP and IP-A, shall be in accordance with ASTM C 618,

class C or class F with the loss on ignition of the
pozzolan limited to a maximum of 3%.

40 c. The pozzolan in the portland-pozzolan cements, types

IP and IP-A, shall be interground with the portland
cement clinker.

2. Acceptance Criteria
Portland cements and blended cements will be accepted based upon the
manufacturer’s or manufacturer/distributor’s documented ability to consistently
furnish these materials in accordance with the applicable AASHTO requirements.

a. General Requirements
50 Cements shall comply with the applicable requirements of 901 and will be
accepted by certification from qualified manufacturers or manufacturer/distributor.
The manufacturer is defined as the plant producing the cement. A manufacturer or
manufacturer/distributor shall become qualified by establishing a history of
satisfactory quality control of cement produced as evidenced by results of tests
performed by a testing laboratory which is regularly inspected by the Cement and
Concrete Reference Laboratory of the National Institute of Standards and Technology.
Proof of such inspection shall be furnished upon request. All certifications shall be
prepared by the manufacturer or distributor in accordance with the applicable
requirements of 916. If a manufacturer or distributor elects to supply portland cement
60 with a higher sulfur trioxide content in accordance with footnote B from Table 1 in
AASHTO M 85, it shall supply all of the required supporting data to the Office of
Materials Management prior to supplying such cement. A list of Qualified
Manufacturers and Manufacturer/Distributors will be maintained by the Department.

The manufacturer or manufacturer/distributor shall conduct sufficient tests to

ensure that adequate quality control is maintained and that cement furnished is in
accordance with the specification requirements. Documentation pertaining to cement
shipped on certification shall be maintained for a period of at least three years and
shall be provided when requested.
70
Random samples of cement will be obtained at the concrete plant. If the sample
is not in accordance with the specification requirements, an investigation will be
conducted. A copy of the findings and conclusions resulting from the investigation
will be furnished to the Contractor. Unless the investigation finds the Department is
responsible for the failure to comply, the cost of the investigation plus any required
corrective action will be assessed to the Contractor.

b. Requirements for Domestic Source Qualification

Cement manufacturers requesting to be qualified to supply cement shall provide
80 the following:

910
 901.01

(1) For the initial qualification, the manufacturer shall

provide to the Office of Materials Management a
QCP in accordance with the applicable
requirements of ITM 806. The QCP shall also
include the location and type of samples taken, and
a monthly summary of mill test data for the
previous years production. A current Material
Safety Data Sheet shall be submitted as an integral
90 part of the initial qualification package.

(2) To maintain qualification, a monthly average of

mill test data shall be submitted to the Office of
Materials Management. If a specific type of
cement is not manufactured in a given month, the
monthly submittal shall state “No type ______
cement was manufactured during the month of
__________, 20____”.

100 c. Requirements for Foreign Source Qualification

Foreign cement manufacturers or their domestic distributors requesting to be
qualified to supply cement shall provide the following:

(1) For the initial qualifications, the manufacturer and

distributor shall provide to the Office of Materials
Management a QCP in accordance with the
applicable requirements of ITM 806. The QCP
shall also include the location and type of samples
taken, and a summary of complete test results from
110 the proposed cement source. A current Material
Safety Data Sheet shall be submitted as an integral
part of the initial qualification package. The QCP
shall explain the linkage between the cement being
furnished and the manufacturer’s/distributor’s
quality control data, relative to ship-loads, barge-
loads, railroad car-loads, and other applicable
loads.

(2) Once the initial qualifications have been met, the

120 manufacturer or distributor shall be required to
furnish the cement test results for each shipment
prior to Department cement usage for the first five
cement shipments, which are intended for
Department use. The test results for all five of these
cement shipments shall fully comply with the
required material specifications. If not, this
requirement will be continued for subsequent

911
 901.02

cement shipments until five consecutive cement

shipment test results fully comply with the
130 required material specifications, or Department
source approval is withdrawn due to the inability
to consistently supply satisfactory cement.

(3) To maintain qualification after compliance with

the previous requirements, a monthly submission
of all cement shipment test results for cement
which is intended for Department usage shall be
submitted to the Office of Materials Management.
If no cement shipments are received during a given
140 month, the monthly submittal shall state “No
cement was received during the month of
__________, 20____”.

d. Certification
Only qualified manufacturers and manufacturer/distributors as identified by the
Department’s list of Qualified Manufacturers and Manufacturer/Distributors may
furnish cement on certification.

A sample certification form addressing all of the required information is included

150 in ITM 804. Alternate procedures and forms will be considered when requested, and
will be approved if there is a positive link between the cement furnished and the
manufacturer’s quality control data.

(c) Masonry Cement

Masonry cement shall be in accordance with ASTM C 91, except the air content
test and the water retention test may be waived.

901.02 Fly Ash Used as a Pozzolan

160 (a) General

Fly ash is the finely divided residue that results from the combustion of ground or
powered coal. In general, class F fly ash is produced from burning anthracite or
bituminous coal and class C fly ash is produced from burning lignite or subbituminous
coal.

Fly ash will be accepted from one of the sources on the Department’s list of
approved Fly Ash and Ground Granulated Blast Furnace Slag Sources. Fly ash from
different sources or different types of fly ash shall not be mixed or used alternately in
the same construction unless authorized in writing. Fly ash will be subject to random
170 assurance sampling and testing by the Department. Failure of these random samples
to meet the specified requirements will be cause for suspension of the fly ash source
approval.

912
 901.02

(b) Acceptance Criteria

Acceptance is based upon the supplier’s documented ability to consistently
furnish material in accordance with the specified requirements.

1. Requirements
The fly ash shall be in accordance with AASHTO M 295 for class C or class F,
180 with the following exceptions:

Loss on Ignition, LOI, max. % ................................................. 3

Autoclave Expansion or Contraction, max. % .......................... 0.5
Fineness: Amount retained when wet-sieved on
No. 325 (45 µm) sieve, max. % ........................................ 30

On days when fly ash is being accumulated for use as a pozzolan, the supplier
shall obtain a minimum of one sample per day and furnish test results for moisture
content, loss on ignition, and No. 325 (45 µm) sieve residue for each sample.
190
For each 2,000 t produced, a complete AASHTO M 295 analysis shall be
performed on a sample composited randomly from the daily samples. The method of
randomization shall be subject to approval by the Department.

2. Test and Calibration Procedure

The testing procedures followed shall be in accordance with ASTM C 311 or other
methods approved in writing by the Department.

The minimum frequency for calibration of test equipment is:

200
a. The No. 325 (45 µm) sieve shall be calibrated every
100 determinations or every six months, whichever
comes first.

b. The muffle furnace used for LOI determinations shall

have a newly installed thermocouple every six months.

c. The analytical balances and scales shall be calibrated

each year.
210
d. The concrete compression machine shall be calibrated
annually.

e. The Blaine apparatus shall be calibrated annually.

f. All instrumentation used for rapid chemical analysis

shall comply with applicable requirements of ASTM C
114 using NIST Fly Ash reference materials.

913
 901.03

220 3. Documentation
Fly ash suppliers requesting approval shall supply the following:

a. For the initial approval, a current Materials Safety Data

Sheet and a summary of results for all specified tests
for six consecutive months shall be submitted. No test
results shall be more than one year old at the time of
request.

b. To maintain approval, a summary of results for all

230 specified tests shall be submitted monthly. The results
of the daily tests shall be available by telephone during
normal working hours.

c. The fly ash suppliers shall furnish a QCP in accordance

with the applicable requirements of ITM 806. The QCP
shall ensure the Department of a continuous supply of
fly ash complying with the requirements. This QCP
will be reviewed to determine its adequacy.

240 d. Certification:

(1) For source approval, the supplier shall furnish a

certification indicating the class of fly ash, the
name, location, and unit of the generating plant. It
shall state that all fly ash shipped for use on
Department projects will be produced under
appropriate quality control and shall be in
accordance with the specified requirements. It
shall further indicate that the power company will
250 participate in appropriate inspection and assurance
testing. A sample certification form is set out in
ITM 804.

(2) For certification of test reports, the test results

generated in accordance with 901.02(b)1 shall be
summarized and submitted monthly. The reports
shall state the name and location of the testing
facility, and shall be signed by the chemist or
technical manager. This certification shall also
260 identify the concrete plants receiving fly ash
represented by these results.

901.03 Ground Granulated Blast Furnace Slag Used As a Pozzolan

(a) General
Blast furnace slag shall consist of the non-metallic product, consisting essentially
914
 901.03

of silicates and aluminosilicates of calcium and other bases, that is developed in a

molten condition simultaneously with iron in a blast furnace. A glassy granular
material is formed when molten blast furnace slag is rapidly chilled by immersion in
270 water. This material is then ground to cement fineness, producing ground granulated
blast furnace slag.

Ground granulated blast furnace slag will be accepted from one of the sources on
the Department’s list of approved Fly Ash and Ground Granulated Blast Furnace Slag
Sources. Ground granulated blast furnace slag from different sources or different
grades of ground granulated blast furnace slag shall not be mixed or used alternately
in the same construction unless approved in writing. Ground granulated blast furnace
slag will be subject to random assurance sampling and testing by the Department.
Failure of these random samples to be in accordance with the specified requirements
280 will be cause for suspension of ground granulated blast furnace slag source approval.

(b) Acceptance Criteria

Ground granulated blast furnace slag will be accepted based on the manufacturer’s
or manufacturer/distributor’s documented ability to consistently furnish these
materials in accordance with the applicable ASTM and AASHTO requirements.

1. Requirements
The ground granulated blast furnace slag shall be in accordance with ASTM
C 989 for grade 100 or 120.
290
For each 2,500 t produced, a complete ASTM C 989 analysis shall be performed
on a sample composited randomly from the daily samples. The method of
randomization shall be subject to approval by the Department.

2. Test and Calibration Procedure

The testing procedures followed shall be in accordance with ASTM C 989 or other
methods approved in writing by the Department.

The minimum frequency for calibration of test equipment is:

300
a. The No. 325 (45 µm) sieve shall be calibrated every
100 determinations or every six months, whichever
comes first.

b. The analytical balances and scales shall be calibrated

each year.

c. The concrete compression machine shall be calibrated

annually.
310
d. The Blaine apparatus shall be calibrated annually.

915
 901.03

e. All instrumentation used for rapid chemical analysis

shall be in accordance with the applicable requirements
of ASTM C 114 using NIST reference materials.

3. Documentation
Ground granulated blast furnace slag suppliers requesting approval shall supply
the following:
320
a. For the initial approval, a current Materials Safety Data
Sheet and a summary of results for all specified tests
for six consecutive months shall be submitted. No test
results shall be more than one year old at the time of
request.

b. To maintain approval, a summary of results for all

specified tests shall be submitted monthly. The results
of the daily tests shall be available by telephone during
330 normal working hours.

c. The ground granulated blast furnace slag suppliers shall

furnish a QCP in accordance with the applicable
requirements of ITM 806. The QCP shall ensure the
Department of a continuous supply of ground
granulated blast furnace slag which is in accordance
with the requirements. This QCP will be reviewed to
determine its adequacy.

340 d. Certification:

(1) For source approval, the supplier shall furnish a

certification indicating the grade of ground
granulated blast furnace slag, the name, location,
and type of manufacturing facility. It shall state
that the ground granulated blast furnace slag
shipped for use on Department projects will be
produced under appropriate quality control and
shall be in accordance with the specified
350 requirements. A sample certification form
addressing all of the required information is
included in ITM 804.

(2) For certification of test reports, the test results

generated in accordance with 901.03(b) shall be
summarized and submitted monthly. The reports
shall state the name and location of the testing
facility, and shall be signed by the chemist or

916
 901.04

technical manager. This certification shall also

360 identify the concrete plants receiving ground
granulated blast furnace slag represented by these
results.

901.04 Silica Fume Used As a Pozzolanic Mineral Admixture

(a) General
Silica fume will be accepted from one of the suppliers on the Department’s list of
approved Pozzolanic suppliers. Silica fume from more than one of these suppliers shall
not be mixed or used alternatively in the same construction unless authorized in
370 writing. Silica fume will be subject to random assurance sampling and testing by the
Department. Failure of the random samples to meet the specified requirements will be
cause for suspension of the silica fume supplier’s approval.

(b) Acceptance Criteria

Acceptance of silica fume will be based on the manufacturer’s documented ability
to consistently furnish material in accordance with the specified requirements.

1. Requirements
The silica fume shall be in accordance with AASHTO M 307 with the following
380 exceptions:

a. Reactivity with cement alkalies shall not be required.

b. The oversize, amount retained on the No 325 (45 µm)

sieve, in accordance with ASTM C 1240, shall be
conducted.

c. The oversize, amount retained on the No. 325 (45 µm)

sieve, shall not be more than 10%.
390
d. Accelerated pozzolanic activity index, in accordance
with ASTM C 1240, shall be conducted in lieu of
strength activity index.

e. The accelerated pozzolanic activity index shall be a

minimum of 85% at seven days.

f. The increase of drying shrinkage of mortar bars at 28

days shall be conducted in accordance with ASTM C
400 1240.

g. The increase of drying shrinkage of mortar bars at 28

days shall be not more than 0.10%.

917
 901.04

2. Frequency of Testing

a. The manufacturer shall obtain a minimum of one

sample for each 400 t of material produced. Test results
for moisture content, and loss on ignition, shall be
410 furnished for each sample.

b. For each 2,000 t produced, a complete AASHTO M

307 analysis shall be performed on a sample composed
randomly from daily samples. The method of
randomization shall be subject to approval by the
Department. The optional chemical requirements
identified in AASHTO M 307 shall be reported in
addition to the increase of drying shrinkage of mortar
bars as well as the standard chemical and physical
420 requirements.

3. Test and Calibration Procedure

The minimum frequencies for calibration of test equipment shall be as follows:

a. The analytical balances and scales shall be calibrated

annually.

b. The concrete compression machine shall be calibrated

annually.
430
c. The Blaine apparatus shall be calibrated annually.

d. All instrumentation used for rapid chemical analysis

shall be in accordance with AASHTO T 105.

4. Documentation
Silica fume suppliers requesting approval shall supply the following to the Office
of Materials Management:

440 a. For initial approval, a current Material Safety Data

Sheet and a summary of results for all specified tests
for six consecutive months shall be submitted. No test
results shall be more than one year old at the time of the
request.

b. To maintain approval, a summary of results for all

specified tests shall be submitted monthly.

c. A QCP in accordance with the applicable requirements

450 of ITM 806 shall be submitted. The QCP shall ensure

918
 901.05

the Department a continuous supply of silica fume

complying with the material requirements and
calibration procedures. This QCP will be reviewed by
the Office of Materials Management to determine its
adequacy.

d. Certification:

(1) For approval, the supplier shall furnish a

460 certification indicating the name, location, and
type of manufacturing facility, which includes the
metallurgical process and furnace. It shall state that
the silica fume shipped for use on Department
projects will be produced under appropriate quality
control and shall be in accordance with the
specified requirements. A sample certification is
set out in ITM 804.

(2) For certification of test reports, the results

470 generated in accordance with 901.04(b) shall be
summarized and submitted monthly. The reports
shall state the name and location of the testing
facility, and shall be signed by the chemist or
technical manager. This certification shall also
identify the concrete plants receiving silica fume
represented by these results.

901.05 Chemical Anchor System

Chemical anchor systems shall be furnished from the Department’s list of
480 approved Chemical Anchor Systems. Chemical anchor systems may be added to the
approved list by completing the requirements of ITM 806, Procedure F and passing
required laboratory testing.

(a) Requirements
Chemical anchor systems shall be in accordance with the following:

1. Chemical anchor systems shall be two part systems which

are capable of anchoring deformed steel reinforcing bars
and grouting load transfer dowels.
490
2. Chemically anchored steel reinforcing bars shall be
capable of withstanding a tensile load equal to the yield
strength of a #7, grade 60, epoxy coated, deformed steel
reinforcing bar.

3. Chemical anchor systems shall be capable of filling the

entire annular space between the concrete and the steel
919
 901.06

reinforcing bar or dowel and remain in place until the

chemical anchor is completely cured.
500
(b) Laboratory Testing
The Department will test chemical anchor systems in accordance with ITM 807.

901.06 PCC Sealer/Healers

PCC sealer/healers shall be furnished from the Department’s list of approved PCC
Sealer/Healers. PCC sealer/healers may be added to the approved list by completing
the requirements in ITM 806, Procedure F and passing required laboratory testing.

(a) Requirements
510 PCC sealer/healers shall be in accordance with the following:

1. PCC sealer/healers shall be two part systems, capable of

sealing and healing cracks in PC pavement.

2. PCC sealer/healers shall be capable of restoring the

original integrity of a PCC beam broken in flexure.

3. All four beams used for testing sealer/healers shall break at

a location different from the original break or with a
520 flexural strength greater than or equal to 550 psi.

4. The viscosity of PCC sealer/healers shall be sufficient to

penetrate a crack 1/32 in. wide and 6 in. in depth.

(b) Laboratory Testing

The Department will test PCC sealer/healers in accordance with ITM 808.

901.07 Rapid Setting Patch Materials

Rapid setting patch materials shall be selected from the Department’s list of
530 approved Rapid Setting Patch Materials. A rapid setting patch material may be added
to the approved list by completing the requirements in ITM 806, Procedure F.

(a) Normal Weather Mixes

Normal weather rapid setting patch materials shall be used for ambient
temperatures of 32 to 85°F.

(b) Hot Weather Mixes

Hot weather rapid setting patch materials shall be used for ambient temperatures
above 85°F.
540
(c) Requirements
Rapid setting patch materials shall be capable of being utilized in patches ranging
from 1 in. to full depth without bonding agents.

920
 901.07

These products shall not contain soluble chlorides as an ingredient of manufacture

or require chemical additives. The color shall be similar to PCC.

They shall be single packaged dry mix requiring only water just prior to mixing.
They shall be packaged in 40 to 60 lb bags with a neat yield of approximately 0.40 cu
550 ft and shall allow at least a 50% extension, by weight with a 3/8 in. or a 1/2 in. round
aggregate. The minimum shelf life shall be 12 months.

Mixing shall be conducted with small concrete mixers or with a drill or paddle
mixer and shall be suitable for finishing with hand tools.

Rapid setting patch materials shall be in accordance with ASTM C 928 with the
following exceptions.

Physical Test Specification Requirement

Setting Time: ASTM C 266
Normal Weather Initial at 72°F 10 – 20 min
Final at 72°F 12 – 35 min
Hot Weather Initial at 95°F 10 – 20 min
Final at 95°F 12 – 35 min
Compressive Strength, minimum* ASTM C 109 72°F, Normal
1h 2,000 psi
2h 3,000 psi
24 h 5,000 psi
28 days 8,000 psi
Compressive Strength, minimum* ASTM C 109 95°F, Hot
3h 3,000 psi
24 h 5,000 psi
28 days 8,000 psi
Relative Dynamic Modulus
ASTM C 666
Procedure B, 300 cycles 95% min.
Slant Shear Bond Strength, minimum
ASTM C 882
28 days 2,500 psi
Flexural Strength, 24 h ASTM C 78
mortar only 500 psi
mortar – aggregate extension 600 psi
Shrinkage, maximum
ASTM C 157
28 days 0.03%
Scaling Resistance ASTM C 157
5 cycles 0 rating, No scale
25 cycles 0 rating, No scale
50+ cycles 1.5 rating, Lt. scale
* Material used shall be neat rapid setting patch material mixed in accordance with the
manufacturer’s installation instructions.

921
 901.08

560 All rapid setting patch materials complying with the specified physical
requirements will be subjected to a field performance demonstration. The field
performance demonstration will take place as directed. Rapid setting patch materials
shall be used to patch a designated site, typical of a standard repair. The site will be
evaluated after one year’s exposure. Approval will be based on visible signs of
distress, such as cracking, crazing, scaling, spalling, wearing, edge fraying, corner
cracking, or debonding.

(d) Test Report

Testing shall be performed by a recognized laboratory in accordance with
570 ITM 806. Test reports shall not be more than five years old on January 1 of the
approval year.

901.08 Packaged, Dry, Combined Materials for Mortar and Concrete

These materials shall be in accordance with ASTM C 387. All packages shall be
identified as conforming to ASTM C 387. The markings shall also show the kind and
type of material, the net weight in each bag, the yield in cubic feet or yield in square
feet per inch of thickness, and the amount of water recommended for mixing to
produce a 2 in. to 3 in. slump.

580 The following exceptions to ASTM C 387 shall apply for packaged patching
products used in accordance with 710:

Physical Test Specification Requirement

Compressive Strength, minimum ASTM C 109 on
24 h 2 in. cubes (neat) 2,000 psi
28 days 5,000 psi
Length Change, maximum ASTM C 157,
28 days (dry cure) modified C 928 -0.09%
28 days (wet cure) +0.03%
Slant/Shear Bond Strength, minimum ASTM C 882
28 days modified* 2,000 psi
Modulus of Elasticity ASTM C 469
Minimum @ 28 days 3,000,000 psi
Maximum @ 28 days 5,000,000 psi
* Product scrubbed into substrate or as recommended by the manufacturer.

901.09 Air-Cooled Blast Furnace Slag for Retaining Walls

If ACBF or coarse aggregate is used, and soil, B borrow, structural backfill, or
coarse aggregate is to be placed above the ACBF or coarse aggregate, a single layer
of geotextile shall be placed on top of the ACBF or coarse aggregate in accordance
with 616.11. A type C certification in accordance with 916 for the geotextile materials
shall be furnished to the Engineer prior to use.
590
ACBF shall be in accordance with the pH, chlorides, sulfates, organic content,
resistivity, and permeability requirements of structure backfill as listed in 211.03.1. It

922
 901.10

shall also be in accordance with ITM 212. Total sulfides shall also be determined in
accordance with EPA 376.1, using the 100-mL pH water samples obtained during the
ITM 212 test, and shall not exceed 400 ppm. The ACBF shall have a maximum
corrosion rate as follows if tested in accordance with ASTM G 59.

(a) Zinc corrosion rate, first two years ....................... 15 µm/yr/side

(b) Zinc corrosion rate, to depletion ........................... 4 µm/yr/side
600 (c) Carbon-steel corrosion rate ................................... 12 µm/yr/side.

901.10 Components of MSE Retaining Walls

(a) PCC Components

1. Face Panels
Precast concrete face panels shall be produced from a source listed in the
Department’s List of Certified Precast Concrete Producers, in accordance with ITM
813. Concrete shall have a compressive strength equal to or greater than 4,000 psi at
610 28 days.

The target water/cementitious ratio for the concrete mix design shall not exceed
0.435. The cement content and target water/cementitious ratio of the concrete mix
design shall be sufficient to obtain the specified minimum 28-day compressive
strength. Approved air entraining admixture and chemical admixture Type A, B, C, D,
or E may be used.

Ground-reinforcement connection hardware and reinforcing bar lifting devices

shall be set in place and secured prior to beginning casting, in accordance with the
620 dimensions and tolerances shown on the working drawings.

a. Production Control Testing and Inspection

The manufacturer shall provide for all testing and inspection services during each
day’s production of the panels. The frequency of production control testing shall be
based on a lot of 50 panels, or fraction thereof, for each day’s production. Sampling
and testing of the plastic concrete shall be in accordance with 505.01, or the ASTM
equivalent. A minimum of one water/cementitious ratio, and slump, air content, and
relative yield tests shall be run per production lot, per day. A minimum of two 6 in. by
12 in. cylinders shall be cast per day’s production lot for compressive strength
630 determination. Cylinders shall be cured in the same manner as the panels they
represent. Relative yield, air content, and slump of the concrete shall be in accordance
with 702.05. Compressive strength shall be determined in accordance with AASHTO
T 22 or ASTM C 39, with lot acceptance based on the average of 2 cylinders tested at
an age no greater than 28 days. Panels shall not be shipped until the compressive
strength meets or exceeds the 28 day requirement.

If the cylinder-test results do not satisfy the requirements described herein, and
additional cylinders for testing are not available, the manufacturer may core the panels.

923
 901.10

The wall manufacturer shall randomly select two panels from the lot for coring in
640 accordance with AASHTO T 24 or ASTM C 42. The wall manufacturer shall obtain
one core on the backside of each panel with a device that produces uniform test
samples without coring completely through the panel. Coring shall not be located
within 6 in. of the panel fasteners or the edges of the panels, and shall avoid the panel's
reinforcing steel. The wall manufacturer shall fill the core holes with equivalent
concrete materials or rapid setting patch materials, and trowel to produce a smooth
finish. Excess material removed during troweling shall not be reused. If rapid setting
patch material is used, mixing and curing shall be in accordance with the
manufacturer's recommendations. Compressive strength testing shall be performed on
the cores. If the average strength-test results from the cores satisfy or exceed the
650 requirements described herein, the production lot panels may be shipped.

b. Casting
The panels shall be cast on a flat area, with the front face of the form at the bottom,
and the back face at the upper part. Tie strip guides shall be set on the rear face. The
concrete in each unit shall be placed without interruption and shall be consolidated as
necessary to prevent the formation of segregation or cleavage planes. Clear form oil
from one manufacturer shall be used throughout the casting operation.

c. Curing
660 The panels shall be cured for a sufficient length of time such that the concrete
develops the specified compressive strength.

d. Removal of Forms
The forms shall remain in place until they can be removed without damage to the
unit.

e. Concrete Finish
The concrete surface for the front panel face shall have a surface finish produced
from contact with the form. The rear face of the panel shall be screeded to eliminate
670 open pockets of aggregate and surface distortions in excess of 1/4 in.

f. Tolerances
All panels shall be manufactured within the tolerances as follows:

(1) Panel Dimensions

Lateral position of tie strips shall be within 1 in. All other dimensions shall be
within 3/16 in.

(2) Panel Squareness

680 Squareness, as determined by the difference between the two diagonals, shall not
exceed 1/2 in.

(3) Panel-Surface Finish

Surface defects on smooth formed surfaces measured on a length of 5 ft shall not

924
 901.10

exceed 1/8 in. Surface defects on textured finished surfaces measured on a length of 5
ft shall not exceed 5/16 in.

g. Compressive Strength Verification

Verification of the panels compressive strengths will be conducted by the
690 Engineer. The frequency of verification testing will be one test for every 750 panels
per manufacturer with a minimum of one test per contract. One panel will be randomly
selected and two locations will be selected for coring. The Contractor shall obtain two
4 in. cores on the backside of the panel without coring completely through the panel,
in the presence of the Engineer. The Contractor shall refill the core holes with rapid
setting patch materials and trowel to produce a smooth finish. Excess material
removed during troweling shall not be reused. Mixing and curing of the patching
materials shall be in accordance with the manufacturer’s recommendations.

The Engineer will test the cores in accordance with AASHTO T 24. The
700 verification test results will be averaged and shall be in accordance with 901.10(a)1a.
If the initial verification test results do not satisfy the requirements described herein,
the Engineer will randomly select two different panels for additional verification
testing. If the additional verification tests satisfy the requirements described herein, no
further action is required. If the test results still do not satisfy the requirements
described herein, installation of panels shall cease and the Engineer will conduct an
investigation. Panels manufactured on the same dates as the panels cored for
verification tests that have already been installed will be considered and adjudicated
as a failed material in accordance with 105.03. The Engineer will conduct verification
testing until three consecutive dates of production satisfy the strength requirements
710 described herein. The Contractor or wall manufacturer shall make arrangements so
that panels from three consecutive dates of production are accessible for coring.
Installation of panels may resume once acceptable verification testing results are
achieved.

h. Rejection
Units shall be subject to rejection due to their failure to be in accordance with the
requirements specified above. The following defects may result in rejection:

(1) Defects which indicate imperfect molding.

720
(2) Defects which indicate honeycombed or open
texture concrete.

(3) Defects in the physical characteristics of the

concrete, such as broken or chipped concrete, or
color variations or dunnage marks on the front face
due to excessive form oil or other reasons.

The Engineer will determine whether spalled, honeycombed, chipped, or

730 otherwise defective concrete shall be repaired or be cause for rejection. Repair of

925
 902.01

concrete, if allowed, shall be completed in a manner which is acceptable to the

Engineer. Repair to concrete surfaces that are to be exposed to view after completion
of construction shall be subject to approval.

i. Marking
The place and date of manufacture, and production lot number shall be shown on
the rear face of each panel.

j. Handling, Storage, and Shipping

740 All panels shall be handled, stored, and shipped so as to eliminate the danger of
chipping, cracks, fractures, or excessive bending stresses. Panels in storage shall be
supported on blocking located immediately adjacent to tie strips to avoid bending the
tie strips.

2. Coping
The coping may be precast or cast-in-place.

(b) Joint Spacers and Joint Covering

The horizontal and vertical joint spacers shall include compression blocks, pins,
750 or other manufacturer’s recommended materials to provide a uniform joint.

The joint cover shall be either a non-woven needle-punch polyester geotextile or

a woven monofilament polypropylene. The joint cover shall be attached to the rear
face of the panels with a manufacturer’s recommended adhesive.

A letter certifying that the joint spacers and joint cover adhesive material supplied
is in accordance with the manufacturer’s recommendations shall be provided prior to
use of the materials.

760
SECTION 902 – ASPHALT MATERIALS

902.01 Asphalt
Asphalt is defined as a cementitious material obtained from petroleum processes.
Asphalts shall be sampled and tested in accordance with the applicable requirements
of 902.02.

(a) Performance Graded Asphalt Binders

Performance graded asphalt binders shall be supplied by an approved supplier in
10 accordance with ITM 581.

Performance graded, PG asphalt binders shall be in accordance with the

following:

926
 902.01

PG PG PG PG PG PG
GRADE
58-28 64-22 64-28 70-22 70-28 76-22
ORIGINAL BINDER
Flash Point, minimum, °C 230
Viscosity, maximum, 3 Pa·s,
135
Test Temp, °C
DSR, G*/sin δ (delta),
minimum, 1.00 kPa, Test 58 64 64 70 70 76
Temp. @ 10 rad/s, °C
ROLLING THIN-FILM OVEN RESIDUE
Mass Loss, maximum, % 1.00
DSR, G*/sin δ (delta),
minimum, 2.20 kPa, Test 58 64 64 70 70 76
Temp. @ 10 rad/s, °C
PRESSURE AGING VESSEL (PAV) RESIDUE
PAV Aging Temperature, °C 100 (Note 1)
DSR, G*sin δ (delta),
maximum, 5,000 kPa, Test 19 25 22 28 25 31
Temp. @ 10 rad/s, °C
Physical Hardening Report (Note 2)
Creep Stiffness, S, maximum,
300 MPa, m-value, minimum, -18 -12 -18 -12 -18 -12
0.300, Test Temp. @ 60 s, °C
Notes: 1. Oven temperature tolerance shall be ±0.5°C.
2. Physical Hardening is performed on a set of asphalt beams according to
AASHTO T 313, Section 12.1, except the conditioning time is extended to
24 h ±10 minutes at 10°C above the minimum performance temperature.
The 24 h stiffness and m-value are reported for information purposes only.

A PG 58-28 or PG 64-22 binder may be modified by in-line blending with styrene

butadiene rubber, SBR, polymer latex at the HMA plant in accordance with ITM 581.
A PG 58-28 may be modified to a PG 64-28 and a PG 64-22 may be modified to a PG
70-22.
20
The SBR polymer latex shall be in accordance with the following:

SBR Polymer Latex

Total Polymer Solids, % by weight 60 – 72
Butadiene, % by weight, min. 68
Residual Styrene, % by weight, max. 0.1
Ash, % of total polymer solids by weight, max. 3.5
pH 9 – 11
Viscosity, Brookfield model RVF,
2,000
Spindle No. 2 @ 20 rpm @ 25oC, max.

927
 902.01

A type A certification for the SBR polymer latex shall be furnished in accordance
with 916.

The minimum SBR polymer latex content shall be 2.5 %. The SBR polymer latex
content may be reduced below the minimum content provided, if the following
requirements are met:
30
1. An AASHTO accredited laboratory shall blend the PG binder and
SBR polymer latex at the proposed SBR polymer latex content and
test and grade the modified PG binder in accordance with AASHTO
M 320.

2. The laboratory test results verifying the blend and compliance with
902.01(a) shall be submitted to the Engineer for approval.

3. The source of the PG Binder or SBR polymer latex shall not be

40 changed.

1. Sampling
An acceptance sample and backup sample shall be taken from the asphalt delivery
system at the HMA plant. A copy of a load ticket identifying the binder source shall
be submitted with the samples. The Engineer will take immediate possession of the
samples.

2. PG Binder Testing
The Department will perform complete testing in accordance with AASHTO
50 M 320. Complete PG binder testing will consist of RTFO DSR and PAV BBR testing.
Rotational viscosity and flashpoint tests are not required. If the material is not in
accordance with the specifications, the material will represent one week of HMA
production and be adjudicated as a failed material in accordance with 105.03.

3. Appeals
If the Contractor does not agree with the acceptance test results, a request may be
made in writing for additional testing. The appeal shall be submitted within 15
calendar days of receipt of the Department’s written results. The basis of the appeal
shall include complete AASHTO M 320 test results.
60
(b) Asphalt Emulsions
Asphalt emulsions shall be supplied by an approved supplier in accordance with
ITM 593 and shall be composed of an intimate homogeneous suspension of a base
asphalt, an emulsifying agent, and water. Asphalt emulsions may contain additives to
improve handling and performance characteristics. Failure of an emulsion to perform
satisfactorily in the field shall be cause for rejection, even though it passes laboratory
tests. The grade used shall be in accordance with the table for asphalt emulsions as
shown herein. A certification for the asphalt emulsion shall be furnished in accordance
with ITM 804.
70
928
 902.01

The requirements for asphalt emulsions are as follows:

RS-2, HFRS-2, and SS-1h shall be in accordance with AASHTO M 140 except
the cement mixing test is waived.

CRS-2P shall be in accordance with AASHTO M 316. The distillation

temperature shall be 350°F.

CSS-1h shall be in accordance with AASHTO M 208.

80
1. Asphalt Emulsion Warranted Micro-Surfacing
The polymer modified asphalt emulsion shall be a quick-set, CSS-1h emulsion in
accordance with AASHTO M 208 except the cement-mixing test is waived. The
polymer material shall be milled or blended into the asphalt or blended into the
emulsifier solution prior to the emulsification process. The minimum polymer solids
content will be 3.0% based on the residual of the emulsion. Mix set additives shall be
added as required to provide control of the quick-set properties. Additional
requirements shall be in accordance with the following:

Characteristics Test Method Requirement

Residue by Distillation, % (Note 1) AASHTO T 59 62+
Softening Point, °F (°C) AASHTO T 53 140+ (60+)
Viscosity @ 140°F (60°C) AASHTO T 202 8000+
Elastic Recovery @ 77°F (25°C), % AASHTO T 301 60
Note 1: The distillation temperature for this test shall be 350°F (175°C)
90
2. Asphalt Emulsion Ultrathin Bonded Wearing Course

Characteristics Test Method Min. Max.

Viscosity, Saybolt Furol @ 77°F (25°C), s AASHTO T 59 20 100
Storage Stability Test, 24 h, % (Note 1) AASHTO T 59 1
Sieve Test, % AASHTO T 59 0.05
Residue by Distillation, % (Note 2) AASHTO T 59 63
Oil Distillate by volume of emulsified asphalt, % AASHTO T 59 2
w/35 mL, 0.02 N CaCl2 or AASHTO T 59
Demulsibility, % 60
w/35 mL, 0.8% DSS AASHTO T 59
Tests on Residue from Distillation
Penetration (0.1 mm) at 77°F (25°C), 100g, 5 s AASHTO T 49 90 150
Elastic Recovery @ 39°F (4°C), % AASHTO T 301 58
Notes: 1. After 24 h, the emulsion shall be a homogeneous color.
2. Except maximum temperature of 400 ±10°F (205 ±5°C).
3. Organic solvent shall be from the list of Approved Solvents.

929
902.01

3. Asphalt Emulsion Recycling

Characteristics (Note 1) Test Method Min. Max.

Viscosity, Saybolt Furol, @ 77 °F (25°C), SFS AASHTO T 59 20 100
Sieve Test, No. 20, retained on sieve, % AASHTO T 59 0.10
Storage Stability Test, 24 hr, % AASHTO T 59 1
Residue by Distillation, % (Note 2) AASHTO T 59 64
Oil Distillate by volume of emulsified asphalt, % AASHTO T 59 1
Penetration, 77°F (25°C), 100 g, 5 s, dmm AASHTO T 49 50 200
Notes: 1. The asphalt emulsion shall be selected for the project by the asphalt
emulsion supplier based on the Contractor’s mixture design. The
penetration of the supplied asphalt emulsion shall be within ±25 dmm of
the penetration of the design asphalt emulsion. The asphalt emulsion shall
be received on the job site at a temperature no greater than 120ºF (50°C).
2. Modified AASHTO T 59 – distillation temperature of 350 ±9°F (175 ±5°C)
with a 20 minute hold.

930
 Characteristic(1) Test Method AE-90 AE-90S AE-NT AE-F AE-150 AE-PL
Test on Emulsion
Viscosity, Saybolt Furol at 77°F (25°C), min. AASHTO T 59 15 50
Viscosity, Saybolt Furol at 77°F (25°C), max. AASHTO T 59 100 100 115
Viscosity, Saybolt Furol at 120°F (50°C), min. AASHTO T 59 50 50 75
Viscosity, Saybolt Furol at 120°F (50°C), max. AASHTO T 59 300
Demulsibility w/35 mL, 0.02N CaC12, % min. AASHTO T 59 30
Demulsibility w/50 mL, 0.10N CaC12, % min. AASHTO T 59 75
Oil Distillate by Distillation, mL/100 g Emul(2) max. AASHTO T 59 4.0 3.0 4.0 4.0 7.0 3.0
Residue by Distillation, % min. AASHTO T 59 65 65(4) 50 27 65 30
Residue by Distillation, % max. AASHTO T 59 35
Sieve Test, % max. AASHTO T 59 0.10 0.10 0.30 0.10 0.10 0.10
Penetrating Ability, mm, min. 902.02(w) 6
Stone Coating Test, % 902.02(t)3a 90 90
Settlement, % max. AASHTO T 59 5 5
Storage Stability, % max. AASHTO T 59 1
Tests on Residue
Penetration (0.1 mm) at 77°F (25°C), 100g, 5 s, min.(3) AASHTO T 49 100 90
Penetration (0.1 mm) at 77°F (25°C), 100g, 5 s, max.(3) AASHTO T 49 200 150 40 90
Penetration (0.1 mm) at 77°F (25°C), 50g, 5 s, min. (3) AASHTO T 49 100
Penetration (0.1 mm) at 77°F (25°C), 50g, 5 s, max.(3) AASHTO T 49 300
Ductility at 77°F (25°C), mm, min. AASHTO T 51 400
Ash Content, % max. AASHTO T 111 1.0 1.0 1.0 1.0 1.0 1.0
Float Test at 140°F (60°C), s, min.(3) AASHTO T 50 1200 1200 1200
Force Ratio AASHTO T 300 0.3
Elastic Recovery, at 39°F (4°C) AASHTO T 301 58
Notes: (1) Broken samples or samples more than 4 days old will not be tested.
(2) Oil distillate shall be in accordance with ASTM D 396, table 1, grade No. 1.
(3) The Engineer may waive the test.
(4) Maximum temperature to be held for 15 minutes at 350 ±9°F (175 ±5°C).

902.01
931
 902.01

(c) Cutback Asphalts

100 Cutback asphalts shall be composed of an intimate homogeneous mixture of an
asphalt base and a suitable distillate designed for medium, or slow curing. Cutback
asphalts may also contain an additive as an aid in uniformly coating wet, damp, or dry
aggregates used in patching mixtures or HMA pavements. These asphalts shall not
contain more than 0.3% water as determined by ASTM D 95, shall not separate when
allowed to stand, and shall not foam when heated to permissible temperatures. When
an additive is used, it shall be incorporated homogeneously in the asphalt at the point
of manufacture. The temperature of the cutback asphalt shall not be higher than shown
for that grade in 902.03. A type A certification for the cutback asphalt shall be
furnished in accordance with 916.
110
1. Medium Curing Asphalts With and Without Additives
Medium curing asphalts with and without additives shall be in accordance with
the following:

Grades
Characteristics MC-70 MC-250 MC-800 MC-3000
MCA-70 MCA-250 MCA-800 MCA-3000
Flash Point (Open Tag.), °C(4) 38+ 66+ 66+ 66+
Kinematic Viscosity at 60°C (cSt)(2) 70 - 140 250 - 500 800 - 1600 3000 - 6000
Saybolt-Furol Viscosity at 50°C (s) 60 - 120
Saybolt-Furol Viscosity at 60°C (s) 125 - 250
Saybolt-Furol Viscosity at 83°C (s) 100 - 200 300 - 600
Distillation(1)
Distillate (% of total distillate to
360°C MC-70 @ 225°C):
to 225°C 0 - 20 0 - 10
to 260°C 20 - 60 15 - 55 35+ 15+
to 316°C 65 - 90 60 - 87 45 - 80 15 - 75
Residue from distillation to 360°C
(volume % by difference) 55+ 67+ 75+ 80+
Tests on Residue from Distillation(1)
Penetration, 25°C, 100 g, 5 s, -
(0.1 mm)
(without additive) 120 - 250 120 - 250 120 - 250 120 - 250
(with additive) 120 - 300 120 - 300 120 - 300 120 - 300
(3)
Ductility, 25°C (10 mm) 100+ 100+ 100+ 100+
Solubility in organic solvents, % 99.5+ 99.5+ 99.5+ 99.5+
(1) Test may be waived when approved.
(2) Viscosity may be determined by either the Saybolt-Furol or Kinematic test. In case of
dispute, the Kinematic viscosity test shall prevail.
(3) If the ductility at 25°C is less than 100, the material will be acceptable if its ductility at
16°C is 100+.
(4) Flash point by Cleveland Open Cup may be used for products having a flash point
greater than 80°C.

932
 902.01

2. Slow Curing Asphalts With and Without Additives

Slow curing asphalts with and without additives shall be in accordance with the
following:

Grades
Characteristics SC-70 SC-250 SC-800 SC-3000
SCA-70 SCA-250 SCA-800 SCA-3000
Flash Point (Cleveland Open Cup), °C 66+ 79+ 93+ 107+
(2)
Kinematic Viscosity at 60°C (cSt) 70 - 140 250 - 500 800 - 1600 3000 - 6000
Saybolt-Furol Viscosity at 50°C (s) 60 - 120
Saybolt-Furol Viscosity at 60°C (s) 125 - 250
Saybolt-Furol Viscosity at 83°C (s) 100 - 200 300 - 600
(1)
Distillation
Total Distillate to 360°C
(% by volume) 10 - 30 4 - 20 2 - 12 5
Float Test of Distillation Residue
at 50°C (s) 20 - 100 25 - 110 50 - 140 75 - 200
Ductility of Asphalt Residue at 25°C
(10 mm)(1) 100+ 100+ 100+ 100+
(1)
Solubility in organic solvents, % 99.5+ 99.5+ 99.5+ 99.5+
(1)
Test may be waived when approved.
(2) Viscosity may be determined by either the Saybolt-Furol or Kinematic test. In case
of dispute, the Kinematic viscosity test shall prevail.
120
(d) Utility Asphalt
The asphalts shall be uniform in character and shall not foam when heated to
350°F. Utility asphalts shall be in accordance with the following:

Characteristics/Grades UA-I UA-II UA-III

Softening Point (Ring & Ball), °C 46 - 63 63 - 85 79.5 - 96
Penetration of Original Samples(1) (0.1 mm)
at 4°C, 200 g, 60 s, min. 10 10 10
at 25°C, 100 g, 5 s 50 - 100 25 - 45 15 - 35
at 46°C, 50 g, 5 s 100 min. 130 max. 90 max.
Ductility @ 25°C, 50 mm/min, 10 mm, min.(1) 30 10 2.5
(1)
Solubility in Organic Solvents, % min. 99.0 99.0 99.0
(1)
Flash Point (Cleveland Open Cup), °C, min. 225 225 225
Penetration of Residue from Thin Film Oven Test,
25°C, 100 g, 5 s, (0.1 mm) min.(1) 30 15 10
(1) Test will be performed when complete physical characteristics are needed or desired.

A type A certification for the utility asphalt shall be furnished in accordance with
916.

933
 902.02

(e) Asphalt for Coating Corrugated Metal Pipe

130 Asphalt for coating corrugated metal pipe shall be in accordance with the
following:

Physical Properties Min. Max.

Softening Point (Ring & Ball), °C 93 110
Penetration of Original Samples (0.1 mm)
at 4°C, 200 g, 60 s 20
at 25°C, 100 g, 5 s 35(1)
Solubility in Organic Solvents, % 99.0
Flash Point (Cleveland Open Cup), °C 232
Flow Test, mm 6.4
Shock Test 3 of 4 specimens shall pass
(1) May be 30 minimum provided all four shock test specimens pass.

A type A certification shall be submitted to the pipe fabricator in accordance with

908.07.

902.02 Sampling and Testing Asphalt Materials

The tests and AASHTO references are as follows:

140 (a) Sampling Bituminous Materials ........................... AASHTO R 66

The following exceptions to AASHTO R 66 shall apply:

1. Samples may be obtained at any time before material is

incorporated into the work.

2. Samples for all grades of asphalt emulsion shall be a

minimum of 1/2 gal. The size of samples of other liquid
material may be 1 qt.
150
3. Samples of liquid materials shall be obtained at one of the
following:

a. bulk storage tanks from sampling valves located in the

tank or line and asphalt plant storage tanks from
sampling valves located in the tank
b. transports from sampling valves
c. distributors from valves
d. other storage or locations as approved
160 e. sampling by other recognized devices may be approved
f. sampling valves beyond the in-line blending location.

(b) Water in petroleum products, except the solvent

or carrier may be toluene ...................................... ASTM D 95

934
 902.02

(c) Density, Specific Gravity, or API Gravity of

Crude Petroleum and Liquid Products by
Hydrometer Method ............................................. ASTM D 1298

170 (d) Specific Gravity of Semi-Solid Bituminous

Materials ............................................................... AASHTO T 228

(e) Specific Gravity of Solid Pitch and Asphalt ......... ASTM D 71

(f) Flash and Fire Points (Open Cup)

1. When the flash point is higher than 175°F,

“Flash and Fire Points by
Cleveland Open Cup” ................................... AASHTO T 48
180
2. When the flash point is 175°F,
or lower, “Flash Point with Tagliabue
Open Cup”..................................................... AASHTO T 79

(g) Softening Point of Bituminous Materials,

Ring and Ball ........................................................ AASHTO T 53

(h) Penetration of Bituminous Materials .................... AASHTO T 49

190 (i) Loss of Heating..................................................... ASTM D 6

(j) Solubility in Organic Solvents, except the

solvent may be 1,1,1,-Trichloroethane ................. AASHTO T 44

(k) Inorganic Matter or Ash ....................................... AASHTO T 59

(l) Saybolt-Furol Viscosity ........................................ AASHTO T 72

(m) Ductility of Binder Material, except that the conditioning period

200 of the specimens may be shortened, and that only one normal
test will be required. Shortened conditioning period: The
specimen shall be allowed to cool in air for at least 30 minutes.
It shall then be trimmed and placed in the water bath for a period
of 60 to 90 minutes before testing. In case of failure or dispute,
three normal tests will be required and specimens shall be
conditioned as in AASHTO T 51.

(n) Distillation of Cutback Asphaltic Products, except the

length of condenser tube may be
210 400 mm ±24 mm................................................... AASHTO T 78

935
 902.02

(o) Float Test for Bituminous Materials ..................... AASHTO T 50

(p) Kinematic Viscosity of Asphalts .......................... AASHTO T 201

(q) Absolute Viscosity of Asphalts ............................ AASHTO T 202

(r) Effect of Heat and Air on Asphalt Materials,

Thin-Film Oven Test ............................................ AASHTO T 179
220
(s) Effect of Heat and Air on a Moving Film of
Asphalt, Rolling Thin Film Oven Test ................. AASHTO T 240

(t) Testing Asphalt Emulsions ................................... AASHTO T 59

The following exceptions to T 59 shall apply:

1. For the Residue by Distillation test, the specified aluminum

alloy still shall be the referee still.

230 2. When tests on the residue are not required, the % of residue
for emulsion grades RS-2 and AE-90 only, may be
determined by the Residue by Evaporation test of
AASHTO T 59. The % of residue shall be determined by
the Residue of Distillation test in all cases of failure or
dispute.

3. The stone coating test shall be performed as follows on a

mixture of 465 ±1 g of reference stone and 35.0 ±0.1 g of
asphalt emulsion:
240
a. For AE-90 the mixture of stone and asphalt shall be
mixed vigorously for 5 minutes. At the end of the
mixing period, the mix shall be rinsed by running
sufficient tap water at the side of the container to
completely immerse the mix. The tap water shall then
be poured off and the rinsing step repeated as necessary
until the rinse water pours off essentially clear. The
stone shall remain a minimum of 90% coated.

250 b. For AE-150 the mixture of stone and asphalt shall be

mixed vigorously for 5 minutes and then allowed to
stand for 3 h. At the end of this time, the mixture shall
again be mixed vigorously for 5 minutes. At the end of
the mixing period, the mix shall be rinsed by running
sufficient tap water at the side of the container to
completely immerse the mix. The tap water shall then

936
 902.02

be poured off and the rinsing step repeated as necessary

until the rinse water pours off essentially clear. The
stone shall remain a minimum of 90% coated.
260
4. For the Demulsibility test, normally only one test will be
required. In case of failure or dispute, the specified
procedure in AASHTO T 59 will be followed.

5. For oil portion from Residue by Distillation, report the

number of milliliters of oil per 100 g of emulsion.

(u) For coating test for cutback asphalts with additive, 20 g of 20 to

30 mesh Ottawa sand shall be placed in a clean 2 oz (60 mL)
270 wide-mouthed jar and covered with 25 g of distilled water at
room temperature. One gram of the liquid asphalt to be tested
shall be placed gently upon the surface of the water so that it
floats and does not contact the sand. The lid shall then be placed
on the jar and tightened securely. If the liquid asphalt to be
tested is grade 70 or 250, the jar and contents shall be shaken
vigorously for 30 s. If the grade is 800 or 3,000, the jar and
contents shall be immersed in a 115°F water bath for 5 minutes
to bring the contents of the jar to a temperature of approximately
100°F. The jar shall then be shaken vigorously for 30 s. After
280 shaking, the asphalt coating on the sand shall be observed under
a constant, strong light. Complete coating of the sand is
required.

(v) Stripping tests for HMA mixtures using binder materials, with
or without additives, shall be performed as follows:

1. Test 1. A sample of produced mixture, 500 g, minimum,

shall be obtained for testing. The size of test specimen and
the amount of distilled water shall be:
290
Approximate Size Minimum Weight Amount of
of Aggregate of Test Specimen Distilled Water
Sand 100 g 400 mL
12 100 g 400 mL
11 150 g 600 mL
9 200 g 600 mL

Place the specimen in the boiling distilled water and stir with a
glass rod at the rate of one revolution per second for 3 minutes.
The aggregate shall retain a minimum of 90% of its asphalt film
compared with the remainder of the sample, upon completion
of this procedure.

937
 902.02

2. Test 2. Approximately 500 g of produced mixture shall be

heated to 250°F in a laboratory oven for 2 h; stirred and
300 cooled to 200°F. Then a portion of the mix shall be placed
in boiling distilled water, quantity of mix and quantity of
boiling water shall be as specified in Test 1, and stirred
with a glass rod at the rate of one revolution per second for
3 minutes. The aggregate shall retain a minimum of 90%
of its asphalt film compared with the remainder of the
sample, upon completion of this procedure.

Note: The purpose of these tests is to determine the relative

compatibility of the aggregate and asphalt, and to
310 detect tendency of Asphalt Emulsions to re-emulsify.
Test 2 may be performed as a method of determining
whether compatibility can be achieved, Test 1 having
given unsatisfactory results.

(w) Penetrating Ability of AE-PL.

1. Apparatus and Equipment:

a. Sand mixture:
320
(1) Dry Ottawa Sand (AASHTO T 106) ................... 90 parts
(2) Dry Reference Limestone Dust, portion
passing No. 50 (300 mm) sieve only.
Reference Limestone Dust used by the
Department is Limestone Calcium Carbonate
manufactured by France Stone Co. The
Department will furnish approximately 5 lb
of Reference Limestone Dust upon request. ........ 10 parts
(3) Water ................................................................... 3 parts
330
b. Container, 6 oz ointment tin

c. Ruler or other measuring device

d. Timing device readable in seconds

e. Compacting Device. Rimac Spring Tester or other

device suitable for compacting sand by applying a 20
psi load. The compacting device shall include an
340 adapter consisting of two metal discs slightly smaller in
diameter than a 6 oz ointment tin separated by a spacer
1 to 2 in. The 2.5 in. diameter discs used in determining

938
 902.03

weight of coating in AASHTO T 65 or ASTM A 90 are

satisfactory.

f. Small, square ended spatula or putty knife

2. Procedure:

350 Thoroughly mix Standard Ottawa Sand, Reference

Limestone Dust, and water. Weigh 190 ±1 g of sand
mixture into a 6 oz ointment tin. Level surface of sand with
a spatula. Place the compacting adapter on the sand surface
and slowly, over a period of about 5 s, compact the sand
until the 20 psi load is achieved, which is approximately
100 lb on the Rimac Spring Tester. Remove the
compacting device, avoiding disturbance to the sand
surface. Quickly pour 12 g of the emulsion from a height
of about 4 in. onto top of sand mixture. Start timer at start
360 of pour. Stop timer when all emulsion penetrates into sand
mixture. Delay 2 minutes then remove sand and mixture
from one side of ointment tin, about 1/2 of mixture.
Measure to determine average depth of penetration into
sand mixture. Penetration time shall be 100 s or less;
penetration depth shall be 1/4 in. or more.

(x) Flow Test for Asphalt for Coating Corrugated

Metal Pipe .....................................................................AASHTO T 190

370 (y) Shock Test for Asphalt for Coating Corrugated

Metal Pipe .....................................................................AASHTO T 190

(z) Viscosity Determinations of Unfilled Asphalts

Using the Brookfield Thermosel Apparatus ................. AASHTO T 316

(aa) Determining the Rheological Properties of Asphalt

Binder Using a Dynamic Shear Rheometer ..................AASHTO T 315

(bb) Accelerated Aging of Asphalt Binder Using a

380 Pressurized Aging Vessel .............................................AASHTO R 28

(cc) Determining the Flexural Creep Stiffness of

Asphalt Binder Using the Bending Beam
Rheometer.....................................................................AASHTO T 313

902.03 Application Temperatures

Binder materials for the several applications indicated in the specifications shall
be applied at temperatures not to exceed those shown in the following:

939
 903.01

Maximum Application
Type and Grade of Material Temperature, °F
Spray Mix
MC-70, MCA-70 ............................................................... 150
MC-250, MCA-250 ........................................................... 225 200
MC-800, MCA-800 ........................................................... 250 225
MC-3000, MCA-3000 ....................................................... 275 250
SC-70, SCA-70 ................................................................. 200
SC-250, SCA-250 ............................................................. 225 225
SC-800-3000, SCA-800-3000 ........................................... 250 250
All Emulsions .................................................................... 160 180
All Penetration and Viscosity, Utility and Pipe Coating ... 350 325
PG Binders ........................................................................ (Note 1) (Note 1)
Note 1: In accordance with manufacturer’s recommendations.
390

SECTION 903 – CLASSIFICATION OF SOILS

903.01 Definitions
All of the soils shall be tested and classified in accordance with AASHTO M 145,
and in accordance with the grain-size classification procedure as follows:

Soil Classification Definition

Boulders Retained on 3 in. (75 mm) sieve
Gravel 3 in. (75 mm) to No. 10 (2.0 mm) sieve
Coarse Sand No. 10 (2.0 mm) to No. 40 (425 µm) sieve
Fine Sand No. 40 (425 µm) to No. 200 (75 µm) sieve
Silt 0.075 to 0.002 mm
Clay Smaller than 0.002 mm
Colloids Smaller than 0.001 mm

903.02 Soils Having 0% to 19% Retained on No. 10 (2.00 mm) Sieve

These soils shall be classified as follows:
10
Classification Sand and Gravel, % Silt, % Clay, %
Sand 80 – 100 0 – 20 0 – 20
Sandy Loam 50 – 80 0 – 50 0 – 20
Loam 30 – 50 30 – 50 0 – 20
Silty Loam 0 – 50 50 – 80 0 – 20
Silt 0 – 20 80 – 100 0 – 20
Sandy Clay Loam 50 – 80 0 – 30 20 – 30
Clay Loam 20 – 50 20 – 50 20 – 30
Silty Clay Loam 0 – 30 50 – 80 20 – 30
Sandy Clay 50 – 70 0 – 20 30 – 50
Silty Clay 0 –20 50 – 70 30 – 50
Clay 0 – 50 0 – 50 30 – 100
940
 903.06

903.03 Soils Having 20% or More Retained on No 10 (2.00 mm) Sieve and
More Than 20% Passing No. 200 (75 µm) Sieve
These soils shall be classified in accordance with 903.02, followed by a term
describing the relative amount of gravel as follows:

20% to 35%: “with some gravel”

36% to 50%: “and gravel”

20 903.04 Soils Having 20% or More Retained on No. 10 (2.00 mm) Sieve and
Less Than 20% Passing No. 200 (75 µm) Sieve
These soils shall be classified as follows:

Classification Gravel, % Sand, % Silt, % Clay, %

Gravel 85 – 100 0 – 15 0 – 15 0 – 15
Sandy Gravel 40 – 85 15 – 40 0 – 20 0 – 20
Gravelly Sand 20 – 40 40 – 80 0 – 20 0 – 20
Sand and Gravel 20 – 50 20 – 50 0 – 20 0 - 20

If the gradation of a given sample is not in exact accordance with the requirements
for a given classification, it shall be placed in the classification to which it comes the
closest.

903.05 Organic Soils

30 The following classification system shall be used for organic soils in accordance
with AASHTO T 21 and AASHTO T 267.

Classification Organic Content, %

With Organic Matter* 4 - 15
Organic Soil (A-8)* 16 - 30
Peat (A-8) More than 30
* Soils classified in accordance with 903.02 shall also
include this classification.

903.06 Marly Soils

The following classification system shall be used for marly soils with calcium and
magnesium carbonate content in accordance with ITM 507.

Classification Percentage
With Trace Marl* 1-9
With Little Marl* 10 - 17
With Some Marl* 18 - 25
Marly Soil (A-8) 26 - 40
Marl (A-8) More than 40
* Soils classified in accordance with 903.02 shall also
include this classification.

941
 904.01

SECTION 904 – AGGREGATES

904.01 Aggregates
Aggregates shall consist of natural or manufactured materials produced from but
not limited to limestone, dolomite, gravels, sandstones, steel furnace slag, SF, air-
cooled blast furnace slag, ACBF, granulated blast furnace, GBF, wet bottom boiler
slag, or other geologic rock types approved by the Engineer.

A source will not be considered for acceptance of material until a preliminary

10 investigation has been made. As part of this investigation, samples will be obtained
and tests conducted to determine the quality and classification of the aggregates in
accordance with ITM 203.

Two types of samples are required for the preliminary investigation: ledge
samples for crushed stone sources and production samples for crushed stone, natural
sand and gravel, and slag sources.

Ledge samples will be obtained from bedrock units as they naturally occur in the
proposed working face of the quarry. Ledges will be identified, at a minimum, by their
20 differences in color, texture, and geological formation.

Production samples will be obtained from stockpiles of finished materials.

Aggregates, except those used for precast concrete units or fine aggregates used
for snow and ice abrasive, shall be supplied by a Certified Aggregate Producer in
accordance with 917. Structure backfill may be obtained from a non-CAPP source in
accordance with 211.02. SF for SMA mixtures shall also require the following.

(a) Specific gravity quality control tests shall be completed at a

30 frequency of one test per 2,000 t produced.

(b) Target bulk specific gravity shall be established using the

average of the first four tests.

(c) Subsequent individual tests shall be within 0.050 of the target

bulk specific gravity.

(d) Moving average of four consecutive tests shall be within 0.040

of the target bulk specific gravity.
40
(e) Tests outside these ranges shall require the material to be
isolated from the approved stockpile until action has been taken
to eliminate the cause of the non-conformity. Any non-
conforming test shall be followed immediately by a corrective
action. Corrective actions shall include, but are not limited to,

942
 904.01

investigation for assignable cause, correction of known

assignable cause, and retesting.

(f) If it is determined that a new target is necessary, a request shall

50 be made in writing to the District Testing Engineer to establish
the new target.

Dolomite aggregates are defined as carbonate rock containing at least 10.3%

elemental magnesium when tested in accordance with ITM 205.

Polish resistant aggregates are defined as those aggregates in accordance with

ITM 214. Aggregates meeting these requirements will be maintained on the
Department’s list of approved Polish Resistant Aggregates.

60 Sandstone aggregates shall only be used in HMA surface or SMA surface

mixtures. Sandstone aggregates are defined as a sedimentary rock composed of
siliceous sandgrains containing quartz, chert, and quartzose rock fragments in a
carbonate matrix or cemented with silica, calcite, or dolomite. The Office of Materials
Management will determine identification of sandstone.

Steel furnace slag, SF, may be used in aggregate shoulders, HMA surface or SMA
surface mixtures, dumped riprap, and snow and ice abrasives. SF slag coarse aggregate
may be used in HMA base and HMA intermediate mixtures if the deleterious content
is less than 4.0% when tested in accordance with ITM 219. RAP with steel slag may
70 be used in accordance with 401.06, 402.08, and 410.06.

Adjustments in weight shall be made to compensate for the difference in specific

gravity of slag compared to natural aggregate when payment is on a weight basis. The
following typical values for specific gravity will be used: natural aggregate both fine
and coarse, 2.6; ACBF slag coarse aggregate, 2.3; ACBF slag fine aggregate, 2.6; GBF
slag fine aggregate, 2.1; and SF slag both fine and coarse, 3.4. The contract quantity
shall not be adjusted on any pay item less than 500 t.

When slag is furnished as an aggregate, the approximate quantity of tons to be

80 supplied will be determined by multiplying the pay item quantity of tons by the
specific gravity of slag divided by 2.6. The adjusted contract quantities will be
determined by multiplying the accepted quantity of tons by 2.6 divided by the specific
gravity of the slag.

At time of use, aggregates shall be free from lumps or crusts of hardened or frozen
materials.

Composite stockpiling of natural sand fine aggregate from multiple sources into
one stockpile will be allowed provided the fine aggregates are within a range of 0.030
90 for the bulk specific gravity (dry) and a range of 0.5% for the absorption. The range
of bulk specific gravity (dry) and absorption values shall be the difference between the

943
 904.02

average values for each of the fine aggregate sources within the stockpile as
determined by the Office of Materials Management. A written request for the
composite stockpiling shall be made to the Office of Materials Management.

904.02 Fine Aggregates

Fine aggregates are defined as 100% passing the 3/8 in. (9.5 mm) sieve and a
minimum of 80% passing the No. 4 (4.75 mm) sieve. Characteristics of fine aggregates
are as follows:
100
Characteristic PCC HMA SMA
Physical
Organic Impurities, AASHTO T 21 lighter
than or equal to, Color Standard (Note 1) ... 3
Acid Insoluble, ITM 202 ............................. (Note 2)
Soundness
Freeze and Thaw, AASHTO T 103,
Procedure A, % max. (Note 3) .................. 10.0 10.0 10.0
Brine Freeze and Thaw, ITM 209,
% max. (Note 3)........................................ 12.0 12.0 12.0
Sodium Sulfate Soundness,
AASHTO T 104, % max. (Note 3) ........... 10.0 10.0 10.0
Notes: 1. When subjected to the colormetric test for organic impurities and a color
darker than the standard is produced, it shall be tested for effect of organic
impurities on strength of mortar in accordance with AASHTO T 71. If the
relative strength at seven days is less than 95% it shall be rejected.
2. The fine aggregate, including blended fine aggregate, used in HMA Surface
4.75 mm mixtures shall have a minimum acid-insoluble content of 40%,
except when using ACBF or GBF slag sands, the minimum acid-insoluble
content shall be 25%. Acid-insoluble requirements shall not apply to crushed
gravel, limestone, or dolomite sands.
3. AASHTO T 104 and ITM 209 may be run at the option of the Engineer, in-
lieu of AASHTO T 103.

(a) For Portland Cement Concrete

Fine aggregate for use in PCCP or bridge decks shall be natural sand. Fine
aggregate for other PCC shall be natural sand or crushed limestone, dolomite, gravel,
or ACBF.

Natural sand which has been used as foundry sand when tested in accordance with
ITM 215, and complying with IDEM Class III or Class IV in accordance with 329 IAC
10-7-4 may be used in precast concrete units or precast concrete pipe. When foundry
110 sand is used, the precast concrete manufacturer shall maintain a copy of the Waste
Classification issued by IDEM and an indemnification statement shall accompany the
precast items to each contract.

(b) For HMA Mixtures

Fine aggregates for use in HMA shall be natural sand or crushed limestone,

944
 904.02

dolomite, gravel, sandstone, SF, or ACBF. SF sand may be used in HMA surface
mixtures. SF sand may only be used in HMA base and HMA intermediate mixtures if
SF in accordance with 904.01 is used to produce the SF sand. The amount of crushed
limestone sand shall not exceed 20% by volume of the total aggregate used in HMA
120 surface mixtures with ESAL equal to or greater than 3,000,000, except limestone sands
manufactured from aggregates on the Department’s list of approved Polish Resistant
Aggregates will not be limited. If soundness testing cannot be conducted, the aggregate
shall come from a Category I source in accordance with ITM 203.

The fine aggregate angularity value of the total blended aggregate material from
the fine and coarse aggregates, and recycled materials shall meet or exceed the
minimum values for the appropriate ESAL category and position within the pavement
structure as follows:

Fine Aggregate Angularity

Depth from Surface
Traffic ESAL
≤ 4 in. > 4 in.
< 3,000,000 40* 40
3,000,000 to < 10,000,000 45 40
≥ 10,000,000 45 40
* For 4.75 mm mixtures, the fine aggregate angularity shall
be 45 for < 3,000,000 ESAL.
130
Fine Aggregate Angularity, Method A ........................ AASHTO T 304

The fine aggregate angularity value shall not apply to OG mixtures.

(c) For SMA Mixtures

Fine aggregate for SMA shall be limestone, dolomite, crushed gravel, SF, or
ACBF. Crushed gravels shall have a minimum fine aggregate angularity of 45 in
accordance with AASHTO T 304, Method A. Fine aggregates shall be non-plastic in
accordance with AASHTO T 90.
140
(d) For Pneumatically Placed Mortar
Fine aggregate shall be natural sand suitable for use with a pneumatic cement gun.
Fine aggregate shall be size No. 15, or size PP in accordance with 904.02(h), or an
approved gradation from a CAPP source.

(e) Mortar Sand

Fine aggregate for mortar shall consist of uniformly graded natural sand in
accordance with gradation requirements of 904.02(h) for size No. 15 or an approved
gradation from a CAPP source.
150
(f) Mineral Filler for SMA
Mineral filler shall consist of dust produced by crushing stone, portland cement,
or other inert mineral matter having similar characteristics. Mineral filler shall be in

945
 904.02

accordance with the gradation requirements of 904.02(h) for size No. 16 or as

approved by the Engineer. Mineral filler shall be in accordance with ITM 203 or from
an ACBF slag source. The sieve analysis of mineral filler shall be conducted in
accordance with AASHTO T 37 except as noted in 904.06. Mineral filler shall be non-
plastic in accordance with AASHTO T 90.

160 (g) Snow and Ice Abrasives

Snow and ice abrasives shall be fine aggregates or cinders in accordance with the
gradation requirements of 904.02(h) for size S&I.

When steel slag is used for snow and ice abrasives, and payment is on a tonnage
basis, the pay quantity shall be adjusted in accordance with 904.01.

(h) Sizes of Fine Aggregates

Sizes (Percent Passing)

Sieve Sizes 23 24 15 16 PP S&I
3/8 in. (9.5 mm) 100 100 100
No. 4 (4.75 mm) 95 - 100 95 - 100 100
No. 6 (3.35 mm) 100
No. 8 (2.36 mm) 80 - 100 70 - 100 90 - 100 85 - 95
No. 16 (1.18 mm) 50 - 85 40 - 80
No. 30 (600 µm) 25 - 60 20 - 60 50 - 75 100 50 - 65
No. 50 (300 µm) 5 - 30 7 - 40 15 - 40 15 - 25 0 - 30
No. 80 (180 µm) 95 - 100
No. 100 (150 µm) 0 - 10 1 - 20 0 - 10 0 - 10
No. 200 (75 µm) 0-3 0-6 0-3 65 - 100 0-7

170 (i) Sampling and Testing

Sampling and testing shall be conducted in accordance with the following
AASHTO and ITMs.

Acid Insoluble Content ....................................................... ITM 202

Amount of Material Finer than
No. 200 (75 µm) Sieve* .............................................. AASHTO T 11
Brine Freeze and Thaw Soundness ..................................... ITM 209
Control Procedures for Classification
of Aggregates............................................................... ITM 203
180 Determining the Plastic Limit and
Plasticity Index of Soils ............................................... AASHTO T 90
Mortar Strength .................................................................. AASHTO T 71
Organic Impurities .............................................................. AASHTO T 21
Sampling Aggregates.......................................................... AASHTO T 2
Sampling Stockpiled Aggregates........................................ ITM 207
Sieve Analysis of Aggregate* ............................................ AASHTO T 27
Sieve Analysis of Mineral Filler* ....................................... AASHTO T 37

946
 904.03

Soundness* ......................................................................... AASHTO T 103,

AASHTO T 104
190 Specific Gravity and Absorption, Fine Aggregate.............. AASHTO T 84
* Except as noted in 904.06.

904.03 Coarse Aggregates

Coarse aggregates are defined as having a minimum of 20% retained on the No. 4
(4.75 mm) sieve. Coarse aggregates shall not contain adherent fines that are
detrimental to the end product as defined in ITM 211.

The coarse aggregate shall comply with the quality requirements and the
additional requirements in accordance with 904.03(a). However, coarse aggregate may
200 be rejected based on previous performance service records. Class AP is defined as the
highest classification and Class F the lowest. Blending of material for compliance with
gradation or crushed particle requirements may be approved when requested in
writing. Blending of aggregate products to improve the quality classification of the
finished product will not be allowed.

947
 904.03
(a) Classification of Aggregates

Characteristic Classes AP AS A B C D E F
Quality Requirements:
Freeze and Thaw Beam Expansion, % max. (Note 1) ................ .060
Los Angeles Abrasion, % max. (Note 2) ................................... 40.0 30.0 40.0 40.0 45.0 45.0 50.0
Freeze and Thaw, AASHTO T 103, Procedure A,
% max. (Note 3) .................................................................. 12.0 12.0 12.0 12.0 16.0 16.0 20.0 25.0
Sodium Sulfate Soundness, % max. (Note 3) ............................ 12.0 12.0 12.0 12.0 16.0 16.0 20.0 25.0
Brine Freeze and Thaw Soundness, % max. (Note 3) ................ 30 30 30 30 40 40 50 60
Absorption, % max. (Note 4) ..................................................... 5.0 5.0 5.0 5.0 5.0
Additional Requirements:
Deleterious, % max.
Clay Lumps and Friable Particles ................................ 1.0 1.0 1.0 1.0 2.0 4.0
948

Non-Durable (Note 5) .................................................. 4.0 2.0 4.0 4.0 6.0 8.0

Coke ............................................................................. (See Note 6)
Iron .............................................................................. (See Note 6)
Chert (Note 7) .............................................................. 3.0 3.0 3.0 5.0 8.0 10.0
Weight per Cubic Foot for Slag, lbs, min. ................................. 75.0 75.0 75.0 70.0 70.0 70.0
Crushed Particles, % min. (Note 8)
Compacted Aggregates .............................................................. 20.0 20.0 20.0 20.0
Notes:
1. Freeze and thaw beam expansion shall be tested and re-tested in accordance with ITM 210.

2. Los Angeles abrasion requirements shall not apply to BF.

3. Aggregates may, at the option of the Engineer, be accepted by the Sodium Sulfate Soundness or Brine Freeze and Thaw
Soundness requirements.
 4. Absorption requirements apply only to aggregates used in PCC and HMA mixtures except they shall not apply to BF. When
crushed stone coarse aggregates from Category I sources consist of production from ledges whose absorptions differ by more
than two percentage points, the absorption test will be performed every three months on each size of material proposed for use
in PCC or HMA mixtures. Materials having absorption values between 5.0 and 6.0 that pass AP testing may be used in PCC. If
variations in absorption preclude satisfactory production of PCC or HMA mixtures, independent stockpiles of materials will be
sampled, tested, and approved prior to use.

5. Non-durable particles include soft particles as determined by ITM 206 and other particles which are structurally weak, such as
soft sandstone, shale, limonite concretions, coal, weathered schist, cemented gravel, ocher, shells, wood, or other objectionable
material. Determination of non-durable particles shall be made from the total weight (mass) of material retained on the 3/8 in.
(9.5 mm) sieve. Scratch Hardness Test shall not apply to crushed stone coarse aggregate.

6. ACBF and SF coarse aggregate shall be free of objectionable amounts of coke, iron, and lime agglomerates.

7. The bulk specific gravity of chert shall be based on the saturated surface dry condition. The amount of chert less than 2.45 bulk
949

specific gravity shall be determined on the total weight (mass) of material retained on the 3/8 in. (9.5 mm) sieve for sizes 2
through 8, 43, 53, and 73 and on the total weight (mass) of material retained on the No. 4 (4.75 mm) sieve for sizes 9, 11, 12,
and 91.

8. Crushed particle requirements apply to gravel coarse aggregates used in compacted aggregates. Determination of crushed
particles shall be made from the weight (mass) of material retained on the No. 4 (4.75 mm) sieve in accordance with ASTM D
5821.

904.03
 904.03

210 (b) Coarse Aggregate Angularity for HMA and SMA

The coarse aggregate angularity, CAA of the total blended aggregate, including
recycled materials, shall meet or exceed the minimum values for the appropriate ESAL
category and position within the pavement structure as follows.

Coarse Aggregate Angularity

Depth from Surface
Traffic ESAL
≤ 4 in. > 4 in.
< 3,000,000 75 50
3,000,000 to < 10,000,000 85/80* 60
≥ 10,000,000 95/90* 95/90*
* Denotes two faced crush requirements.

For SMA mixtures, the total blended aggregate shall be 100% one face and 95%
two face crushed.

Coarse Aggregate Angularity ...................................... ASTM D 5821

220
Coarse aggregate angularity requirements do not apply to 4.75 mm HMA mixture
designation.

(c) Flat and Elongated

The coarse aggregate shall contain 10% or less flat and elongated particles. A flat
and elongated piece is defined as a particle having a ratio of length to thickness greater
than 5. Determination of flat and elongated particles shall be made from the weight
(mass) of material retained on the 3/8 in. (9.5 mm) sieve and each sieve size greater
than the 3/8 in. (9.5 mm) sieve.
230
Flat and Elongated ....................................................... ASTM D 4791

Flat and elongated requirements do not apply to 4.75 mm HMA mixture

designation.

(d) Surface Aggregate Requirements

The surface mixture aggregates selection shall be based on the ESAL category as
follows.

240 1. HMA Coarse Aggregate

a. ESAL Category 2 and type B surface mixtures. All

coarse aggregate types including ACBF slag, SF slag,
sandstone, crushed dolomite, polish resistant aggregate,
crushed stone and gravel may be used.

b. ESAL Category 3 and type C surface mixtures. ACBF

slag, SF slag, sandstone, crushed dolomite, polish

950
 904.03

resistant aggregate or any combination thereof shall be

250 used. Crushed stone or gravel shall not be used unless
the aggregate is classified as a crushed dolomite or
polish resistant aggregate.

c. ESAL Category 4 and type D surface mixtures. High

friction aggregates including ACBF slag, SF slag,
sandstone or aggregates in accordance with ITM 221
shall be used.

Crushed dolomite and polish resistant aggregates may

260 be used up to a maximum 50% by volume of the coarse
aggregate material retained on the No. 4 (4.75 mm)
sieve when blended with a high friction aggregate.

Crushed stone and gravel may be used up to a

maximum 20% by volume of the coarse aggregate
material retained on the No. 4 (4.75 mm) sieve when
blended with a high friction aggregate.

2. SMA Coarse Aggregate

270 SF slag, sandstone, crushed dolomite and polish resistant aggregates in
accordance with 904.03(a) may be used in SMA mixtures provided the mixtures are
designed in accordance with ITM 220.

951
 904.03
(e) Sizes of Coarse Aggregates

Coarse Aggregate Sizes (Percent Passing)

Sieve Sizes Coarse Graded Dense Graded
2 5 8 9 11, SC 11(5) 12, SC 12(5) SC 16(5) 43(1) 91 53(1) 73(1)
4 in. (100 mm)
3 1/2 in. (90 mm)
2 1/2 in. (63 mm) 100
2 in. (50 mm) 80 - 100
1 1/2 in. (37.5 mm) 100 100 100
1 in. (25 mm) 0 - 25 85 - 98 100 70 - 90 100 80 - 100 100
3/4 in. (19 mm) 0 - 10 60 - 85 75 - 95 100 50 - 70 70 - 90 90 - 100
1/2 in. (12.5 mm) 0-7 30 - 60 40 - 70 60 - 85 100 100 100 35 - 50 55 - 80 60 - 90
3/8 in. (9.5 mm) 15 - 45 20 - 50 30 - 60 75 - 95 95 - 100 94 - 100
952

No. 4 (4.75 mm) 0 - 15 0 - 15 0 - 15 10 - 30 50 - 80 15 - 45 20 - 40 35 - 60 35 - 60

No. 8 (2.36 mm) 0 - 10 0 - 10 0 - 10 0 - 10 0 - 35 15 - 35 25 - 50
No. 16 (1.18 mm) 0-4
No. 30 (600 µm) 0-4 5 - 20 12 - 30 12 - 30
(2) (4)
No. 200 (75 µm) 0 - 6.0 5.0 - 10.0 5.0 - 12.0
(3)
Decant (PCC) 0 - 1.5 0 - 1.5 0 - 1.5 0 - 1.5 0 - 1.5 0 - 1.5
Decant (Non-PCC) 0 - 2.5 0 - 2.5 0 - 3.0 0 - 2.5 0 - 2.5 0 - 2.0 0 - 2.5
Decant (SC) 0 - 1.5 0 - 1.5 0 - 1.5
Notes: (1) The liquid limit shall not exceed 25 (35 if slag) and the plasticity index shall not exceed 5. The liquid limit shall be determined in accordance
with AASHTO T 89 and the plasticity index in accordance with AASHTO T 90.
(2) Includes the total amount passing the No. 200 (75 µm) sieve as determined by AASHTO T 11 and AASHTO T 27.
(3) Decant may be 0 - 2.5 for stone and slag.
(4) When slag is used for separation layers as defined in 302.01, the total amount passing the No. 200 (75 µm) sieve shall be 10.0 to 12.0.
(5) Seal coat (SC) aggregates shall be 85% one face and 80% two face crushed. The Flakiness Index in accordance with ITM 224 shall be a
maximum of 25%.
 904.04

(f) Sampling and Testing

Sampling and testing will be in accordance with the following AASHTO, ASTM,
280 and ITMs.

Amount of Material finer

than No. 200 (75 µm) Sieve*................................ AASHTO T 11
Brine Freeze and Thaw Soundness .............................. ITM 209
Clay Lumps and Friable Particles ................................ AASHTO T 112
Control Procedures for Classification of Aggregates .. ITM 203
Crushed Particles ......................................................... ASTM D 5821
Dolomite Aggregates ................................................... ITM 205
Flat and Elongated Particles ........................................ ASTM D 4791
290 Freeze and Thaw Beam Expansion ............................. ITM 210
Lightweight Pieces in Aggregates* ............................. AASHTO T 113
Los Angeles Abrasion ................................................. AASHTO T 96
Micro-Deval Abrasion ................................................. AASHTO T 327
Polished Resistant Aggregates..................................... ITM 214
Sampling Aggregates*................................................. AASHTO T 2
Sampling Stockpiled Aggregates................................. ITM 207
Scratch Hardness ......................................................... ITM 206
Sieve Analysis* ........................................................... AASHTO T 27
Soundness* .................................................................. AASHTO T 103,
300 AASHTO T 104
Specific Gravity and Absorption* ............................... AASHTO T 85
Unit Weight and Voids in Aggregates ......................... AASHTO T 19
*Except as noted in 904.06

904.04 Riprap
Riprap shall consist of SF for dumped riprap only, sound stone, stone masonry, or
other approved material, free from structural defects and of approved quality. Stone
containing shale, unsound sandstone, or other material that will disintegrate readily,
shall not be used.
310
(a) Dumped Riprap
Dumped riprap shall be broken concrete, masonry, or stone removed from an old
structure; broken pieces removed from concrete pavement, base, or monolithic brick
pavement; or broken rock from class X, class Y, unclassified excavation, or solid rock
excavation. Material provided from sources outside the right-of-way shall be coarse
aggregate, Class F or higher.

(b) Grouted Riprap

Grouted riprap material shall be in accordance with dumped riprap or revetment
320 riprap.

(c) Revetment, Class 1, and Class 2 Riprap

The material shall be coarse aggregate, Class F or higher. Gradation shall be in
accordance with 904.04(f).
953
 904.05

(d) Uniform Riprap

The material shall be coarse aggregate, Class F or higher in accordance with
904.03(a). Gradation shall be in accordance with 904.04(f). Either type A or type B
may be utilized.
330
(e) Precast Concrete Riprap
Precast concrete riprap shall consist of unreinforced concrete units of the
thickness specified and shall be in accordance with the details shown on the plans. The
precast concrete units shall be in accordance with ASTM C 139 except the fine
aggregates shall be in accordance with 904.02(a) and the coarse aggregates, class A or
higher, shall be in accordance with 904.03. The minimum compressive strength shall
be 2,500 psi for an average of three units and 2,300 psi for individual units. The
maximum water absorption shall be 12 lb/cu ft for an average of three units.

340 (f) Sizes of Riprap

Gradation Requirements
Percent Smaller
Size, in. Revetment Class 1 Class 2 Uniform A Uniform B
30 100
24 100 85 - 100
18 100 85 - 100 60 - 80
12 90 - 100 35 - 50 20 - 40
8 100
6 20 - 40 10 - 30 0 - 20 35 - 80 95 - 100
3 0 - 10 0 - 10 0 - 10 35 - 80
1 0 - 20 0 - 20
Depth of Riprap, min. 18 in. 24 in. 30 in.

The maximum dimension of individual pieces shall not be greater than three times
the minimum dimension. The riprap will be visually inspected for size, shape, and
consistency.

904.05 Structure Backfill

The material shall be of acceptable quality, free from large or frozen lumps, wood,
or other extraneous matter. It shall consist of suitable sand, gravel, crushed stone,
350 ACBF, or GBF. Structure backfill shall be in accordance with one of the gradations
shown in the table below, or coarse aggregate No. 5, No. 8, No. 9, No. 11, No. 12, No.
53, or No. 73 in accordance with the gradation requirements of 904.03(e). Coarse
aggregate No. 5, No. 8, No. 9, No. 11, No. 12, No. 53, or No. 73 shall be crushed stone
or ACBF, class D or higher.

954
 904.06

Nominal Sizes and Percents Passing

Sieve
2 in. 1 1/2 in. 1 in. 1/2 in. No. 4 No. 30
Sizes
(50 mm) (37.5 mm) (25.0 mm) (12.5 mm) (4.75 mm) (600 µm)
2 1/2 in. (63 mm) 100
2 in. (50 mm) 90 - 100 100
1 1/2 in. (37.5 mm) 70 - 100 90 - 100 100 100
1 in. (25.0 mm) 55 - 95 70 - 100 85 - 100
3/4 in. (19.0 mm) 45 - 90 55 - 95 70 - 100
1/2 in. (12.5 mm) 35 - 85 40 - 90 55 - 95 85 - 100 100 100
No. 4 (4.75 mm) 20 - 65 20 - 70 25 - 75 45 - 85 90 - 100
No. 8 (2.36 mm) 10 - 50 10 - 55 15 - 60 25 - 75 75 - 100
No. 30 (600 µm) 3 - 35 3 - 35 3 - 35 5 - 45 15 - 70 70 - 100
No. 200 (75 µm) 0-8 0-8 0-8 0-8 0-8 0-8

904.06 Exceptions to AASHTO Standard Methods

(a) Exceptions to AASHTO T 2

360 Stockpile sampling shall be in accordance with ITM 207, unless otherwise
approved.

(b) Exceptions to AASHTO T 11, T 27, and T 37

1. When tests are performed in the field where ovens are not
available, test samples may be dried in suitable containers
over open flame or electric hot plates with sufficient
stirring to prevent overheating, then cooled to constant
weight.
370
2. The balance shall be a Class G2 general purpose balance in
accordance with AASHTO M 231.

(c) Exceptions to AASHTO T 27 for Coarse Aggregates

The size of test samples for coarse aggregate shall be as follows:

Aggregate Size Minimum Weight

of Test Sample
No. 2 ............................................................................ 25 lb
380 No 5, 8, 43, 53, 73, and 91 .......................................... 13 - 18 lb
No. 9 ............................................................................ 9 - 13 lb
Structure Backfill
2 in. (50 mm) ........................................................ 25 lb
1 1/2 in. (37.5 mm) and 1 in. (25.0 mm)............... 13 - 18 lb
1/2 in. (12.5 mm) .................................................. 9 - 13 lb
No. 4 (4.75 mm) and No. 30 (600 µm) ................. 10 oz

955
 905.01

(d) Exceptions to AASHTO T 85

The in-water weight shall be determined following the 15 h soaking period prior
390 to determining the SSD weight.

(e) Exceptions to AASHTO T 103 and 104

1. Counting the number of individual particles coarser than

the 3/4 in. (19.0 mm) sieve will not be required.

2. For testing ledge rock, the ledge samples shall be crushed

to obtain test samples for the designated increments
passing the 1 1/2 in. (37.5 mm) sieve and retained on the
400 No. 4 (4.75 mm) sieve. The factors used to calculate the
weighted average loss are 30%, 40%, and 30% of the 1 1/2
in. (37.5 mm) ˗ 3/4 in. (19.0 mm), 3/4 in. (19.0 mm) ˗ 3/8
in. (9.5 mm), and 3/8 in. (9.5 mm) ˗ No. 4 (4.75 mm)
increments, respectively.

3. In the case of ledge rock, modify sections 3.3 and 6.2 of

AASHTO T 103 and AASHTO T 104 respectively. When
the sample received is deficient in material of a component
size of any test portion, that material will be supplemented
410 with the available component size to provide the test
portion.

4. Modify section 8 of AASHTO T 103 and section 10 of

AASHTO T 104. For materials designated as a coarse
aggregate, the weighted loss will be calculated considering
the material retained on the No. 4 (4.75 mm) sieve as 100%
of the sample, and only the total weighted loss reported. In
AASHTO T 104 sections 10.1.3.2 and 10.1.3.3 shall not
apply, and unless otherwise noted only new solution will
420 be used.

SECTION 905 – MASONRY UNITS

905.01 Clay or Shale Brick

Brick shall be in accordance with the following specifications.

(a) Sewer Brick

Sewer brick shall be in accordance with ASTM C 32, grade SS.

(b) Manhole Brick

10 Manhole brick shall be in accordance with ASTM C 32, grade MS.

956
 905.05

(c) Building Brick

Building brick shall be in accordance with ASTM C 62, grade SW.

905.02 Concrete Brick

Concrete brick intended for use in construction of manholes, catch basins, and
similar structures, or as building bricks, shall be in accordance with ASTM C 55, grade
S.

20 905.03 Concrete Masonry Blocks

Concrete masonry blocks may be rectangular or segmented and, when specified,
shall have ends shaped to provide interlock at vertical joints. Solid masonry units shall
be in accordance with ASTM C 139. Hollow load-bearing masonry units shall be in
accordance with ASTM C 90, grade N-II.

905.04 Precast Concrete Curbing

Precast concrete curbing shall consist of precast portland cement concrete curb
units constructed to the length, shapes, and other details shown on the plans. These
units shall be reinforced with steel reinforcement when shown on the plans. Steel
30 reinforcement shall be in accordance with 910.01.

When required for driveways, crossings, closures, or for other reasons a depressed
or modified section of curb is indicated, curbing with the required modification shall
be furnished.

905.05 Detectable Warning Surfaces

The detectable warning surface in concrete curb ramps shall be constructed using
materials from the Departments approved list of Detectable Warning Surfaces, which
is maintained by the Office of Materials Management. A surface manufacturer wishing
40 to add a product to the approved list shall comply with Procedure L of ITM 806.

(a) Brick detectable warning surfaces shall consist of clay, shale, or

similarly naturally occurring earthy substance, subjected to heat
treatment at elevated temperatures to form bricks or pavers. The
dimensions of the brick shall be 8 in. in length, 4 in. in width
including any spacing lugs. The thickness of the brick shall be
2 in., excluding dome height and edge chamfers. The truncated
domes on the surface shall be formed integral with the main
body of the detectable warning surface and be present on the
50 brick prior to heat treatment. The size and physical requirements
of the bricks shall be in accordance with ASTM C 902 for
weather and traffic environment classifications Class SX, Type
II, respectively. The truncated domes may be ground off to meet
the cap thickness requirement for compressive strength testing.

(b) Brick detectable warning surfaces shall be predominantly red-

brown in color and shall be uniform throughout the brick. The

957
 905.06

color will be determined from the average of five color readings

for detectable warning surfaces when measured at the top
60 surface between the raised truncated domes and determined in
accordance with ASTM E 1349, CIE Illuminant D65, 10°
Standard Observer, using instrument geometry of 45°/0°, and
the CIE L*a*b* color system. The tested bricks shall be within
the limits as follows:

Minimum Maximum
L* 35.0 50.0
a* 6.0 36.0
b* 0.0 30.0

The value of a* shall not be less than 90% of the value of b*.
The color difference of any installed brick after one year of
exposure or of an individual detectable warning surface from
70 the average color for any product or model from a manufacturer
shall not be greater than 5.0 ΔE* units. The color shall be
uniform throughout the detectable warning surfaces.

(c) Cast iron detectable warning surfaces shall be manufactured

from gray iron in accordance with AASHTO M 105, Class 30A
as a minimum. The truncated domes shall be as shown on the
plans. The tops of the domes and the space between domes shall
have a non-slip textured surface. The minimum thickness of the
casting shall be 0.20 in. The minimum thickness shall not be
80 measured within the area of integral reinforcing ribs or bracing,
domes or the textured surface.

(d) The height range of the truncated domes shall be between 0.18
in. and 0.26 in. The design values shall be within the ranges
identified in the Standard Drawings. No more than two
truncated domes per surface may be out of tolerance for
dimensions.

(e) Detectable warning surfaces that are not classified as brick in

90 accordance with 905.05(a) or cast iron in accordance with
905.05(c) will be considered. The detectable warning surfaces
shall meet the color requirements of 905.05(b) and the truncated
dome requirements of 905.05(d).

905.06 Precast Concrete Units Not Otherwise Covered

These units shall be cast in substantial permanent steel forms. Structural concrete
shall attain a minimum 28-day compressive strength of 3,000 psi as determined in
accordance with AASHTO T 22. When air entrained concrete is specified, it shall have
an air content of from 5% to 8% by volume. The precast units shall be cured in

958
 906.02

100 accordance with AASHTO M 170. Water absorption of individual cores taken from
such units shall not exceed 9%. Additional reinforcement shall be provided as needed
to handle the precast units.

SECTION 906 – JOINT MATERIALS

906.01 Joint Fillers

Joint fillers shall be preformed materials intended to be used in PCCP and bridge
joints or as otherwise specified. Joint fillers shall be in accordance with AASHTO M
213 or ASTM D 8139.

906.02 Joint Sealing Materials

10 (a) Joint Sealers

Joint sealers shall consist of materials which are intended to be used in sealing
joints and cracks in pavements and structures.

1. Silicone Joint Sealants

a. Physical Requirements
Silicone joint sealants shall be in accordance with ASTM D 5893.

b. Field Evaluation
20 All silicone joint sealants complying with the physical requirements will be
subjected to a field evaluation before approval for general use is granted. The
Department will maintain a list of approved Joint Sealant materials, which comply
with the physical requirements and field evaluation.

c. Specific Requirements for Installation of Silicone Joint

Sealant
The sealant shall be stored in the original unopened container at or below 90°F.
The sealant shall be placed when the ambient temperature is above 40°F. The
equipment used shall be adequate for the placement of the sealant and shall meet the
30 sealant manufacturer’s recommendations. Air compressors used for the placement of
this sealant shall be equipped with traps which remove moisture and oil from the air.

The approved sealants which are self leveling shall be identified as such on the
Department’s list of approved Joint Sealant materials, and will not require tooling.
Sealants not identified as self leveling on the approved list shall be tooled or applied
in such a manner which causes them to wet the joint faces. Such sealants which are
not formulated for self leveling will not position properly in the joint under its own
weight. A backer rod as set out herein shall be used to control sealant configuration
and facilitate tooling. Applicable joint configurations shall be as shown on the plans.
40 After a joint has been sealed, all surplus joint sealer on the pavement surfaces shall be

959
 906.02

promptly removed. Traffic shall not be allowed over sealed joints until the sealer is
tack free.

The sealant shall be delivered in containers plainly marked with manufacturer’s

name or trademark.

2. Hot Poured Joint Sealant

The sealant shall be in accordance with ASTM D 6690, Type II. The material
shall be tested in accordance with ASTM D 5329 except that after blotting, the surface
50 of the blocks shall be blown dry with compressed air. The sealant shall be covered by
type A certification in accordance with 916 for each batch or lot of material furnished.

The sealing compound shall be delivered in the manufacturer’s original sealed

container. Each container shall be legibly marked with the name of the manufacturer,
the trade name of the sealer, the manufacturing batch number or lot, the pouring
temperature, and the safe heating temperature.

The sealant shall be used in accordance with the manufacturer’s recommendations.

A backer rod as set out herein shall be used to provide the joint configuration in
60 accordance with the standard drawings.

3. Preformed Elastomeric Joint Seals

This joint shall be in accordance with ASTM D 2628. Joint seals furnished under
this specification shall be covered by a type A certification in accordance with
916.03(b).

4. Polychloroprene Joint Membrane and Adhesive

Polychloroprene joint membrane shall be general purpose, heavy duty
polychloroprene sheeting with nylon fabric reinforcement. The sheeting shall be in
70 accordance with the following:

Property Test Method Requirement

Thickness ASTM D 751 0.094 in. ±0.01 in.
Breaking Strength, 700 lbf x 700 lbf
ASTM D 751
Grab Test, minimum (Longitudinal x transverse)
Adhesive Strip, 1 in. by 2 in. ASTM D 751 9 lbf (minimum)
Burst Strength ASTM D 751 1,400 psi (minimum)
Heat Aging, 70 h, 212°F ASTM D 2136 180° bend with no cracking of coating
Low Temp. Bend Test, Bend around a 1/4 in. mandrel with no
ASTM D 751
1h, 40°F cracking of coating

Polychloroprene joint membrane shall be covered by a type B certification in

accordance with 916.

960
 906.02

The adhesive used to attach the polychloroprene joint membrane to concrete shall
be a black styrene-butadiene rubber base material compatible with both concrete and
polychloroprene. The adhesive shall be in accordance with the following:

Property Test Method Minimum Maximum

ASTM D 2196,
Viscosity, cps 7,500 18,000
RVF #6 sp @ 20 rpm
Solids, % ASTM D 1259 28 35
Weight per gal., lb ASTM D 1875 6.6 7.0
80
The adhesive shall be covered by a type C certification in accordance with 916.

5. Hot Poured Joint Adhesive

Joint adhesive is a hot applied asphalt material that is used to seal the longitudinal
construction joint formed between the adjacent HMA pavement courses.

Joint adhesive shall be in accordance with the following:

Test Method Test Results

Softening Point, °F (°C) AASHTO T 53 > 170 (77)
Ductility @ 77°F (25°C), mm AASHTO T 51 > 300
Ductility @ 39°F (4°C), mm AASHTO T 51 > 300
Apparent Viscosity @ 400°F (204°C), cp ASTM D 2669 4,000 – 11,000
Asphalt Compatibility ASTM D 5329 Pass
Cone Penetration @ 77°F (25°C), mm ASTM D 5329 50.0 – 100.0
Flow @ 140°F (60°C), mm ASTM D 5329 <5
Resilience @ 77°F (25°C), % ASTM D 5329 > 30
Tensile Adhesion @ 77°F (25°C), mm ASTM D 5329 > 500
Flexibility @ 0°F (-18°C) ASTM D 3111 Pass
Flash Point, °F (°C) AASHTO T 48 > 410 (210)

90 The joint adhesive will be accepted by type A certification in accordance with 916
for each batch or lot of material furnished.

(b) Backer Rod

The rod is to act as a bond breaker, to control the thickness of the bead, and to
provide support for any required tooling of the sealant.

1. Requirements
When hot poured material is used, compatibility of the backer rod with the hot
sealant shall be verified before use. The backer rod shall be a closed cell expanded
100 polyethylene foam or an isomeric polymer foam rod. Diameter and placement shall be
as shown on the plans.

961
 906.03

2. Certification
Backer rod furnished under this specification shall be covered by a type C
certification in accordance with 916.

906.03 Blank

906.04 Blank
110
906.05 Blank

906.06 Blank

906.07 Bridge Expansion Joints

Joints, including anchor assemblies, shall be shop fabricated, delivered and
installed as a continuous unit for lengths up to 46 ft. Joints longer than 46 ft shall be
furnished in continuous units or in appropriate shorter sections as shown on the
working drawings and approved by the Engineer. Joints used in stage construction
120 shall be furnished in sections appropriate to accommodate the work. All joints
furnished in sections shall be spliced with welds, with ends prepared for welding in
the shop. All welds shall be in accordance with 711.32.

The profile of the joint in the roadway area shall conform to the roadway cross
section. Where changes in direction are required, such as at curbs or concrete rails, the
sections shall be cut to the bevel required to produce the same cross section on each
piece being joined. Slider plates shall be provided at curbs, walkways, and concrete
rails as part of the completed joint assembly. The slider plate shall be the same material
as the extrusion and shall be galvanized in accordance with ASTM A 123.
130
All welds in contact with the elastomeric seals shall be ground smooth. Metal
surfaces in direct contact with the elastomeric seal shall be cleaned and treated in
accordance with the manufacturer’s recommendations to provide a high strength bond
between the elastomeric seal and mating metal surfaces. The elastomeric seals shall
be clean and free of foreign materials. All exposed structural steel surfaces, except
stainless steel or polytetrafluoroethylene coated, shall be shop painted in accordance
with 619.

(a) Type SS
140 Structural steel shall be in accordance with ASTM A 36, ASTM A 588, ASTM A
1011, ASTM A 242, or Merchant Quality 1010, 1020.

Sealant and grouts shall be in accordance with the manufacturer’s

recommendation.

The elastomer shall be neoprene in accordance with ASTM D 5973 except that
the physical requirements in Table 1 for low temperature recovery, high temperature
recovery, and compression-deflection properties will not apply.

962
 906.07

150 The strip seal shall be furnished in one continuous length for the entire limits of
the installed joint. Field splicing of the strip seal will not be allowed. Miter cut,
vulcanized shop splices will be required in the strip seal. The shop vulcanization of
the strip seal splice may be either a hot or cold process so long as the process produces
a splice of equal or greater strength than the elastomer.

The structural steel and polyurethane sealant shall be covered by a type C

certification, and the elastomer shall be covered by a type B certification, both in
accordance with 916.

160 (b) Type M

This joint shall consist of prefabricated multiple elastomeric seals, separator
beams, and support bars. The structural design of the joint shall be in accordance with
AASHTO LRFD Bridge Construction Specifications and shall be for the same design
loading as the bridge structure at which it is to be installed, but not less than HS 20-44
truck loading and impact. The joint shall be designed to accommodate the movement
shown on the plans.

The joint assembly shall be preset by the manufacturer in accordance with the
approved working drawings, joint setting data and specifications. The assembly shall
170 be properly secured for shipping and contain provision for final field adjustment at the
time of installation. The manufacturer shall furnish a copy of the installation
instructions prior to the placement of these joints.

Structural steel shall be in accordance with ASTM A 36, ASTM A 1011, ASTM
A 242, ASTM A 588, or Merchant Quality 1010, 1020 in accordance with ASTM A
576.

Sealant and grout shall be in accordance with the joint manufacturer’s

recommendation.
180
Elastomer shall be neoprene in accordance with ASTM D 3542.

The structural steel and sealant shall be covered by a type C certification and the
elastomer by a type B certification, both in accordance with 916.

Bearings above and below the support bar shall be a nylon or urethane compound
with polytetrafluorethylene riding surfaces. All components of the system shall be
accessible to periodic inspection and component replacement if necessary.

190 The elastomer seals shall be in accordance with the requirements as follows:

1. be held in place by compressive forces throughout the

normal limits of joint movement;

963
 906.07

2. be supplied and installed in one piece;

3. have corner locked edges for a watertight fit;

4. not be any part of the load bearing riding surface;

200
5. be installed using seal lubricant-adhesive or be
mechanically clamped in position to produce a watertight
seal;

6. have a shape which promotes self removal of foreign

material during normal joint operation;

7. be recessed 1/2 in. below the riding surface throughout the

normal limits of joint movement;
210
8. be held in position by the separator beams;

9. have a hollow box shape for joints utilizing urethane

equilibrium control spacers or a strip seal configuration for
joints using a mechanical linkage to maintain equidistant
separator beam spacing. The joint shall have a maximum
opening of 3 in. per seal.

The separator beams shall be in accordance with the requirements as follows:

220
1. provide the riding surface across the joint;

2. have an extruded or machined shape suitable to hold the

seals;

3. be stable against tipping, tilting, or lifting during

application of traffic loads by use of a suitable shape and
connection to the support bar;

230 4. be supported individually on their own independent

support bars;

5. maintain equidistant spacing through use of suitable

urethane equilibrium type control spacers to counter the
compressive forces of the seals or through a positive
horizontal mechanical linkage or proportioning bar.

The support bars shall be in accordance with the requirements as follows:

964
 907.02

240 1. incorporate stainless steel sliding surfaces to minimize

resistance to joint movements;

2. be supported above, below, and laterally as required to

prevent lifting, to transmit bearing loads, and to maintain
positioning of the bar.

All support bar boxes and joint housings shall have top, bottom, and sides made
of steel plate with 1/2 in. minimum thickness. Anchorages shall consist of looped No.
5 reinforcing bars welded to 1/2 in. steel plates spaced at 9 in. centers. Non-welded
250 steel to steel contact will not be allowed.

906.08 High Density Bearing Strip

The strip shall be nontoxic multipolymer plastic in accordance with the following
requirements:

Property Test Method Requirement

Compressive
ASTM D 695 8,000 to 9,000 psi
Strength
Coefficient of
ASTM D 696 7.62 x 10-4 mm/mm/ºC to 1.27 x 10-3 mm/mm /ºC
Linear Expansion

The high density bearing strip shall be covered by a type B certification in

accordance with 916.

SECTION 907 – CONCRETE, CLAY, AND PLASTIC DRAINAGE

COMPONENTS

907.01 Non-Reinforced Concrete Pipe

This pipe shall be in accordance with AASHTO M 86 for the specified diameter
and strength classes. When used for underdrain, each section of pipe shall not exceed
3 ft in length.

907.02 Reinforced Concrete Pipe

10 This pipe shall be in accordance with AASHTO M 170 for the specified diameters
and strength classes. Precast concrete units shall be from a source listed in the
Department’s List of Certified Precast Concrete Producers, in accordance with ITM
813. Unless otherwise specified, pipe wall design and use of elliptical reinforcement
in circular pipe are optional.

The pipe provided shall be in accordance with the class and D-load rating shown
in the plans.

When the pipe listed below is specified or allowed, it shall be in accordance with
20 the class noted.

965
 907.03

Extra Strength Reinforced Concrete Pipe .................... Class IV

Heavy Duty Reinforced Concrete Pipe........................ Class V
Reinforced Concrete Pipe ............................................ Class III
Reinforced Concrete Sewer Pipe ................................. Class II.

Precast reinforced concrete end sections shall be in accordance with the cited
specifications to the extent to which they apply.

30 The manufacturer of the steel reinforcement shall furnish to the pipe manufacturer
a mill test report. The pipe manufacturer shall certify, on furnished forms that:

(a) The placement of the steel reinforcement is in accordance with

the Standard Specifications.

(b) The area of steel reinforcement per linear foot of pipe is in

accordance with or exceeds the specification requirements.

(c) Based on the steel reinforcement manufacturer’s mill test

40 report, the steel used in the pipe is in accordance with the
specification requirements.

(d) Copies of the steel reinforcement manufacturer’s mill test

reports shall be on file and available to review for five years.

907.03 Reinforced Concrete Horizontal Elliptical Pipe

This pipe shall be in accordance with AASHTO M 207. Certification shall be in
accordance with 907.02.

50 907.04 Precast Concrete Manholes, Inlets, and Catch Basins

These units shall be in accordance with AASHTO M 199. References to diameter
are applicable to corresponding dimensions in other than circular sections. Absorption
tests will not be required for flat top or base slabs. Certification shall be in accordance
with 907.02.

No more than three holes shall be cast or drilled in each section for the purpose of
handling.

In addition to the requirements of AASHTO M 199, the manhole steps shall be

60 permanently marked with the specific step designation, and the manufacturer’s
identification. This marking shall remain exposed after installation.

Steps shall be selected from the list of approved Manhole Steps. Requests for
adding steps to the list shall be accompanied by: a certified test report demonstrating
compliance with AASHTO M 199; instruction for proper installation; complete
product description including the ancillary equipment required for installation; and a

966
 907.06

sample step. The Department may perform a laboratory evaluation of specific steps
and may not add steps to the list which are not furnished with ancillary installation
equipment.
70
907.05 Precast Reinforced Concrete Structure Sections
Precast reinforced concrete structure sections shall be from a source listed in the
Department’s List of Certified Precast Concrete Producers, in accordance with ITM
813. A water-reducing admixture from the Department’s list of approved Water-
Reducing Admixtures may be used.

Handling devices or holes will be allowed in each structure section. Holes for
handling shall be filled with material in accordance with 901.07, 901.08, or with
precast concrete plugs which shall be secured with portland cement mortar or other
80 approved adhesive before backfilling. Drilled handling holes shall be filled with
portland cement mortar. Prior to backfilling the structure, all holes shall be covered
with joint wrap material with a minimum width of 9 in.

The section ends shall be of such design and shall be so formed that when the
structure sections are erected, they shall make a continuous line of structure with a
smooth interior free of irregularities. The ends of the structure sections shall be normal
to the walls and centerline, except where beveled ends are specified. The surface of
the structure sections shall be cast from a smooth steel form or troweled surface.
Trapped air pockets causing surface defects shall be considered as part of a smooth
90 steel form finish.

(a) Box
Box structure sections shall be in accordance with ASTM C 1577 and the
exceptions to ASTM C 1577 listed in 714.04. Not more than four holes may be cast,
drilled, or otherwise made in each box section for the purpose of handling or laying.

(b) Three-Sided
Three-sided structure sections shall be in accordance with ASTM C 1504 and the
exceptions to ASTM C 1504 listed in 723.04. Not more than six holes shall be cast,
100 drilled, or otherwise made in each section for the purpose of handling or laying.

907.06 Precast Reinforced Concrete Headwalls, Wingwalls, Footings and

Spandrel Walls

Precast concrete units shall be from a source listed in the Department’s List of
Certified Precast Concrete Producers, in accordance with ITM 813. A water-reducing
admixture from the Department’s list of approved Water-Reducing Admixtures may
be used.

110 Handling devices or holes will be allowed in each wingwall and spandrel wall
section. Not more than four holes shall be cast or drilled in each section for the purpose
of handling or setting. Weep holes shall be provided in all wingwalls. Headwalls,

967
 907.07

wingwalls, and spandrel walls shall be free of fractures and shall be given a finish in
accordance with 702.21.

The concrete compressive strength for headwalls, wingwalls, and spandrel walls
shall have a minimum 28-day compressive strength of 4,000 psi, as determined by
compressive strength testing of concrete cylinders. The concrete compressive strength
for footings shall have a minimum 28-day compressive strength of 2,000 psi, as
120 determined by compressive strength testing of concrete cylinders.

Structural steel used in bolted connections of headwalls or wingwalls to a box-

structure section, or of wingwalls to a three-sided-structure section or spandrel wall,
shall be in accordance with 910.02(a), and zinc coated after fabrication in accordance
with ASTM A 153.

Bolts and studs shall be hot dipped in accordance with 910.02(g)1. Nuts shall be
in accordance with ASTM A 563, grade A, Hex style; unless specified otherwise.
Washers shall be in accordance ASTM F 844, unless specified otherwise. Bolts, nuts
130 and washers shall be hot dip zinc coated.

907.07 Joint Membrane System for Precast Reinforced Concrete Box

Structure Sections
The Contractor may elect to use an approved self-adhering membrane system in
lieu of the detail shown on the plans.

Joint membrane systems shall be in accordance with the following requirements.

Property Test Method Requirements

Thickness ASTM D 3767, Procedure A 59 mil, min.
Grab Tensile Strength,
Tensile Strength 650 N, min.
ASTM D 4632
Grab Tensile Strength,
Elongation 20%, min.
ASTM D 4632
Bursting Strength Mullen Burst, ASTM D 3786 290 psi, min.
Peel Strength ASTM D 903 850 N/m, min.
Permeance ASTM E 96, Water Method 1.05 Perm, max.

140 The membrane system shall be supplied in roll widths of at least 12 in. The
membrane shall be a composite sheet material composed of a non-woven fabric and a
polymer membrane material. The membrane shall be protected by a release paper.

Material furnished under this specification shall be covered by a type B

certification in accordance with 916.

907.08 Clay Pipe

This pipe shall be in accordance with ASTM C 700 for the specified diameters
and strength classes for circular non-perforated pipe. When specified, the bell shall

968
 907.11

150 have integral spacer lugs to provide for an annular opening and self centering feature.
The pipe may be glazed or unglazed, unless otherwise specified.

907.09 Perforated Clay Pipe

This pipe shall be in accordance with ASTM C 700 for the specified dimensions
and strength classes. It may be glazed or unglazed, unless otherwise specified. Where
vitrified clay culvert pipe is furnished, a pipe end section compatible to that as required
for concrete or metal pipe shall be used.

907.10 Drain Tile

160 This pipe shall be in accordance with AASHTO M 178 for concrete or ASTM C
4 for clay for the specified material, diameters, and quality classes. Standard quality
drain tile shall not be used. When specified, the pipe spigot shall have integral spacer
lugs to provide for an annular opening and self centering feature. Material furnished
under this specification shall be covered by a type C certification in accordance with
916.

907.11 Pipe Joint Sealant

Material for sealing the joints of bell and spigot or tongue and groove concrete or
clay pipe or culverts furnished under this specification shall not contain asbestos
170 fibers, shall be covered by a type B certification in accordance with 916, and shall be
in accordance with one of the following:

(a) Preformed Flexible Joint Sealants

Joint sealants shall be either bitumen or butyl rubber in accordance with ASTM
C 990. The results of the following tests shall be shown on the type B certification.

Property Test Method

Hydrocarbon Blends ASTM D 4 (bitumen) or D 297 (butyl)
Ash-Inert Mineral Matter AASHTO T 111
Volatile Matter ASTM D 6
Specific Gravity @ 77°F ASTM D 71
Ductility @ 77°F AASHTO T 51 or ASTM D 113
Flash Point ASTM D 92
Fire Point ASTM D 92
Softening Point ASTM D 36
Compression Index @ 77°F and 32°F ASTM C 972
Cone Penetration @ 77°F and 32°F,
ASTM D 217
150 g, 5 s, mm/10
Chemical Resistance ASTM C 990

(b) Bituminous Mastic Sealant

A cold applied, mineral filled, bituminous joint sealing compound that can be
180 applied to the joints with a trowel when the air temperature is between 20° and 100°F.
The bituminous material shall adhere to the concrete or clay pipe so as to make a

969
 907.12

watertight seal and shall not flow, crack, or become brittle when exposed to the
atmosphere.

The mastic shall also be in accordance with the following. The results of the tests
shall be shown on the type B certification.

Property Minimum Maximum

Grease cone penetration unworked, 77°F,
125 275
150 g, 5 s, ASTM D 217, mm/10
Non-Volatile, 10 g, 220° - 230°F, 24 hr 75%
Loss on Heating, 325°F, 5 hr, 50 g 20%
Inorganic Content (complete burn, 1200° to 1400°F) 15% 45%
Flash Point, ASTM D 92 or D 1310 100°F
Fire Point, ASTM D 92 or D 1310 150°F
High Temperature Resistance to Flow No sag
Cold Temperature Flexibility No cracks

The test for high temperature resistance to flow shall be as follows: trowel joint
190 mastic approximately 1/2 in. thick on a porous concrete slab or piece of concrete block.
Place in oven at 140°F for 10 h.

The test for cold temperature flexibility shall be as follows: trowel joint mastic
approximately 1/4 in. on heavy kraft paper or very light gauge sheet metal. Condition
in a freezer at 10°F for 3 h. Bend the sample over a 1 in. diameter pin or mandrel.

907.12 Joint Mortar

Pipe joint mortar shall consist of 1 part portland cement and 2 parts sand with
water as necessary to obtain the required consistency. Mortar shall be used within 30
200 minutes after its preparation.

907.13 Rubber Type Gaskets

Ring gaskets for pipe shall be in accordance with ASTM C 1619, class C. Material
furnished under this specification shall be covered by a type B certification in
accordance with 916. The results of the following tests shall be provided on the type
B certification.

Property Test Method

Tensile Strength and Elongation ASTM D 412
Hardness ASTM D 2240
Oven-age tensile reduction, of original ASTM D 573 and D 412
Oven-age elongation reduction, of original ASTM D 573 and D 412
Compression Set ASTM D 395
Water Absorption ASTM D 471
Ozone resistance ASTM D 1149
Splice Strength Classification ASTM D 2527

970
 907.17

907.14 Blank
210
907.15 Blank

907.16 Thermoplastic Pipe Requirements

A list of approved thermoplastic pipe and liner pipe will be maintained by the
Department. The list will specify the manufacturer and thermoplastic pipe designation.
All of these materials shall comply with the applicable AASHTO or ASTM
requirements listed in the following table and will only be accepted from qualified
manufacturers. The manufacturer is defined as the plant which produces the
thermoplastic pipe. The manufacturer shall become qualified by establishing a history
220 of satisfactory quality control of these materials as evidenced by the test results
performed by the manufacturer’s testing laboratory.

Summary of Thermoplastic Pipe Specification Requirements

Standard Manufacturer
Pipe Material AASHTO ASTM
Specifications Requirements
Corrugated
ITM 806,
Polyethylene 907.17(a) M 252
Procedure O
Drainage Tubing
Corrugated ITM 806,
907.17(b) M 294*
Polyethylene Pipe Procedure O
Corrugated ITM 806,
907.19 M 330
Polypropylene Pipe Procedure O
Perforated PVC ITM 806,
907.18 D 3034
Semicircular Pipe Procedure A
Profile Wall PVC ITM 806,
907.22 M 304
Pipe Procedure O
Profile Wall ITM 806,
907.20 F 894
Polyethylene Pipe Procedure A
Schedule 40 PVC D 1785 or 916,
907.24(b)
Pipe D 2665 Type C Cert.
Smooth Wall ITM 806,
907.21 F 714
Polyethylene Pipe Procedure A
Smooth Wall PVC ITM 806,
907.23 M 278 F 679
Pipe Procedure A
Type PSM PVC Pipe ITM 806,
907.24(a) D 3034
and Fittings Procedure A
* Pipe in accordance with AASHTO M 294 shall be manufactured
with virgin materials.

907.17 Corrugated Polyethylene Drainage Tubing and Pipe

(a) Corrugated Polyethylene Tubing

Tubing and fittings shall be in accordance with AASHTO M 252. Perforations
shall be required for tubing used as a longitudinal underdrain. Qualification

971
 907.18

requirements for the manufacturers shall be in accordance with ITM 806, Procedure
230 O.

(b) Corrugated Polyethylene Pipe

Pipe and fittings shall be in accordance with AASHTO M 294. Pipe shall be
manufactured with virgin materials, and be marked with the code "V". Pipe shall not
be manufactured with recycled materials. Qualification requirements for the
manufacturers shall be in accordance with ITM 806, Procedure O.

907.18 Perforated PVC Semicircular Pipe

Perforated PVC semicircular pipe may be used as an alternate to 6 in. or less
240 diameter pipe or tile. Pipe shall be in accordance with ASTM D 3034, SDR 35. This
semicircular pipe shall have a smooth top and a smooth, semicircular bottom,
nominally 4 5/8 in. in diameter, with perforations uniformly distributed along the top
of the bottom section in accordance with AASHTO M 252 perforation requirements.
The top section shall extend a minimum of 1/2 in. beyond the top of the semicircular
section. The top section shall be approximately 6 3/8 in. wide including the sloping
overhangs on each side. Qualification requirements for the manufacturers shall be in
accordance with ITM 806, Procedure A.

907.19 Corrugated Polypropylene Pipe

250 Pipe and fittings shall be in accordance with AASHTO M 330. Qualification
requirements for the manufacturers shall be in accordance with ITM 806, Procedure
O.

907.20 Profile Wall Polyethylene Pipe

Pipe and fittings shall be either closed profile or ribbed open profile in accordance
with ASTM F 894. Qualification requirements for the manufacturers shall be in
accordance with ITM 806, Procedure A.

907.21 Smooth Wall Polyethylene Pipe

260 Pipe shall be in accordance with ASTM F 714 for nominal diameters of 39 in. or
less. Fittings shall be in accordance with ASTM F 1055. The pipe sizes shall be in
accordance with ISO sizing system. The pipe dimension ratio shall be 26 or less. The
resin used in manufacturing this type of pipe shall have a minimum cell classification
of 335434C in accordance with ASTM D 3350 or a minimum grade of PE4710 in
accordance with ASTM F 714. Qualification requirements for the manufacturers shall
be in accordance with ITM 806, Procedure A.

907.22 Profile Wall PVC Pipe

Pipe and fittings shall be in accordance with AASHTO M 304. Perforations shall
270 be required when used as a longitudinal underdrain or end bent drain pipe.
Qualification requirements for the manufacturers shall be in accordance with ITM 806,
Procedure O.

972
 907.25

907.23 Smooth Wall PVC Pipe

Pipe and fittings shall be in accordance with AASHTO M 278 for pipe sizes 4 in.
through 15 in., and ASTM F 679 for pipe sizes 18 in. through 27 in. Qualification
requirements for the manufacturers shall be in accordance with ITM 806, Procedure
A.

280 907.24 Smooth Wall Pipe for Outlets

Pipe and pipe fittings shall be smooth wall, non-perforated plastic pipe.
Qualification requirements for the manufacturers shall be in accordance with ITM 806,
Procedure A.

(a) Type PSM PVC Pipe and Fittings

Pipe and fittings shall be in accordance with ASTM D 3034, SDR 23.5.

(b) Schedule 40 PVC Pipe

Pipe shall be in accordance with ASTM D 1785 or D 2665 and shall have a
290 minimum pipe stiffness of 150 psi at 5% deflection when determined in accordance
with ASTM D 2412. Material furnished under this specification shall be covered by a
type C certification in accordance with 916 and shall reference ASTM D 1785 or
ASTM D 2665 in the product print line.

907.25 Thermoplastic Liner Pipe

Thermoplastic liner pipe shall be HDPE or PVC pipe with sufficient rigidity to
withstand the installation operation and shall exhibit a minimum amount of distortion.
The liner pipe shall be free from visible cracks, holes, foreign inclusions, or other
defects. A certification addressing all of the required information for HDPE liner pipe
300 shall be prepared by the manufacturer, when required. A sample certification is
included in ITM 804.

(a) Solid Wall HDPE Liner Pipe

Solid wall HDPE liner pipe shall be in accordance with ASTM F 714. The
maximum standard dimension ratio, SDR, as defined in ASTM F 412 for the liner pipe
shall be 32.5. The actual calculated minimum dimension ratio, DR, as defined in
ASTM F 412 for the liner pipe shall be 30.0. The resin used in the manufacture of the
liner pipe shall have a minimum cell classification of 345464C in accordance with
ASTM D 3350 or a minimum grade of PE4710 in accordance with ASTM F 714. A
310 12 in. section of the liner pipe shall show no evidence of splitting, cracking, or
breaking when compressed between parallel plates to 40% of its outside diameter
within 2 to 5 minutes. Thermoplastic liner pipe may be added to the Department’s
approved list by completing the requirements of ITM 806, Procedure Q.

(b) Profile Wall HDPE Liner Pipe

Profile wall HDPE liner pipe shall be in accordance with ASTM F 894. The
minimum liner ring stiffness constant, RSC, shall be 160 for circular installations and
250 for deformed installations. Thermoplastic liner pipe may be added to the
Department’s approved list by completing the requirements of ITM 806, Procedure A.

973
 907.26

320
(c) Profile Wall PVC Liner Pipe
Profile wall PVC liner pipe shall be in accordance with ASTM F 949.
Thermoplastic liner pipe may be added to the Department’s approved list by
completing the requirements of ITM 806, Procedure A.

907.26 Solvent Cements for PVC Pipe and Pipe Fittings

Solvent cement for PVC pipe and fittings shall be in accordance with ASTM D
2564. Material furnished under this specification shall be covered by a type C
certification in accordance with 916.
330
907.27 Elastomeric Seals
Elastomeric seals for joining plastic pipe shall be in accordance with ASTM F
477. Material furnished under this specification shall be covered by a type B
certification in accordance with 916. The results of the following tests shall be
provided on the type B certification.

Test ASTM
Tensile Strength D 412 or D 1414
Ultimate Elongation D 412 or D 1414
100% Modulus D 412 or D 1414
Hardness (Durometer) D 2240 or D 1414
Low-Temperature Hardness D 2240 or D 1414
Compression Set D 395 Method B, or D 1414
Accelerated Aging D 573
Water Immersion D 471
Ozone Resistance D 1149
Elastomer Compound Effect on Pipe F 477
Force Decay (Stress Relaxation) F 913

907.28 Reinforced Thermosetting Resin Pipe and Pipe Fittings

Reinforced thermosetting resin pipe and accompanying fittings shall be in
340 accordance with ASTM D 2996 for the specified sizes. The short-term rupture strength
hoop tensile stress shall be a minimum of 30,000 psi. All pipes shall be pigmented
resin throughout the wall thickness. The color of the pipe shall match color No. 26400
of SAE-AMS-STD-595. Painting, gel-coating, or exterior coating of the pipe to obtain
the specified color shall not be done. Pipe shall be tested in accordance with ASTM G
154 for 2,500 h of accelerated weathering following cycle 2 as defined in Appendix
X2. After testing, the surface of the pipe shall show no fiber exposure, crazing, or
checking, and may have only a slight chalking or color change. An adhesive
recommended by the manufacturer shall be used for joining pipe and fittings. Material
furnished shall be covered by a type A certification in accordance with 916. The results
350 of the following tests shall be provided on the type A certification.

974
 908.02

Test ASTM
Wall Thickness and Diameter D 3567
Short-Term Hydrostatic Failure Strength D 1599
Stiffness Factor (for direct-bury only) D 2412, based on 5% deflection

A lot will be defined as the production quantity in a given calendar month for each
pipe diameter, not to exceed 10,000 lft. The accelerated weathering test shall be
performed once for each pipe material formulation that is provided. A new accelerated
weathering test will be required if the pipe material formulation changes. Test results
shall be provided to the Engineer at the time of delivery and shall be from tests
performed on the formulation representative of the pipe delivered.

SECTION 908 – METAL PIPE

908.01 Blank

908.02 Corrugated Steel Pipe and Pipe-Arches

Corrugated steel pipe and pipe-arches shall be type I, IA, IR, II, or IIA in
accordance with AASHTO M 36.

Corrugated steel pipe, pipe-arches, and coupling bands shall be zinc coated steel
10 or aluminum coated steel in accordance with AASHTO M 36, except as noted herein.
They may be fabricated with circumferential corrugations and riveted lap joint
construction or with helical corrugations or spiral ribs with continuous lock or welded
seam extending from end to end of each length of pipe. Reforming the ends of helical
corrugated pipe to form circumferential corrugations will be allowed to enable use of
circumferential corrugated coupling bands. The reforming shall be limited to the
length required to accommodate the coupling bands and in such a manner that there is
not appreciable slippage of the seam or a plane of weakness created.

Polymer precoated galvanized corrugated steel pipe type IA and pipe-arch type
20 IIA have an outer shell of corrugated sheet with helical corrugations and an inner liner
of smooth sheet attached to the shell with a helical lock seam.

Fittings, including stub-tee connections and saddle connectors specified in

715.06, shall be shop fabricated. Damage to the coating on fittings shall be repaired in
accordance with AASHTO M 36.

If the pipe or pipe-arch invert is to be paved, it shall first be coated over half its
circumference in accordance with 908.07. The paved invert shall then be constructed
in accordance with 908.07.
30
Sheet metal used to fabricate pipe shall be the same brand from the same
manufacturer in any one length of finished pipe.

975
 908.03

The manufacturer shall furnish to the fabricator a certified mill report for materials
shipped to the fabricator. This certified mill report shall list the kind of base metal,
actual test results of the chemical analysis and mechanical tests of each heat, the
thickness, the weight of coating, and shall certify that the material complies with
specified requirements for the type of metal furnished.

40 The fabricator shall certify, on furnished forms that:

(a) the fabricated structure has been manufactured in accordance

with these Standard Specifications;

(b) based on the sheet manufacturer’s certified mill report, the

materials used in fabricating the structure were tested and the
test results are in accordance with the specified requirements;
and

50 (c) copies of the sheet manufacturer’s certified mill report shall be

on file and available to review for five years.

908.03 Blank

908.04 Corrugated Aluminum Alloy Pipe and Pipe-Arches

Pipes, pipe-arches, and coupling bands shall be in accordance with AASHTO
M 196. The pipe shall be type I, IA, II, or IIA. If the pipe invert is to be paved, it shall
be in accordance with 908.07.

60 The sheet manufacturer’s certified mill report and the fabricator’s certification
shall be in accordance with the applicable requirements of 908.02.

Where aluminum alloy pipe culvert is furnished, aluminum alloy end sections
shall also be furnished. All component parts shall be aluminum alloy.

908.05 Blank

908.06 Metal End Sections

The end section’s metal shall be in accordance with AASHTO M 36 or M 196,
70 whichever is applicable. The sheet metal manufacturer’s certified mill report and the
fabricator’s certification shall be in accordance with the applicable requirements of
908.02.

End sections consisting of multiple panels shall have lap seams which shall be
tightly jointed with 3/8 in. galvanized rivets or bolts.

All steel pipe end sections shall have a toe plate anchor constructed of 0.138 in.
thick galvanized steel. The toe plate anchor shall be match punched to fit holes in the
skirt lip, and shall be supplied loose, and complete with 3/8 in. diameter galvanized
80 bolts.
976
 908.07

Straps for pipe end sections shall be either galvanized No. 6 reinforcing bars or
zinc coated 3/8 in. diameter aircraft cable.

908.07 Fully Bituminous Coated Corrugated and Lined Steel Pipe and
Pipe-Arches
The material, fabrication, the manufacturer’s certified mill report, and fabricator’s
certification shall be in accordance with the applicable requirements of 908.02.
Coupling bands shall be fully bituminous coated.
90
After fabrication, the pipe or pipe-arch shall be fully bituminous coated.

Connecting or coupling bands shall be of the two-piece type when used with
coated pipe of 36 in. diameter or larger.

The asphalt material for coating shall be in accordance with 902.01(e). Samples
of the asphalt material will be obtained from the working tank prior to or during
coating of the pipe, or from strippings off the pipe after coating. When applied to the
pipe, the asphalt material shall be free from impurities. The metal shall be free from
100 grease, dust, or moisture. Either process set out below may be used for application.

(a) When the pipe is not preheated, the temperature of the asphalt
at the time of immersion shall be 400°F ±5°F. The duration of
the immersion in the asphalt shall be in accordance with the
following:

Thickness, inches 0.052 0.064 0.079 0.109 0.138 0.168

Minimum Immersion Time
2.0 2.5 3.0 5.0 6.5 8.0
for 1st Dip, minutes

(b) When the pipe is preheated it shall be brought to a temperature

of 300°F and the asphalt shall be heated to a temperature of
110 380°F ±5°F before the pipe is dipped.

In either process, the pipe shall be dipped a second time or more if necessary, to
give a minimum thickness of 0.05 in.

If paved invert is specified, the pipe or pipe-arch shall first be fully coated as
required. Additional bituminous material shall be applied in the bottom section to form
a smooth pavement. Except where the upper edges intersect the corrugations, the
pavement shall have a minimum thickness of 1/8 in. above the crests of the
corrugations. The pavement shall be applied to the lower quarter of the circumference.
120
The manufacturer of the asphalt material shall furnish to the pipe fabricator the
type of certification specified in the Frequency Manual and in accordance with 916 for
each shipment or lot of asphalt material. The pipe fabricator shall keep these

977
 908.08

certifications on file and available to review for five years. In addition, samples from
the working tank will be obtained for verification of requirements.

908.08 Polymer Precoated Galvanized Corrugated Steel Culvert Pipe and

Pipe-Arches
The pipe or pipe-arch and coupling bands shall be in accordance with AASHTO
130 M 245 with additions in accordance with 908.02. The polymer precoated galvanized
steel sheets shall be in accordance with AASHTO M 246, grade 10/10.

908.09 Structural Plate Pipe, Pipe-Arches, and Arches

(a) Steel
Steel structural plate pipe, pipe-arches, and arches shall be constructed from
individually galvanized corrugated steel plates as described herein. For pipes and
pipe-arches having a thickness less than 0.280 in., the bottom plates shall be of the
next greater thickness than that specified for the top and side plates, not including
140 corner plates for pipe-arches. The individual plates shall be in accordance with
AASHTO M 167 and AASHTO LRFD Bridge Construction Specifications.

The materials and fabrication shall be as follows:

1. The minimum corner plate radius of the arc joining the top
and bottom plates of pipe-arches shall be 18 in. for
openings up to and including 131 sq ft and 31 in. for
openings over 131 sq ft. The minimum radius of the arc
shall be 31 in. for openings from 98 sq ft up to and
150 including 214 sq ft.

2. Assembly bolts shall be in accordance with ASTM F 3125,

grade A 325, or ASTM A 449. Nuts shall be in accordance
with ASTM A 563, grade C or ASTM F 3125, grade A 325.
Assembly bolts, nuts, and washers shall be galvanized in
accordance with ASTM A 153, or be mechanically
galvanized and conform to the coating thickness,
adherence, and quality requirements of ASTM A 153, class
C.
160
3. The sheet manufacturer’s certified mill report and the
fabricator’s certification shall be furnished in accordance
with 908.02, except the documents shall be in accordance
with the applicable requirements of AASHTO M 167.

(b) Aluminum Alloy

Aluminum alloy structural plate pipe, pipe-arches, and arches shall be in
accordance with AASHTO M 219. The sheet manufacturer’s certified mill report and
the fabricator’s certification shall be furnished in accordance with 908.02.

978
 908.14

170
908.10 Cast Iron Soil Pipe
This pipe shall be in accordance with ASTM A 74. Markings shall be in
accordance with ASTM A 74 or ANSI A 40.1.

908.11 Steel Pipe

This item shall be electric-fusion, arc-welded steel pipe in accordance with ASTM
A 139, grade B, or electric-resistance welded pipe in accordance with ASTM A 53,
type E, grade B, as applicable. Material furnished under this specification shall be
covered by a type C certification in accordance with 916.
180
908.12 Straps, Hook Bolts and Nuts Used in Anchors
Straps shall be of the type and size shown on the plans. Reinforcing bars used for
straps shall meet the applicable requirements of 910.01 and shall be galvanized in
accordance with ASTM A 767, class I. Aircraft cable used for straps shall be made of
zinc coated steel wire, 3/8 in. nominal diameter, consisting of seven 19-wire flexible
steel strands, with a minimum breaking strength of 14,000 lb. The cable shall be in
accordance with Military Specification MIL-W-83420D.

Hook bolts and nuts shall be of the size shown on the plans, shall be in accordance
190 with ASTM A 307, and shall be galvanized in accordance with ASTM A 153. Threads
shall be American Standard Coarse Thread Series Class 2 fit. Threads shall be cleaned
after galvanizing to provide a free running fit. Maximum oversizing of the nut threads
shall be 1/64 in.

908.13 Blank

908.14 Slotted Drain or Slotted Vane Drain Pipe

Slotted drains shall be manufactured from helically corrugated steel pipe in
accordance with AASHTO M 36. At the end of the pipe there shall be two annular
200 corrugations to allow the corrugated band to fully mesh with the pipe.

The grated assembly shall be made of structural steel in accordance with ASTM
A 36, Grade 36. The assembly shall be suitably welded to the pipe and galvanized after
assembly in accordance with AASHTO M 111. The grate shall be of the size and
spacing shown on the plans and shall be welded on both sides to each bearing bar with
a 3/16 in. fillet weld.

The size and thickness of the corrugated steel slotted drain pipe shall be as shown
on the plans.
210
Slotted vane drain pipe shall be smooth wall PVC in accordance with 907.23, and
shall be of the diameter specified. The casting shall be in accordance with 910.05(b).
The finish shall be standard black asphalt emulsion. Individual units shall have a
minimum weight of 155 lb.

979
 909.01

SECTION 909 – PAINT AND LIQUID EPOXY

909.01 General Requirements

All necessary facilities for inspection of materials and manufacture of coatings,
paints, and ingredients shall be granted. Free access to all parts of the premises where
any or all of these products are being prepared shall be allowed. Material Safety Data
Sheets shall be provided.

Paints and coatings shall be furnished ready for use without modification and shall
10 not settle, cake, curdle, liver, gel, or develop excessive change in viscosity between
time of manufacture and time of use. It shall remain capable of being readily dispersed
with a paddle, or other approved methods, to a consistency appropriate for the intended
use. Paints and coatings may be sampled and tested at any time prior to use. If, for any
reason, re-sampling and re-testing following initial or prior approval is indicated, the
latest test results shall prevail over all previous tests for material that has not been
used. Previously approved paint or coating that are stored for future use may be re-
sampled and re-tested.

Paints and coatings shall be delivered in new containers of such strength,

20 durability, design, fabrication, and material that the paint shall be suitably protected in
transit and in storage against any change in characteristics which would cause rejection
on the basis of laboratory or field evaluation. Each container shall bear a label which
shows the name and address of the manufacturer, kind of paint or coating, formula
identification, date of manufacture, and lot or batch number. The container shall be so
filled that the net weight of the material in the container shall be the product of the
weight per gallon at 77°F and the stated number of gallons in the container.

All containers shall be labeled in accordance with the OSHA requirements for
labeling of hazardous chemicals as described in the Hazardous Communications
30 Standard.

909.02 For Metal

Paints for metal surfaces shall be in accordance with the requirements shown
below.

(a) Zinc Primers

Both inorganic zinc primer and organic zinc primer for use on faying surfaces at
all slip-critical structural bolted connections using ASTM F 3125, grade A 325 or
grade A 490, high-strength bolts in primary members shall meet class B slip coefficient
40 in accordance with Test Method to Determine the Slip Coefficient for Coatings Used
in Bolted Joints as adopted by the Research Council on Structural Connections.

1. Multi-Component Inorganic Zinc Silicate Primer

Inorganic zinc primers shall be multi-component and of the self-cure type which,
when mixed and applied in accordance with these specifications, shall cure without
the use of a separate curing solution. Multi-component inorganic zinc silicate primers

980
 909.02

shall have a maximum of three components. The components of each primer shall be
packaged in such proportions that when the full quantity of each component is mixed
together, the specified mixed primer shall be yielded.
50
Inorganic zinc primers shall be in accordance with AASHTO M 300.

2. Organic Zinc Primer

Organic zinc primer shall be a self-curing type primer. It shall be in accordance
with SSPC Paint Specification No. 20, Type II. The organic zinc primer shall be
compatible with inorganic zinc and finish coat paints already on the bridge. The color
shall be able to produce a distinct contrast with blast cleaned metal surface and the
finish coat. The cured organic zinc film shall be compatible with a top coating of
waterborne finish coat paint.
60
The organic zinc primer shall also be in accordance with the following
requirements.

Viscosity, ASTM D 562, Krebs Units ............................................. 70 - 100

Viscosity variation from the initially approved
formulation, ASTM D 562, Krebs Units, max. ........................ ±10
Volatile organic compounds, ASTM D 3960, max. ........................ 419 g/L
Weight/volume, ASTM D 1475, 25°C, min. ................................... 2.040 kg/L
Weight/volume variation from the initially approved
70 formulation, ASTM D 1475, 25°C, max. ................................. ±0.048 kg/L
Dry time, ASTM D 1640, 6 mils wet film thickness
on a tin-coated steel panel, max.:
Set-to-touch ................................................................. 1 h
Dry hard ...................................................................... 24 h
Total solids of sample, ASTM D 2369 ............................................ 70 – 100%
Total solids variation from the initially approved
formulation, ASTM D 2369, %, max. ...................................... ±2.0
Pigment by mass of total solids, SM 9030, min. ............................. 83 %
Metallic zinc in zinc dust, ASTM D 521, min. ................................ 94 %
80 Metallic zinc by mass of pigment, ASTM D 521, min. ................... 84 %
Metallic zinc by mass of total solids, ASTM D 521, min. ............... 72 %

The infrared spectrum of the vehicle when extracted from the organic zinc primer,
in accordance with ASTM D 3168, shall match the infrared spectrum of the vehicle of
the sample submitted for formulation approval.

The cured film shall not contain any toxic heavy metals above the limits of the
regulatory levels of 40 CFR 261.24, Table 1. The cured paint shall not contain any
other material which will require characterization as a hazardous waste for the disposal
90 of the dried film.

981
 909.02

3. Approval of Formulation
The manufacturer shall obtain approval of the formulation prior to furnishing the
primers. Only zinc primers from the Department’s list of approved Coating
Formulations shall be used. Zinc primers will be placed and maintained on the
Department’s list of approved Coating Formulations in accordance with ITM 606.

(b) Epoxy Intermediate Paint

Epoxy intermediate paint shall be a two-component coating consisting of an
100 epoxy resin and a curing agent, together with prime and filler pigments, colorants,
gellant, leveling agents and solvents. When mixed, this coating shall be suitable for
application over inorganic and organic zinc primers and shall be compatible with a
polyurethane finish coat. The color of this coating shall contrast significantly from the
other coatings within the coating system.

The mixed paint shall be in accordance with the following requirements.

Volatile organic compounds, ASTM D 3960, max. ........................ 336 g/L

Volume solids, ASTM D 2697, min. ............................................... 60%
110 Set-to-touch, ASTM D 1640, 6 mils wet film thickness, max. ........ 4 h
Weight/volume variation from the initially approved
formulation, ASTM D 1475, 25°C, max. ................................. 0.060 kg/L
Total solids variation from the initially approved
formulation, ASTM D 2369, max. ........................................... 3.0%

The coating shall be applied within the pot life recommended by the paint
manufacturer with no evidence of gelation. The coating shall be in a free-flowing
condition and easily sprayed.

120 The infrared spectrum of each component and of the mixed coating shall match
the spectrums of the initially approved batch.

(c) Polyurethane Finish Coat

Polyurethane finish coat shall be a two-component polyester or acrylic aliphatic
polyurethane suitable for use as a finish coat over epoxy intermediate paint.

The mixed paint shall be in accordance with the following requirements.

Volatile organic compounds, ASTM D 3960, max. ........................ 336 g/L

130 Volume solids, ASTM D 2697, min. ............................................... 60%
Set-to-touch, ASTM D 1640, 5 mils wet film thickness, min. ......... 30 minutes
Total solids ASTM D 2369, min. .................................................... 70%
Specular gloss, 60°, ASTM D 523, min. ......................................... 75
Viscosity, ASTM D 562, Krebs Units, max. ................................... 100
Contrast ratio, ASTM D 2805, 5 ±0.5 mils wet film thickness,
dried 24 h on Leneta Form 2A or 2C, min. .............................. 0.95
Dry hard, ASTM D 1640, 5 mils wet film thickness, max. ............. 24 h

982
 909.02

The infrared spectrum of each component and of the mixed coating shall match
140 the spectrum of the initially approved batch.

The color of the dried paint film shall match the color number of SAE-AMS-STD-
595 as follows:

Color Number Color

13538 Yellow
13711 Buff
14260 Green
15450 Light Blue
17038 Black
17886 White

(d) Waterborne Finish Paint

The waterborne finish coating shall be a single package, high build acrylic
emulsion for use as a finish coat over inorganic and organic zinc primers. It shall be
compatible with and adhere to the cured zinc primers.
150
1. Vehicle Component
The vehicle shall consist of an acrylic emulsion together with the necessary
antifoamers, cosolvents, coalescing agent, preservatives, and antifreeze in order to
produce a coating in accordance with this specification.

2. Pigment Component
The active pigment shall consist of titanium dioxide in accordance with ASTM
D 476, type IV, and non-reactive color retentive tinting pigments. The pigment shall
contain extenders and additives as required for proper application.
160
3. Mixed Paint Properties
The mixed paint shall be in accordance with the following requirements.

Viscosity, ASTM D 562, Krebs Units ............................................. 80 – 110

Weight/volume, ASTM D 1475, variation from
the initially approved formulation, 25°C, max. ........................ 0.024 kg/L
Pigment grind, ASTM D 1210, Hegman, min. ................................ 5
Total solids, % by weight, ASTM D 2369, min. ............................. 48
Vehicle solids, % by weight of vehicle, min. .................................. 37.5
170 Dry time, ASTM D 1640, 3 mils wet film thickness
on a tin coated steel panel, max.:
Set-to-touch ....................................................................... 1 h
Dry hard .............................................................................. 24 h
Contrast ratio, ASTM D 2805, 5 ±0.5 mils wet film thickness
dried 24 h on Leneta Form 2A or 2C, min. .............................. 0.97

983
 909.02

Specular gloss, 60°, 10 mils ±0.5 mils wet film thickness

on a tin coated steel panel, dried 48 h, ASTM D 523, max. ..... 30
pH, ASTM E 70 ................................................................................ 7.0 – 9.5
Volatile organic compounds, ASTM D 3960, max. ........................ 180 g/L
180
The infrared spectrum of the vehicle when extracted from the mixed paint in
accordance with ASTM D 3168 shall match the infrared spectrum of the sample
submitted for formulation approval.

The mixed paint shall be in accordance with the requirements of Sections 5.4
through 5.17 of SSPC Paint Specification No. 24.

The cured waterborne finish paint shall not contain any toxic heavy metals above
the limits of the regulatory levels of 40 CFR 261.24, Table 1. The cured paint shall not
190 contain any other material which will require characterization as a hazardous waste
for the disposal of the dried film.

4. Color
The color of the dried paint film shall match the color number of SAE-AMS-STD-
595 as follows:

Color Number Color

23538 Yellow
23717 Buff
24227 Green
24466 Light Green
25526 Light Blue
27038 Black
27780 White

5. Approval of Formulation
The manufacturer shall obtain approval of the formulation prior to furnishing the
200 waterborne finish paint. Only waterborne finish paint from the Department’s list of
approved Coating Formulations shall be used. Waterborne finish paint formulations
will be placed and maintained on the list of approved Coating Formulations in
accordance with ITM 606.

(e) Finish Coat for Weathering Steel

The finish coat shall be an aliphatic polyurethane or a waterborne acrylic paint,
and the dried paint film shall match color number 20045 of SAE-AMS-STD-595. It
shall be suitable for use as a finish coat over epoxy intermediate paint. The mixed paint
shall be in accordance with the following requirements.
210
For aliphatic polyurethane paint:

Weight/volume, ASTM D 1475, 25°C, min. ................................... 1.200 kg/L

984
 909.04

Total solids, % by weight, ASTM D 2369, min. ............................. 60

Volatile Organic Compounds, ASTM D 3960, max. ....................... 336 g/L
Specular gloss, 60°, ASTM D 523, max. ......................................... 25

For waterborne acrylic paint:

220 Weight/volume, ASTM D 1475, 25°C, min. ................................... 1.200 kg/L

Total solids, % by weight, ASTM D 2369, min. ............................. 48
Volatile Organic Compounds, ASTM D 3960, max. ....................... 180 g/L
Specular gloss, 60°, ASTM D 523, max. ......................................... 25

909.03 Structural Steel Coating System

This coating system shall consist of an inorganic zinc primer, an epoxy
intermediate paint, and a polyurethane finish coat for the painting of steel bridges and
other structural steel. All of the coatings within any coating system shall be
manufactured by the same manufacturer and shall be compatible with one another. All
230 coatings shall be in accordance with 909.02.

(a) Toxicity
The cured film of each coating within the structural steel coating system shall not
contain any toxic heavy metals above the limits of the regulatory levels of 40 CFR
261.24, Table 1 or contain any other material which will require characterization as a
hazardous waste for the disposal of the dried film.

(b) Resistance
The coating system shall be tested in accordance with the requirements of
240 NEPCOAT, Specification Criteria For Protective Coatings, dated June 6, 1996. The
coating system shall be in accordance with all of the acceptance criteria and shall
maintain a specular gloss retention of 60% relative of the initial gloss and a maximum
color change of 15 ΔE for Test No. 3, Weathering Resistance.

(c) Approval of Structural Steel Coating System

The manufacturer shall obtain approval of each structural steel coating system
prior to furnishing any of these coatings. Only structural steel coating systems from
the Department’s list of approved Structural Steel Coating Systems shall be used.
Structural steel coating systems will be placed and maintained on the Department’s
250 list of approved Structural Steel Coating Systems in accordance with ITM 606.

909.04 Field Paint for Wood or Metal

The primers for field paint shall be formulated for minimal surface preparation,
provide adhesion to the substrate and be compatible with the finish coat. The primers
shall not contain lead, chromium, or other heavy metals which would require
classification as a hazardous waste upon removal. The primers shall comply with the
current IDEM VOC regulations and shall be used as follows:

985
 909.05

a. For unpainted galvanized steel and other ferrous

260 metals, use one coat of a zinc dust-zinc oxide
pigmented primer.

b. For non-ferrous metals, use one coat of primer

formulated for use on non-ferrous metals.

The field paint finish coat shall be an exterior type coating. It shall be chalk
resistant, gloss retentive, and suitable for application by brush, roller, or spray. This
coating shall comply with the current IDEM VOC regulations and shall not contain
lead, chromium, or other heavy metals which would require classification as a
270 hazardous waste upon removal. The color of this coating shall be as specified.

909.05 White and Yellow Waterborne Traffic Paint

White and yellow waterborne traffic paints shall consist of an emulsion of
pigmented binder.

When glass beads are induced into the paint lines, the paint shall provide capillary
action in the interstices and voids between the glass beads sufficient to cause the level
of paint to raise approximately 2/3 the diameter of the glass beads. This capillary action
shall not cause complete envelopment of the glass beads. The paint as furnished shall
280 not contain glass beads. The paint shall be ground to a uniform consistency, and it
shall enable satisfactory application by the pressure-spray type of painting equipment.
The painting equipment shall use a pressurized bead application method that is
designed to apply 4 to 6 in. reflectorized paint lines at paint temperature up to 150°F.
The paint shall be capable of being applied at speeds of 10 to 15 mph.

The paint shall not darken under the heating conditions of application, or show
appreciable discoloration due to sunlight exposure and aging of the paint lines. The
paint shall be furnished ready for use without thinning, screening, or other
modifications and shall not settle, cake, curdle, liver, gel, or have an excessive change
290 in viscosity in the container during a period of one year after manufacture. The paint
shall be capable of being stirred to a uniform consistency. The paint shall be able to
withstand variations of temperatures when stored outside in the containers as
delivered, and in an environment above 40°F. All paint furnished under these
specifications will be rejected if it contains skins, thickened or jelly-like layers, lumps,
coarse particles, dirt, or other foreign materials which prevent the proper application
of the paint, or produces a non-uniform paint line. All paint which cannot be
transferred by pumps on the paint equipment from the shipping containers and through
the paint equipment due to excessive clogging of screens, filters, or paint guns will be
rejected.
300
The paint shall dry to a no-tracking condition in less than 60 s. The no tracking
condition shall be determined by actual application of the paint on the pavement at a
wet film thickness of 15 mils with glass beads at a rate of 6 lb/gal. The paint lines for
the determination of no-tracking condition shall be applied with the specialized

986
 909.05

painting equipment operated so as to have the paint at application temperatures up to

140°F at the spray guns. This maximum no tracking time shall not be exceeded when
the pavement temperature varies from 50 to 120°F, and with all relative humidity
conditions providing that the pavement is dry. The no tracking time shall be
determined by passing over the paint line 60 s after the paint application, in a simulated
310 passing maneuver at a constant speed of 30 to 40 mph with a passenger car. A paint
line with no visual deposition of the paint to the pavement surface when viewed from
a distance of approximately 50 ft from the point where the vehicle crossed the paint
line shall be considered as showing a condition of no tracking and being in accordance
with the requirement.

1. Composition Requirements
The exact composition of the waterborne traffic paint shall be left to the discretion
of the manufacturer, provided that the finished product is in accordance with all of the
specification requirements.
320
The pigment portion of these paints shall be a combination of prime and extender
pigments as required to produce either white or yellow waterborne traffic paint in
accordance with the color and other requirements of the finished product. The yellow
waterborne traffic paint pigment shall contain pigment yellow Color Index No. 65, or
74, or 75 or a combination of each. The white waterborne traffic paint pigment shall
contain titanium dioxide in accordance with ASTM D 476. The non-volatile portion
of the vehicle shall be composed of a 100% acrylic polymer.

The cured film of waterborne traffic paint shall not contain any toxic heavy metals
330 above the limits of the regulatory levels of 40 CFR 261.24, Table 1 or contain any
other material which will require characterization as a hazardous waste for the disposal
of the dried film.

2. Specific Requirements
Min. Max.
Volume solids, ASTM D 2697, % 58.0 --
Total solids by mass, ASTM D 3723, % 73.0 --
Pigment by mass, ASTM D 3723, % 45.0 57.0
Vehicle solids by mass of the vehicle, % 44.0 --
Viscosity, ASTM D 562, Krebs Units 75 95
Weight/volume, ASTM D 1475, 25°C, kg/L 1.498 --
Weight/volume @ 25°C, variation from the manufacturer’s
-- 0.024
initially approved batch, ASTM D 1475, kg/L.
Dry time, ASTM D 711, 15 mils wet film thickness, airflow 10
--
of less than 50 cu ft/min, without glass beads min
Reflectance Factor, Y, C.I.E. illuminant, C, 2° standard
observer, ASTM E 1349, 15 mils wet film thickness, air dried
a minimum of 16 h, %
White .......................................................... 84 --
Yellow ........................................................ 50 57

987
 909.06

Color, yellow only, x - y C.I.E. Coordinates for the strong

limits of FHWA color chart PR1, 15 mils wet film thickness, Match the
±6.00
air dried a minimum of 16 h, measured on white background, strong limits
C.I.E. illuminant, C, 2° standard observer, % deviation
Coarse material retained on a No. 30 sieve, ASTM D 185, % -- 0.05
Bleeding ratio, Federal Specifications TT-P-1952B, except
asphalt saturated felt paper shall be in accordance with 0.97 --
ASTM D 226, Type I
Contrast ratio, ASTM D 2805, 10 mils wet film thickness on
0.96 --
Leneta Form 2A or 2C, air dried a minimum of 16 h
Volatile organic compounds, ASTM D 3960, g/L -- 150
Abrasion resistance, Federal Specifications TT-P-1952B, L 190 --
Freeze-thaw stability, Federal Specifications TT-P-1952B,
-- 10
change in consistency, Krebs Units
Heat stability, Federal Specifications TT-P-1952B, change in
-- 10
consistency, Krebs Units
Scrub resistance, ASTM D 2486, with abrasive medium and
300 --
shims, cycles
Film shall not soften,
Water resistance, Federal Specification TT-P-1952B blister, wrinkle, or
lose adhesion
No cracking or
Flexibility, Federal Specifications TT-P-1952B
flaking of film
Shall match
spectrum of
Infrared spectrum of the vehicle ASTM D 3168 manufacturer’s
previously submitted
samples

Dilution test shall be capable of dilution with water at all levels without curdling
or precipitation such that wet paint can be cleaned up with water only.

3. Formulation Approval
340 The manufacturer shall obtain approval of the waterborne traffic paint formulation
prior to furnishing the paints. Only waterborne traffic paints from the Department’s
list of approved Coating Formulations shall be used. Waterborne traffic paint
formulations will be placed and maintained on the Department’s list of approved
Coating Formulations in accordance with ITM 606.

909.06 Blank

909.07 Blank

350 909.08 Blank

988
 909.12

909.09 Blank

909.10 Non-Epoxy PCC Sealers

Non-Epoxy PCC sealers shall be selected from the Department’s list of approved
Non-Epoxy Portland Cement Concrete Sealers. A non-epoxy PCC sealer may be
added to the approved list by completing the requirements in accordance with ITM
806, Procedure C.

360 (a) Properties

The non-epoxy PCC sealer shall be in accordance with NCHRP 244, Series IV,
Southern Climate Weathering Test and possess the following properties.

Property Requirement
Reduction of Chloride Ion Content 90% of the Control
Active Ingredients, minimum, Silane Based 40%

(b) Test Report

The testing shall be performed by a recognized laboratory in accordance with ITM
806.

The non-epoxy PCC sealers shall be delivered to the jobsite in unopened

370 containers with the manufacturer’s numbered seal intact.

909.11 Epoxy-Resin-Base System for Bonding Plastic Concrete to Hardened

Concrete
Two-component, epoxy-resin bonding systems for use in bonding freshly mixed
concrete to hardened concrete shall be in accordance with ASTM C 881 for type II,
grade 2, and the class consistent with the ambient temperature as follows. Class A for
use below 40°F; class B for use between 40°F and 60°F; and class C for use above
60°F. Material furnished under this specification shall be covered by a type C
certification in accordance with 916.
380
909.12 Epoxy Resin Additives for Injection into Concrete
The epoxy resin adhesive shall be of low enough viscosity such that it flows to
the next open port in the surface seal material. The adhesive shall be capable of
penetrating crack widths down to 0.005 in. The adhesive shall be capable of bonding
to dry or damp surfaces. The adhesive shall exhibit a slant shear strength exceeding
the concrete strength when tested fully cured in accordance with AASHTO T 237.

The surface seal material shall have adequate strength to hold injection fittings in
place and to resist injection pressures adequately to prevent leakage during injection.
390
The epoxy resin adhesive for injection shall be covered by a type C certification
in accordance with 916.

989
 910.01

SECTION 910 – METAL MATERIALS

910.01 Reinforcing Bars, Dowel Bars and WWR

(a) General
Unless otherwise specified, bars for concrete reinforcement shall be deformed
billet steel, grade 60. Tie bar assemblies used in lieu of bent tie bars shall be in
accordance with the minimum total ultimate strength and minimum total yield strength
requirements specified for bent tie bars; bend test and elongation will not be required.
10 Coiled reinforcing bars shall only be used for fabrication of spiral and ring
reinforcement or for rectangular ties and stirrups. When approved by the Engineer,
coiled reinforcing bars may also be used for supports in accordance with 703.06.

Reinforcing bars and WWR shall be furnished by selecting materials made by a

manufacturer or fabricator on the list of Certified Uncoated Reinforcing Bar
Manufacturers and WWR Fabricators in accordance with ITM 301. When shipped to
the project site, the reinforcing bars and WWR shall be accompanied by the type of
certifications specified in ITM 301 and in accordance with 916.

20 (b) Specific Requirements

1. Billet Steel Bars

Billet steel bars shall be in accordance with ASTM A 615.

2. Threaded Tie Bar Assembly

The threaded tie bar assembly shall be deformed billet steel, grade 60 or higher,
in accordance with 910.01(b)1 and a coupling device. The minimum strength of the
tie bar assembly shall be 125% of the designated yield strength of the bar from which
it is manufactured. Where epoxy coated threaded tie bar assemblies are specified, an
30 epoxy coating with a minimum film thickness of 6 mils shall be applied to the coupling
device and epoxy coated reinforcing bars shall be provided in accordance with
910.01(b)9 with the exception that the epoxy coated bar is not required to be furnished
from the list of Certified Reinforcing Bar and WWR Epoxy Coaters.

3. Splicing Systems
Reinforcing bar splicing systems shall be selected from the list of approved
Reinforcing Bar Splicing Systems. A manufacturer may request to have a splicing
system added to the list by submitting three randomly selected epoxy coated bars of
each bar designation to be included as an approved splicing system on the list. The
40 samples furnished shall be assembled. The splicing system will be tested for tensile
strength in accordance with ASTM A 370 and shall reach the specified ultimate tensile
strength on all three samples for each bar size submitted. The manufacturer shall
identify the grade or grades of reinforcing bar for which the system is being submitted.
Splicing systems demonstrating consistent, repeatable, and passing test results will be
added to the list. Approved bar designations will be noted on the list.

990
 910.01

4. Blank

5. Deformed and Smooth Steel WWR

50 Deformed and smooth steel WWR shall be in accordance with ASTM A 1064,
except as follows:

a. The wire used in manufacturing the WWR shall be

drawn, not galvanized, unless otherwise specified.

b. WWR shall be furnished in flat sheets.

c. When epoxy-coated WWR is specified, it shall receive

a type 1 coating in accordance with ASTM A 884.
60 Repairing or patching of the coating shall be in
accordance with ASTM A 884 with the patching
material in accordance with ASTM A 775 Annex A2.
The average coating thickness shall be 9 to 14 mils after
cure. Epoxy coated WWR shall be furnished by
selecting WWR coated from an applicator’s plant on
the list of Certified Reinforcing Bar and WWR Epoxy
Coaters and in accordance with ITM 301.

d. When galvanized WWR is specified, it shall be in

70 accordance with ASTM A 1060, including repair or
renovation of the coating. It shall be coated after
fabrication.

e. The size and spacing of the WWR shall be provided as

specified. If over-sized wire is proposed for
substitution, the Contractor shall obtain written
approval from the Engineer prior to delivery. The
WWR shall be identified as the size provided, not the
size originally ordered.
80
6. Blank

7. Uncoated Seven-Wire Strand

Uncoated seven-wire strand shall be in accordance with ASTM A 416. The strand
shall have the minimum tensile strength and initial tension shown on the plans.

Uncoated seven-wire strand shall be covered by a type A certification in

accordance with 916. The certification shall include the lot number, size, cross-
sectional area, yield strength, breaking strength, strand composition, modulus of
90 elasticity, and a load-elongation curve for each size of strand supplied.

991
 910.01

8. Steel Spiral Reinforcement

Steel spiral reinforcement shall be either:

a. deformed billet steel, ASTM A 615, grade 60; or

b. cold drawn steel wire, ASTM A 82.

9. Epoxy Coated Reinforcing Bars

100 Epoxy coated reinforcing bars shall be furnished by selecting bars coated from an
applicator’s plant on the list of Certified Reinforcing Bar and WWR Epoxy Coaters
and in accordance with ITM 301. The epoxy coating material shall be selected from
the list of approved Epoxy Coating for Steel.

Epoxy coated reinforcing bars shall be in accordance with ASTM A 775, except
as follows.

a. the bars shall be in accordance with 910.01(b)1;

110 b. the coating color shall contrast with the color of iron
oxide;

c. tensile and bend tests shall be performed on the bars. If

an examination of the bend test specimen suggests the
need, the adhesion of the coating shall be checked by
subjecting additional specimens to the 120° bend test.
Hairline cracks without bond loss will be acceptable
provided there are not more than two and the length of
either crack does not exceed 1/4 in. The average coating
120 thickness shall be 9 to 14 mils after cure. The thickness
measurements shall be made in accordance with ASTM
G 12. The coating thickness shall be an average based
on 12 individual readings. No specific correction for
the base preparation process shall be applied to the
thickness measurements.

d. epoxy coated reinforcing bars furnished by coaters on

the list of approved Certified Reinforcing Bar and
WWR Epoxy Coaters shall be accompanied by the
130 types of certifications specified in ITM 301 and in
accordance with 916.

e. repair and handling procedures shall be in accordance

with 703.04. The patching material shall be in
accordance with the Annex to ASTM D 3963.

992
 910.02

Epoxy coated support devices for epoxy coated reinforcing bars shall be in
accordance with ASTM A 775, except as follows.

140 a. the steel shall be in accordance with 910.01(b)1;

b. the coating color shall contrast with the color of iron

oxide;

c. the coating thickness shall be 6 to 20 mils after cure.

The thickness measurements shall be made in
accordance with ASTM G 12.

10. Dowel Bars

150 Dowel bars shall be plain billet steel in accordance with ASTM A 615, grade 40
or higher, except that the bend test and elongation requirements will not apply. The
dowel bar area and weight for the nominal bar diameter shall be as follows.

Nominal Bar Cross Sectional Weight,

Diameter, in. Area, sq in. lb/ft
1 0.79 2.670
1 1/4 1.23 4.172
1 1/2 1.77 6.008

Dowel bars shall be coated with an epoxy coating material selected from the list
of approved Epoxy Coating for Steel. The coating thickness after cure shall be a
minimum of 7 mils. Dowel bars shall not have burring or other deformation restricting
slippage in concrete. Dowel bar ends shall be saw cut. Chips from the cutting operation
shall be removed from coated bars.
160
Dowel bars shall be furnished by selecting bars made by a coater and
manufacturer on the list of approved Certified Reinforcing Bar and WWR Epoxy
Coaters and in accordance with ITM 301. When shipped to the project site, the dowel
bars shall be accompanied by the types of certifications specified in ITM 301 and in
accordance with 916.

(c) Inspection, Sampling, and Testing

All reinforcing bars may be inspected, sampled, and tested after delivery to the
project.
170
910.02 Structural Steel

(a) Structural Steel

Unless otherwise specified, structural steel shall be in accordance with ASTM
A 709, grade 36.

993
 910.02

(b) Weathering Steel

Steel in accordance with ASTM A 709 that has an atmospheric corrosion
resistance index that meets or exceeds the index value shown in ASTM A 709.
180
(c) High Strength Structural Steel
This steel, when specified, shall be in accordance with ASTM A 709, grade 100;
ASTM A 709, grade 50; or ASTM A 709, grade 50W.

The corrosion resistance of ASTM A 709, grade 50W steel shall be at least four
times that of structural carbon steel. The steel fabricator, when placing the order, shall
state that the steel is for bridge use, and that the steel shall be used in the bare,
unpainted condition.

190 All fasteners used in conjunction with ASTM A 709, grade 50W steel shall be
friction type high-strength steel bolts in accordance with ASTM F 3125, grade A 325
type 3. Certification and a sample shall be submitted to the Engineer prior to start of
erection.

All plates and bars produced from ASTM A 572 steel over 3/4 in. in thickness
shall be “killed fine grain practice”.

(d) High Performance Steel

High performance steel, HPS, shall be in accordance with ASTM A 709. In
200 addition to the conditions listed in Section 6.7 of ASTM A 709, high performance steel
may be furnished as hybrid/mixed design structural components using high
performance steel plates in combination with high strength, low alloy steel plates and
shapes, for welded or bolted applications in bridge construction.

The impact testing requirements for HPS in accordance with 10.1 and 10.2 of
ASTM A 709 shall meet temperature zone 2.

(e) Charpy V-Notch Toughness Tests

Structural steel, except members exempted below, shall meet the longitudinal
210 Charpy V-Notch test requirement as specified in the following table for the type or
types of steel specified or furnished. Sampling and testing procedures shall be in
accordance with ASTM A 673. The H frequency of heat testing shall be used. Charpy
V-Notch test data shall be included on the mill test reports for structural steel specified
in 711.08 and 916.

994
 910.02

Foot-Pounds Joule @
ASTM Designation Thickness, in.
40°F
A 709, grade 36 15
Up to 4 in. mechanically fastened 15
A 709, grade 50*
Up to 2 in. welded 15
Up to 4 in. mechanically fastened 15
A 709, grade 50W* Up to 2 in. welded 15
Over 2 in. to 4 in. welded 20
* If the yield point of the material exceeds 65,000 psi, the temperature for the CVN value for
acceptability shall be reduced by 15°F for each increment of 10,000 psi above 65,000 psi.

This test requirement shall apply to all structural steel members and components
except diaphragms, cross frames, stiffeners, lateral bracing, railroad ballast retainers
and components, shoe assemblies, expansion joints, and compression members of
220 trusses.

(f) Mill Test Reports

Mill test reports for structural steel shall be in accordance with 711.08 and 916
and shall include Charpy-Impact test data as set out in 910.02(e).

(g) High Strength Bolts, Nuts, and Washers

1. General Use
High strength bolts shall be in accordance with ASTM F 3125, grade A 325. Type
230 3 bolts will be required if the structural steel is to remain unpainted. High strength nuts
shall be of the grade and finish specified in ASTM F 3125, grade A 325 and in
accordance with ASTM A 563 or ASTM A 194. High strength washers shall be of the
type specified in ASTM F 3125, grade A 325 and in accordance with ASTM F 436.
The bolts, washers, and nuts shall be coated after fabrication in accordance with
ASTM A 153, class C or ASTM B 695, class 55.

2. Assembly of Structural Steel in Bridges

High strength bolts, nuts, and washers used in the assembly of structural steel in
bridges, excluding shoes and bearing assemblies, shall be provided in accordance with
240 910.02(g)1 and the following additional requirements.

a. Bolts
The maximum tensile strength shall be 150,000 psi for bolts 1 in. or less in
diameter. The maximum tensile strength shall be 120,000 psi for bolts greater than 1
in. in diameter. The maximum hardness shall be 33 Rc.

b. Nuts
The nuts shall be in accordance with ASTM A 563, grade DH; or ASTM A 194,
grade 2H.
250

995
 910.02

c. Tests

(1) Rotational Capacity

High strength fasteners shall be subjected to the rotational capacity test in
accordance with ASTM F 3125, grade A 325, Section 6.3. The fastener shall complete
two times the required number of turns from snug tight conditions in accordance with
AASHTO LRFD Bridge Construction Specifications, in a Skidmore-Wilhelm
calibrator or equivalent tension measuring device without stripping or failure. During
this test, the maximum recorded tension shall be at least 1.15 times the required
260 fastener tension indicated in AASHTO LRFD Bridge Construction Specifications. The
measured torque required to produce the required fastener tension shall not exceed the
value obtained by the following equation.

Torque = 0.25 PD
where:

Torque = Measured Torque, (foot-pounds)

P = Measured Bolt Tension, (pounds)
D = Nominal Diameter (feet).

(2) Proof Loads

Proof load tests for bolts shall be conducted in accordance with ASTM F 606,
270 Section 3.2.3. Proof load test for nuts shall be conducted in accordance with ASTM
F 606, Section 4.2.

(3) Wedge Tension Test

The wedge tests of full size bolts shall be conducted in accordance with ASTM
F 606, Section 3.5.

d. Certification
The supplier shall provide a certification of compliance with all requirements for
high strength bolts, nuts, and washers used in the assembly of structural steel in
280 bridges. The certification, in addition to complying with the applicable requirements
of 916, shall include the lot number on the shipping package and indicate when or
where all testing was performed.

(h) Bolts other than High Strength Bolts

1. General
Bolts shall be unfinished, turned, or ribbed bolts conforming to the requirements
for Grade A bolts of specification for low carbon steel externally and internally
threaded fasteners, ASTM A 307. Bolts shall have single, self-locking nuts or double
290 nuts unless otherwise shown on the plans or in the special provisions. Beveled washers
shall be used where bearing faces have a slope of more than 1:20 with respect to a
plane normal to the bolt axis.

996
 910.03

Bolts, washers, and nuts utilized in the U channel steel post splice as shown on
the plans shall be in accordance with ASTM A 449, SAE J429-G7.9, or ASTM F 3125,
grade A 325 and shall be galvanized.

2. Unfinished Bolts
Unfinished bolts shall be furnished unless other types are specified.
300
3. Turned Bolts
The surface of the body of turned bolts shall meet the ANSI roughness rating
value of 125. Heads and nuts shall be hexagonal and standard dimensions for bolts of
the nominal size specified or the next larger nominal size. Diameter of threads shall
be equal to the body of the bolt or the nominal diameter of the bolt specified. Holes
for turned bolts shall be carefully reamed. Bolts furnished shall provide for a light
driving fit. Threads shall be entirely outside of the holes. A washer shall be provided
under the nut.

310 4. Ribbed Bolts

The body of ribbed bolts shall be of an approved form with continuous
longitudinal ribs. The diameter of the body measured on a circle through the points of
the ribs shall be 5/64 in. greater than the nominal diameter specified for the bolts.
Ribbed bolts shall be furnished with round heads conforming to requirements of ANSI
B 18.5 unless otherwise specified. Nuts shall be hexagonal, either recessed or with a
washer of suitable thickness. Ribbed bolts shall make a driving fit with the holes. The
hardness of the ribs shall be such that the ribs do not mash down enough to allow the
bolts to turn in the holes during tightening. If for any reason the bolt twists before
drawing tight, the hole shall be carefully reamed and an over sized bolt used as a
320 replacement.

910.03 Permanent Metal Forms

Metal bridge deck falsework and supports shall be fabricated from steel sheet,
zinc-coated structural steel in one of the following grades: 33, 37, 40, 50 Class 1, 80
Class 1, or 50 Class 3, having a coating designation of G165, oiled but not chemically
treated, all in accordance with ASTM A 653.

A type A certification in accordance with 916 shall be provided for all material
furnished under this specification. The certification shall list the results of the
330 following tests. The properties and parameters shall be listed for each gauge, thickness,
of material used in the panels and the hardware necessary to erect them.

Property ASTM
Yield Strength, ksi A 653*
Tensile Strength, ksi A 653*
Elongation in 2 in., % A 653*
Weight of Zinc Coating A 653*
* The minimum mechanical requirements as stated in
ASTM A 653 for the respective grade shall be provided
on the type A certification in addition to the test results.

997
 910.04

The materials will also be sampled at the work site as specified in the Frequency
Manual. The sample will include a representative portion of a panel of each gauge,
thickness, to be used and a representative portion of each type and size of hardware
necessary to erect the panels, excluding the fasteners.

910.04 Steel Forgings and Steel Shafting

340
(a) Carbon Steel Forgings
Steel forgings shall be in accordance with ASTM A 668 for carbon steel forgings
for general industrial use. Class F forgings shall be furnished unless otherwise
specified.

(b) Cold Finished Carbon Steel Shafting

Shafting shall be in accordance with ASTM A 108 for cold finished carbon steel
bars and shafting. Grade designation 1016-1030, inclusive, shall be furnished unless
otherwise specified.
350
(c) Alloy Steel Forgings
Alloy steel forgings shall be in accordance with ASTM A 668 for alloy steel
forgings for general industrial use. Class G forgings shall be furnished unless
otherwise specified.

(d) Certification
Steel forgings and steel shafting shall be covered by a mill certification reporting
the test results of:

360 1. chemical analysis;

2. heat treatment, not required for shafting;
3. tensile strength, yield strength, and elongation.

Elongation is not required for shafting.

910.05 Castings
The casting design shall be proof loaded to 40,000 lbs in accordance with
AASHTO M 306. Castings shall be in accordance with the plan dimensions and to the
following requirements for the designated materials. A certified inspection report shall
370 be submitted by the manufacturer with each shipment of castings, except as otherwise
provided herein. Inspection and testing shall be done by the manufacturer. The
certified inspection report shall list the casting number, and the type of material,
including the class of gray iron, and the grade of ductile iron. It shall state that
inspection and testing has been performed, that all parts shipped meet the pertinent
specification requirements, and that all component parts fit. The supporting test results,
including proof load data, shall be retained and be available on request for a period of
seven years. All castings shall have the manufacturer’s identification and the date of

998
 910.05

manufacture cast on an exposed surface. Acceptance of castings will be based on the

certified inspection report, visual inspection, and check measurements.
380
(a) Steel Castings
Chromium alloy steel castings shall be in accordance with ASTM A 743. Grade
CA 15 shall be furnished unless otherwise specified.

(b) Iron Castings

Iron casting shall be gray iron castings in accordance with ASTM A 48, class
No. 35B, unless otherwise specified. Tension tests will be required for all castings
including drainage castings.

390 Castings shall be true to pattern in form and dimensions. A tolerance of ±1/8 in.
in general dimensions as shown on the plans will be allowed with the exception that
the tolerance in the dimensions of grates or covers and the openings into which they
fit shall be limited to ±1/16 in. Each casting shall weigh at least 95% of the
manufacturer’s specified weight of the type specified and shall be cast to the
dimensions shown on the plans. They shall be free from sponginess, cracks, blowholes,
warping, sand inclusions, cold shots, cold shuts, chilled iron shrinks, or any defects
which would affect the strength and value for the intended purpose. The castings shall
completely fill the molds and shall not be removed until properly cooled. The casting
date and a casting code number shall be cast on each casting.
400
All corners of the castings shall be filleted and outside corners and edges shall be
rounded to a radius of not less than 1/8 in. All contact surfaces between different
castings shall present a firm and even bearing without rattling or rocking. The lid frame
bearing surfaces on all round castings shall be machine milled to provide true bearings
around the entire circumference. All other contact surfaces shall be ground.

All castings shall be cleaned of molding or core sand, rust, scale, and foreign
material just prior to shipment. Iron castings shall be delivered unpainted.

410 (c) Ductile Iron Castings

These castings shall be in accordance with ASTM A 536. Grade 65-45-12 shall
be furnished unless otherwise specified. In addition, they shall be in accordance with
all requirements of 910.05(b), except the first paragraph.

(d) Malleable Castings

These castings shall be in accordance with ASTM A 47. Grade No. 32510 or
35018 shall be furnished unless otherwise specified. In addition, they shall be in
accordance with all requirements of 910.05(b), except the first paragraph.

420 (e) Carbon Steel Castings

These castings shall be in accordance with ASTM A 27. The grade shall be 60-
30, 65-35, or 70-36.

999
 910.06

Castings shall be true to pattern in form and dimensions and free from pouring
faults, sponginess, cracks, blowholes, and any defects in positions affecting their
strength and value for the service intended.

Blowholes appearing on finished castings shall be located so that a straight line

laid in any direction does not cut a total length of cavity greater than 1 in. in any 1 ft
430 nor shall any single hole exceed 1 in. in any dimension or have an area greater than
1/2 sq in. Blowholes shall not be deep enough to affect the strength of the casting
adversely.

Minor defects which do not impair strength may, with approval, be welded by an
approved process. Defects shall be removed in solid metal by chipping, drilling, or
other satisfactory methods and, after welding, the castings shall be annealed if
required. Castings which have been welded without permission will be rejected. No
sharp unfilleted angles or corners will be allowed.

440 910.06 Bronze and Copper Alloy

(a) Bronze Castings

Bronze castings shall be in accordance with ASTM B 22, alloys 911 or 913.
Material furnished under this specification shall be covered by a type A certification
in accordance with 916.

(b) Copper Alloy Plates

Copper alloy plates shall be in accordance with ASTM B 100. Material furnished
under this specification shall be covered by a type A certification in accordance with
450 916.

910.07 Steel Components of MSE Retaining Walls

(a) Backing Mats, Clevis Connector, Connector Bar, and Wire-Facing

1. Backing Mats
Backing mats shall be smooth steel welded wire reinforcement in accordance with
910.01(b)5. Galvanization, if required, shall be in accordance with ASTM A 1060.
The Engineer will test samples in accordance with ASTM A 1064.
460
2. Clevis Connector
Clevis connectors, if used, shall be attached to the alignment templates using the
bars provided with the forms. The vertical and horizontal alignment of the connectors
shall be ±1/8 in. The holes inside the loops shall be free of all concrete and debris,
loose or otherwise.

The clevis connector shall be fabricated of cold-drawn steel wire in accordance

with ASTM A 1064. Loops shall be galvanized in accordance with ASTM A 153 class
B-3, ASTM A 123, coating grade 55.

1000
 910.07

470
A type A certification in accordance with 916 shall be furnished for the clevis
connector. The results of the tension, bend, and coating adhesion tests, and
measurements of coating thickness and average weight of the coating, shall be
included on the certification for the clevis connector.

3. Connector Bar
The connector bar, if used, shall be fabricated of cold-drawn steel wire in
accordance with ASTM A 1064, and galvanized, if so shown on the plans, in
accordance with ASTM A 123, coating grade 55.
480
A type A certification in accordance with 916 shall be furnished for the connector
bars. The results of the coating adhesion test and the measurements of coating
thickness, average weight of the coating, and coating flexibility, shall be included on
the certification for the connector bar.

4. Wire-Facing
Wire-facing shall be smooth steel WWR in accordance with 910.01(b)5.
Galvanization, if required, shall be in accordance with ASTM A 1060. All wire-facing
shall be handled, stored, and shipped so as to eliminate the danger of excessive bending
490 stresses. The Engineer will test samples in accordance with ASTM A 1064.

(b) Ground Reinforcement

The ground reinforcement shall be either a deformed steel strip or a welded-wire
grid. The grid or strip used shall be consistent with that used in the pullout test and
shall be consistent throughout the project.

The grid shall consist of not less than two longitudinal wires, perpendicular to the
wall, welded to equally-spaced cross ribs capable of developing passive pressure with
the fill. The deformed strip shall be of constant width. The strip thickness shall vary
500 only from the undeformed section to the deformed section as required to produce the
pullout resistance.

The face-panel edges shall be configured to conceal the joints. All horizontal and
vertical joints shall be covered with a joint cover to prevent backfill leakage while
passing water.

Ground-reinforcement units shall be hot rolled from bars to the required shape
and dimensions. Physical and mechanical properties of the units shall be in accordance
with ASTM A 572, grade 65. Tie strips shall be shop fabricated with hot-rolled steel
510 in accordance with the minimum requirements of ASTM A 1011, grade 50.
Galvanization for ground-reinforcing units and tie strips shall be in accordance with
ASTM A 123, coating grade 85, for strip-type reinforcements or ASTM A 641, class
5 or class C, for bar mat or grid-type reinforcements. All ground-reinforcement units
and tie strips will be inspected to ensure that they are true to size and free from defects
which can impair their strength and durability.

1001
 910.08

A type A certification in accordance with 916 shall be furnished for ground

reinforcement prior to use of the materials. The results of the yield strength, coating
thickness, and coating adhesion tests shall be shown on the certification.
520
(c) Fasteners
Fasteners shall consist of 1/2 in. diameter, bolts, nuts, and washers and shall
otherwise be in accordance with 910.02(g)1 with the exception that the hardware shall
be coated in accordance with ASTM A 153, class C.

The supplier shall provide a certificate of compliance with all requirements for
high strength bolts, nuts, and washers used in the assembly of MSE retaining walls.
The certification, in addition to complying with the applicable requirements of 916,
shall include the lot number and heat number on the shipping package and indicate
530 when or where all testing was performed.

(d) Alignment Pins

The rods used to align the face panels during construction shall be 3/4 in. diameter
and 12 in. in length. The rods shall be mild steel, PVC, or fiberglass. A type C
certification in accordance with 916 shall be furnished for the alignment pins.

910.08 Steel Bin-Type Retaining Wall Units

Wall units shall consist of adjoining closed-face cells filled with structure backfill
to form a gravity-type retaining structure. The cells shall be constructed of members
540 in accordance with AASHTO M 218 that are bolted together. The necessary bolts and
appurtenances shall be furnished for complete assembly of the units into a continuous
closed-face wall of connected bins.

Working drawings shall be submitted in accordance with 105.02.

The units shall present a uniform workmanlike appearance once assembled. The
base metal shall be not less than 16 gauge.

The steel sheets shall be galvanized on both sides in accordance with ASTM A
550 123, coating grade 85. All sheets will be inspected to ensure that they are true to size
and free from defects, which may impair their strength and durability.

A type A certification in accordance with 916 for the bin-wall sheets shall be
furnished prior to use. The results of the steel yield strength and coating adhesion tests,
and measurement of the coating thickness, shall be shown on the certification.

910.09 Guardrail
Guardrail of the same type shall be interchangeable regardless of the source.
Guardrail materials shall be in accordance with the applicable AASHTO or ASTM
560 requirements listed herein and will only be accepted from qualified manufacturers on

1002
 910.10

the Department’s list of Certified Guardrail Manufacturers. Qualification requirements

for the manufacturers shall be in accordance with ITM 806, Procedure O.

Steel beam rail shall be galvanized, corrugated sheet steel beams in accordance
with AASHTO M 180 as modified herein. The rails, including terminal sections, shall
be either class A, base metal nominal thickness of 0.105 in., 12 gauge, or class B, base
metal nominal thickness or 0.135 in., 10 gauge. They shall be type 2, zinc coated with
3.60 oz/sq ft minimum single spot and 4.00 oz/sq ft minimum triple spot. Tests for
adherence of the coating may be made including the test specified in ASTM A 123,
570 when deemed necessary.

Where beam rail is set on a curve of 150 ft radius or less, the rail plate shall be
shop curved with its traffic face concave or convex as required. The radii of curvature
shall be in increments of 10 ft from a radius of 150 to 50 ft inclusive and in increments
of 5 ft from a radius of 50 ft to and including 20 ft.

The steel channels specified on the plans shall be standard 5 in. channels weighing
6.7 lb/ft. The material shall be in accordance with ASTM A 36. The channel shall be
galvanized in accordance with ASTM A 123 after fabrication. The weight of zinc
580 coating per area of actual surface shall average not less than 2 oz/sq ft for any
individual piece of channel.

Construction details for the rails and channels shall be as shown on the plans.
Whenever field fabrication, as approved, requires cutting or drilling, the cut or drilled
member shall be coated with a high zinc dust-zinc oxide paint in accordance with
Federal Specification TT-P-641, type II, or Military Specifications DOD-P-21035.
When spray paints are used, two coats shall be applied.

910.10 Guardrail Posts

590 Guardrail posts shall be either steel or timber as specified and shall be in
accordance with the following requirements.

(a) Steel Guardrail Posts

The dimensions of the steel guardrail posts shall be as shown on the plans. The
material shall be in accordance with ASTM A 36. The posts shall be galvanized in
accordance with ASTM A 123 after fabrication. However, the weight of zinc coating
per square foot of actual surface shall not average less than 2.0 oz for an individual
post.

600 The weight of the W6 x 15 post, after fabrication and coating, shall not be less
than 14.60 or more than 16.00 lb/ft.

Construction details shall be as shown on the plans. Whenever field fabrication,

as approved, requires cutting or drilling, the cut or drilled member shall be coated with
a high zinc dust-zinc oxide paint conforming to the requirements of Federal

1003
 910.11

Specification TT-P-641, or Military Specifications DOD-P-21035. When spray paints

are used, two coats shall be applied.

(b) Timber Guardrail Posts

610 Timber guardrail posts shall be in accordance with 911.02(f). Dimensions and
construction details shall be as shown on the plans.

910.11 Guardrail Accessories, Fittings, and Hardware

These items consist of brackets, splice plates and bars, post anchors, diaphragms,
clamps and clamp bars, end caps, connections, anchor rod assemblies, deadmen, bolts,
screws, nuts, washers and blockouts of the type, dimensions, and design shown on the
plans. They shall be in accordance with the requirements set out below. Items of the
same type shall be interchangeable regardless of the source.

620 (a) For Steel Beam Guardrail

1. Post brackets, bars, plates and shapes for bridge railing

brackets, and plate washers shall be in accordance with
ASTM A 36. Post brackets, bars, and plates and shapes for
bridge railing brackets shall be galvanized in accordance
with 910.10(a). Plate washers shall be galvanized after
fabrication in accordance with ASTM A 153. The weight
of the W6 x 15 post bracket shall be in accordance with
910.10.
630
2. Splice plates and rail portion of bridge railing brackets
shall be class B, type 2, in accordance with the first
paragraph of 910.09(a).

3. Bolts and nuts of the sizes specified on the plans shall be

in accordance with ASTM A 307. Cut washers and lock
washers shall be standard round steel washers of the sizes
specified on the plans. The diameter of cut washers shall
be 1 3/4 in. for 5/8 in. bolts and 2 in. for 3/4 in. bolts with
640 a thickness of 0.134 in. ±0.026 in. measured at the hole.
The bolts, washers, and nuts shall be coated after
fabrication in accordance with ASTM A 153, or be
mechanically galvanized and conform to the coating
thickness, adherence, and quality requirements for class C
of ASTM A 153.

4. Whenever approved field fabrication requires cutting or

drilling, the cut or drilled members shall be coated with a
high zinc dust-zinc oxide paint conforming to Federal
650 Specification TT-P-641, type II, or Military Specifications

1004
 910.11

DOD-P-21035. When spray paints are used, two coats shall

be applied.

5. Pipe spacers of the size specified on the plans shall be

galvanized after fabrication in accordance with ASTM A
153, class C. The weight of coating per square foot of
actual surface shall average no less than 1.25 oz for the
specimen tested and shall be no less than 1 oz for any
individual specimen.
660
6. For breakaway cable terminal, and cable terminal anchor
system, the rail element, standard bolts, nuts, and washers
shall be in accordance with 910.09 and requirements 1 and
3 of 910.11(a).

7. For cable terminal anchor system, the anchor bracket, end

plate, soil plate, bearing plate, strut and yoke shall be in
accordance with AASHTO M 270, grade 250. They shall
be zinc coated after fabrication in accordance with
670 AASHTO M 111. The steel tube shall be in accordance
with ASTM A 500, grade B and zinc coated in accordance
with AASHTO M 111. The post sleeve shall be in
accordance with ASTM A 53, grade B and zinc coated in
accordance with AASHTO M 111. The stud shall be in
accordance with ASTM F 568, class 8.8, and zinc coated
in accordance with AASHTO M 111. The threads shall be
in accordance with ANSI B1.13M and shall be M24 by 3,
class 6g pitch. The swaged fitting shall be in accordance
with ASTM A 576, grade 1035, zinc coated in accordance
680 with AASHTO M 111, and shall be annealed for cold
swaging. A lock pin hole to accommodate a 1/4 in. plated
spring-steel pin shall be drilled through the head of the
swaged fitting.

8. Timber blockouts shall be in accordance with 911.02(f).

Alternate material blockouts shall be in accordance with
926.03.

High strength bolts shall be in accordance with ASTM F 3125, grade A 325 or
690 ASTM A 449. High strength nuts shall be in accordance with ASTM A 563, grade B
or better. Galvanizing shall be in accordance with ASTM A 153 or mechanically
galvanized and conform to the coating thickness, adherence, and quality requirements
for class C of ASTM A 153. Foundation plates and bearing plates shall be in
accordance with ASTM A 36, and shall be galvanized after fabrication in accordance
with ASTM A 123, except the weight of zinc coating per square foot of actual surface

1005
 910.11

shall average no less than 2.0 oz and shall be no less than 1.8 oz for any individual
specimen. Welding shall be in accordance with AWS D1.1.

Terminal posts shall be fabricated from tubing meeting ASTM A 500, grade B, or
700 ASTM A 501 and from plates meeting ASTM A 36. Welding shall be in accordance
with AWS D1.1. They shall be galvanized after fabrication in accordance with ASTM
A 123, except the weight of zinc coating per square yard of actual surface shall average
no less than 2.0 oz. The average for any component part, including paddle plate,
tubing, or base plate, shall be no less than 1.8 oz.

The steel pipe in the type 5 anchor and the steel spacer tube in the transition type
WGB shall be Schedule 40.

Tapered washers may be of steel or malleable iron, and galvanized in accordance

710 with ASTM A 153.

The wire rope used in the cable assemblies shall be in accordance with AASHTO
M 30 and shall be 3/4 in. preformed, 6 by 19, wire strand core or independent wire
rope core, IWRC, galvanized, right regular lay, manufactured of improved plow steel,
with a minimum specified breaking strength of 42,800 lbf. The swaged fitting, stud,
and nut shall develop the breaking strength of the wire rope. The fitting shall be
galvanized in accordance with ASTM A 123 before swaging. After galvanizing, the
head and nut may be tapped 0.023 in. over the ANSI B1.1, class 2B tolerance.

720 (b) For Steel Tube Guardrail

1. Channels and bars for connections, splice bars, and

diaphragms shall be in accordance with ASTM A 36.

2. Cap screws shall be stainless steel in accordance with

ASTM A 276, type 304 or 430.

3. Rail end caps shall be malleable iron castings in

accordance with ASTM A 47, grade 35018, or steel
730 castings in accordance with ASTM A 27, grade 70-36.

4. Cut washers and lock washers shall be standard round steel

washers. The diameter of cut washers shall be 1 1/2 in. and
1/8 in. thick measured at the hole. Washers shall be coated
after fabrication in accordance with requirement 3 of
910.11(a).

5. All materials other than cap screws and washers shall be

galvanized after fabrication in accordance with ASTM A
740 123.

1006
 910.13

6. When field fabrication, as approved, requires cutting or

drilling, the cut or drilled members shall be coated with a
high zinc dust-zinc oxide paint conforming to the
requirements of Federal Specification TT-P-641 type II or
Military Specifications DOD-P-21035. When spray paint
is used, two coats shall be applied.

910.12 Blank
750
910.13 Steel Fence Posts
Tubular steel fence posts and line posts shall meet the following specifications
and the requirements as shown on the plans.

(a) Line Posts

Line posts shall be in accordance with AASHTO M 281 and galvanized in
accordance with AASHTO M 111, coating grade 65.

Line posts for farm field fence shall be furnished with anchor plates. End, corner,
760 pull, and gate posts for farm field type fence shall be furnished with braces and all
fittings and details required to make a complete installation as shown on the plans.

(b) Tubular Steel Fence Posts

Two groups of tubular steel fence posts are included in these specifications.
Tubular section posts shall have heavy malleable iron caps or pressed galvanized steel
caps. Such caps shall be made to provide a drive fit over the outside of the section to
exclude moisture. The weight per foot for tubular posts and braces shall be no less than
90% of the weight specified. Unless specified otherwise, the tubular steel fence post
shall be group 1.
770
1. Group 1
Tubular steel fence posts for group 1 shall be hot-dipped zinc-coated and shall be
in accordance with ASTM F 1083 except tests shall be conducted on sample posts
selected as being representative of the posts furnished. The weight per foot will be
acceptable provided it is at least 90% of the specified weight.

2. Group 2
Tubular steel fence posts for group 2 shall have a minimum 50 ksi yield strength
and be in accordance with AASHTO M 181, except that the inner pipe surface may be
780 galvanized in lieu of a zinc rich coating or hot dipped aluminum coated, Type 2,
meeting the chemical requirements of AASHTO M 274. The aluminum coated, Type
2, steel fence posts shall be manufactured by roll forming aluminum coated, Type 2,
steel strip and electric resistance welding it into tubular form. The outside of the weld
area shall be metallized with commercially pure aluminum to a thickness sufficient to
provide resistance to corrosion equal to that of the remainder of the outside of the post.
The aluminum coating weight (mass) shall be a minimum of 0.75 oz/sq ft average, and
0.70 oz/sq ft for an individual test specimen, as measured in accordance with ASTM

1007
 910.14

A 428. Specimens for determining weight of coating shall be obtained in accordance

with ASTM F 1083.
790
(c) Fence Fastenings
When fastenings are necessary for attaching the farm field fence to the posts, they
shall be either galvanized or aluminum coated No. 9 wire, or galvanized or aluminum
coated clamps of the manufacturer’s standard design. The coating weights shall be a
minimum of 0.60 oz/sq ft and 0.30 oz/sq ft for galvanized and aluminum coated,
respectively. A sufficient quantity of individual tie wires or clamps shall be furnished
to provide for five attachments of the fencing to each line post and one tie wire for
each strand of barbed or tension wire.

800 Line posts for chain link type fence shall be furnished with the necessary tie wires
or fabric bands for fastening the fabric to the posts. These fastenings shall be made of
aluminum strip or wire of approved gauge and design or of galvanized steel wire and
may be in accordance with the manufacturer’s standard design. If galvanized steel wire
ties are furnished, the wire shall be no smaller than No. 9 gauge. A sufficient quantity
of individual ties or bands shall be furnished to provide for attaching the fabric to each
line post each 1 ft or as called for on the plans.

910.14 Sign Posts

810 (a) Steel, Flanged, Channel Posts

1. General Requirements
Posts shall be made from open hearth, basic oxygen, or electric furnace steel rolled
from standard tee rails or new billets. The steel used in the posts shall conform to the
physical properties of ASTM A 499, grade 60, and to the chemical compositions of
ASTM A 1 for 91 lb/yd or larger steel rails.

Posts fabricated from other steels will be acceptable providing that the following
criteria are met. A notarized copy of a dynamic crash test report shall be furnished
820 substantiating that the posts manufactured from this material, when double mounted
in a 7 ft span, conform to the breakaway requirements of AASHTO Standard
Specifications for Structural Supports for Highway Signs, Luminaires, and Traffic
Signals, except that the maximum change in velocity shall not exceed 16 ft/s. For two
posts in a 7 ft path, impact performance may be estimated by multiplying the vehicle
energy loss observed in a single post crash test by 2. This estimated double post energy
loss may then be used to calculate an estimated impact velocity change and momentum
change for a double post sign design. The minimum yield strength shall be 60,000 psi
and the minimum tensile strength shall be 90,000 psi.

830 The tensile strength shall be determined by either the standard Rockwell Hardness
test, Brinnel Hardness test, or by actual tensile test. The Rockwell Hardness shall be a
minimum of B 91. The yield strength shall be determined by the manufacturer by
actual test. Tensile and yield strengths and chemical composition shall be determined

1008
 910.14

by the average from the three latest test results the manufacturer has available at the
time of shipment. These test results need not be made on the materials from which the
posts were made. However, the tests shall have been made within 90 days of shipment.
Posts, except those used for temporary construction signs, temporary traffic signs, and
temporary panel signs, shall be certified by a type B certification in accordance with
916. The certification shall include the above three test results and the elastic section
840 modulus value in accordance with 910.14(a)3.

Posts shall be of uniform flanged channel or U section such that the area of contact
between the post and the sign is symmetrical about the vertical axis of both sign and
post. The back of each post shall be formed in a manner to ensure a solid bearing
surface over the entire length of the post when mounted back to back. The bearing
surface on the back of the post shall be flat. The length shall be as specified with a
tolerance of ±1 in. Sign posts shall be punched with 58 holes which shall be 3/8 in. in
diameter located on the center-line and spaced on 1 in. centers beginning 1 in. from
the top. The remainder of the post shall be punched with 3/8 in. holes on 1 in. or 2 in.
850 centers.

The finished posts shall be machine straightened and have a smooth uniform
finish free from cracks, flaws, injurious seams, laps, blisters, and edges which are
ragged, sharp, and imperfect, or other defects affecting their strength, durability, or
appearance. The maximum variation in straightness shall be no more than 1/4 in. in
any 5 ft of length, or exceed in inches 1/4 times the number of feet of length divided
by 5. Bolt holes of the diameter specified shall be accurately spaced vertically and
centered horizontally so that holes will register for back to back application. All holes
and sheared ends shall be commercially free from burrs.
860
The steel sign posts shall be galvanized in accordance with ASTM A 123.

Galvanizing shall be the final process after all fabrication and punching has been
completed. Posts saw cut after galvanizing shall have the cut surface treated with a
zinc-based solder in rod form which complies with ASTM A 780. The cut surface shall
not be treated until the fuse plate is installed and all bolts are tightened. The top of the
fuse plate shall be 1 in. below the bottom of the sign.

Posts saw cut before galvanizing shall have temporary fasteners provided with
870 sufficient strength to prevent warping or deforming of the post during the
galvanization process. The surface under the temporary fasteners shall be treated with
an approved zinc solder meeting the above mentioned specifications. The surface shall
be treated before the fuse plate is installed. The break-away stubs shall be galvanized
a minimum of 8 in. below the top of the concrete foundation.

Steel posts shall be wired or strapped securely in bundles of not more than
2,000 lb. They shall be nested in rows with the edges intermeshed so as to form a
rectangular bundle and shall be fastened in such a manner that they do not slip or rub
against each other and cause damage to the finish. Care shall be taken during shipment

1009
 910.14

880 to prevent the bundles from rubbing against each other and causing damage. Excessive
damage to the finish during shipment will be cause for rejection of the damaged posts.

2. Deflection Test Requirements

Posts will be tested as a simple beam with the flange in compression on
non-restricting supports 24 in. apart. Test specimens shall be 28 in. ±1/4 in. long. A
load of 1500, 3500, or 4600 lb, depending on the type of post, shall be applied at the
center of the span with a mandrel of not less than 1 in. in diameter. Application of the
load shall be at a speed of not to exceed 0.03 in. per minute. Deflection of the post
upon application of the total load shall not exceed 0.16 in. The load shall then be
890 removed. Deflection of the post 1 minute after removal of the load shall not exceed
0.01 in.

3. Type of Posts
Posts shall conform to the following table and to deflection tests required in
910.14(a)2.

Minimum Elastic
Type Loading
Section Modulus
A .200 1500 lb
B .400 3500 lb
C .560 4600 lb
Abb* .670 **
Bbb* 1.190 **
* Back to Back
** Back to Back post shall be tested singly
for deflection prior to assembly.
Note: The elastic section modulus values shall be
included in the type B certification.

(b) Wide Flange Posts

Structural steel members for the support of signs shall be in accordance with
900 ASTM A 36 and ASTM A 709, grade 36. These members shall be galvanized in
accordance with ASTM A 123. Base plates and stiffeners shall be in accordance with
the requirements of ASTM A 709, grade 36. Fuse and hinge plates shall be in
accordance with the requirements of ASTM A 36 and shall be galvanized in
accordance with ASTM A 123. All bolts, nuts, and washers shall be high strength and
be in accordance with ASTM F 3125. Direct Tension Indicator hardware shall be in
accordance with ASTM F 959.

All holes shall be drilled. All cutting shall preferably be saw cuts however flame
cuts as specified in 711.13 may be allowed. Metal projecting beyond the plane of the
910 plate face will not be allowed.

(c) Structural Steel Posts

Steel members for the support of signs shall be standard shapes as specified and
shall be in accordance with 910.02(a). These members shall be galvanized in
1010
 910.14

accordance with ASTM A 123. Material furnished under this specification, except
those used for temporary construction signs, temporary traffic signs, and temporary
panel signs, shall be covered by a type C certification in accordance with 916.

(d) Structural Aluminum Posts

920 These posts shall be standard shapes as specified and shall be aluminum in
accordance with ASTM B 221 alloy 6061-T6. Material furnished under this
specification, except those used for temporary construction signs, temporary traffic
signs, and temporary panel signs, shall be covered by a type C certification in
accordance with 916.

(e) Square Steel Posts

Square steel sign post, except those used for temporary construction signs,
temporary traffic signs, and temporary panel signs, shall be covered by the type of
certification specified in the Frequency Manual and in accordance with 916.
930
1. Steel
Square steel posts shall be roll formed and in accordance with one of the
following:

a. ASTM A 1011, hot rolled carbon sheet steel in either

0.105 in. or 0.075 in. with a minimum yield strength of
60,000 psi. The ultimate tensile strength shall not
exceed 79,800 psi or have an elongation measured over
2 in. greater than 20%.
940
b. ASTM A 1008, cold rolled high strength steel, 0.075 in.
with a minimum yield strength of 60,000 psi. This shall
apply to the 2 in. by 2 in. size posts only.

c. ASTM A 653, cold rolled high strength steel, 0.075 in.

with minimum yield strength of 60,000 psi. The
ultimate tensile strength shall not exceed 79,800 psi or
have an elongation measured over 2 in. greater than
20%. This requirement shall apply to the 2 in. by 2 in.
950 size posts only.

Yield strengths and chemical composition shall be determined from the three
latest test results performed by the steel manufacturer. These test results may not be
determined on materials from which the delivered posts were made. However, the tests
shall have been performed within 90 days of shipment. The certification shall include
the range of test results and the section modulus value in accordance with 910.14(a)3.

2. Fabrication
The posts shall be corner welded and scarfed as necessary to allow sections to
960 telescope within each other. The finished posts shall be machine straightened and have

1011
 910.15

a smooth uniform finish free from cracks, flaws, injurious seams, laps, blisters, and
edges which are ragged, sharp, and imperfect, or other defects affecting their strength,
durability, or appearance. The maximum variation in straightness shall be no more
than 1/4 in. in any 5 ft of length. Cut holes or knockout holes of 7/16 in. diameter shall
be spaced on 1 in. centers, on the centerlines of all four sides in true alignment, and
opposite to each other for back to back applications. All holes and sheared ends shall
be free from burrs.

3. Protective Coating
970 The protective coating shall be applied using one of the following:

a. Before fabrication, both sides of the rolled sheet steel

shall be galvanized in accordance with ASTM A 653,
coating designation G 90.

b. After fabrication, a triple coating system on the outside

of the posts consisting of galvanizing with zinc which
is in accordance with ASTM B 6 weighing 0.60 ±0.15
oz/sq ft followed by a chromatic conversion coating
980 weighing 15 ±5 µg/sq in. and a clear organic exterior
coating with a dry film thickness of 0.2 ±0.1 mil. The
interior surface of the posts shall receive a double in-
line application of a zinc rich organic coating with a
total dry film thickness of 1.2 ±0.6 mil. The dried zinc
rich organic coating film shall contain a minimum of
77% total zinc. Samples from the posts which use these
protective coatings shall be exposed to salt fog testing
in accordance with ASTM B 117 for a total of 500 h.
The samples shall be examined at both 100 and 500 h
990 of salt fog testing and rated for corrosion. At 100 h the
corrosion rating shall be a minimum of 9 and at 500 h
the corrosion rating shall be a minimum of 6 when
determined in accordance with ASTM D 1654.

(f) Portable Construction Sign Trailer

The portable construction sign trailer, not including the signs and lights, shall
weigh no more than 300 lb and shall not be fabricated with heavier than 3 by 3 in.
angles, 2 1/2 in. pipe, or 3 by 2 in. rectangular tubing. The rim size of the wheels shall
not exceed 12 in. Axle assemblies with differential housings shall not be used.
1000
910.15 Delineator Posts
Posts shall be in accordance with 910.14(a)1.

Physical requirements for the finished delineator posts shall be:

Width of flange face .................................................... 2 to 2 3/8 in.

Width of back .............................................................. 3/4 to 7/8 in.
1012
 910.17

Depth from face of flange to back ............................... 7/8 to 1 1/8 in.

Length.......................................................................... 7.0 ft ±1 in.
1010 Weight ......................................................................... 1.0 to 1.5 lb/ft

Delineator posts shall be punched with a minimum of twenty-four 1/4 in. holes on
the centerline spaced on 1 in. centers beginning 1 in. from the top.

910.16 Copper Flashing

Copper flashing shall be soft copper and shall be in accordance with ASTM
B 370, except the minimum copper content shall be 99.5%. The weight per square foot
will be determined by weighing individual samples. If the first sample is not in
accordance with the tolerances for 16 oz sheet, two additional samples shall be tested
1020 and both shall comply with the specified tolerances. The sample shall withstand being
cold bent through an angle of 180° flat upon itself, without failure of the outside of the
bent portion. The type of certification for copper flashing will be covered by the
Frequency Manual and shall be in accordance with 916.

910.17 Bronze or Copper Alloy Plates

Bronze or copper alloy to be used for self lubricating bearing plates shall conform
to one of the following requirements based on the design unit loading set out on the
plans.

Design Unit Loading not over Shall Conform to ASTM

A. 3,000 psi B 22, Alloy C86300
B. 2,500 psi B 100, Alloy C51000
C. 2,000 psi B 22, Alloy C91100
D. 1,000 psi B 22, Alloy C90500*
* Up to 2.5% lead allowed.
1030
The sliding surfaces of the plates shall be provided with cylindrical recesses with
a depth necessary to provide proper containment of the lubricant. The recesses shall
be arranged in a geometric pattern so that each successive row will overlap in the
direction of motion. The total area of the recesses shall comprise no less than 25% and
no more than 35% of the total area of the plate.

The surface finish of bearing areas shall be in accordance with ANSI B46.1 #125.
The lay of tool marks shall be in the direction of expansion or contraction of the
structure. If the surface is ground, grinding knurls may be omni-directional. Flat
1040 bearing surfaces shall be flat to a tolerance of ±0.0005 in. Curved bearing surfaces
shall be machined to a tolerance of ±0.0005 in. in each 1 in. of length perpendicular to
the circular section. The radius of curved bearing surfaces shall have the following
tolerances.

Positive Tolerance Negative Tolerance

Concave Surface 0.010 in. 0.000 in.
Convex Surface 0.000 in. 0.010 in.

1013
 910.18

The lubricant shall be of the solid type. It shall consist of graphite and metallic
substances having lubricating properties with a lubricating binder. The lubricant shall
be free of any material that causes abrasive or corrosive action on the metal surfaces.
It shall withstand the atmospheric elements. The lubricant shall be compressed into
1050 the recesses of the bearing plate by hydraulic pressure to form a dense non-plastic
lubricating insert.

At the time of assembly in place, the steel surfaces which bear on the self
lubricating bearing plate shall be lubricated with additional lubricant furnished by the
manufacturer. White lead, tallow, or other coating shall be removed before the
application of the lubricant.

The coefficient of friction between the self lubricating plate and the steel plates in
contact with them shall not exceed 0.10 when subjected to twice the designed loading.
1060
Material furnished under this specification shall be covered by a type C
certification in accordance with 916.

910.18 Fence, Fittings, and Gates

(a) Farm Field or Woven Wire Fence

This fence shall be in accordance with ASTM A 116. The wire shall be No. 9
gauge (3.8 mm). The design shall be 1047-6-9. The coating shall be class 3. The
method of securing the vertical stays to the horizontal wires may be either of those
1070 shown on the plans. Diagonal braces shall be in accordance with 910.18(b)3.

Material furnished under this specification shall be covered by a type C

certification in accordance with 916.

(b) Steel Fabric Chain Link Fence

This fence shall be in accordance with ASTM A 392 for galvanized steel fabric
or ASTM A 491 for aluminum coated steel fabric. The height of the fabric shall be 48
in. unless otherwise specified. It shall be of No. 9 gauge (3.8 mm) wire woven in
2 in. mesh. The fabric shall be knuckled at the top and bottom selvages when the height
1080 is less than 72 in. Fabric of 72 in. in height or higher shall be knuckled at the top and
shall have the twisted and barbed finish at the bottom. For galvanized fabric, coating
shall be done after weaving and shall be class II, average of two or more specimens no
less than 2.0 oz/sq ft and no less than 1.8 oz/sq ft for any individual specimen. For
aluminum coated fabric, coating shall be class II, 0.40 oz/sq ft minimum.

The fabric shall be furnished with ties required for fastening it to the top and
bottom tension wires. These fastenings may be of aluminum wire or strip of approved
gauge and design, or of galvanized steel wire in accordance with the manufacturer’s
standard design. If galvanized steel wire ties are furnished, the wire shall be no smaller
1090 than No. 12 gauge (2.7 mm). Sufficient ties shall be furnished to provide for attaching

1014
 910.18

to the top and bottom tension wires each 24 in. Fittings necessary to make complete
installation shall be pressed or rolled steel, forged steel, cast steel, or malleable iron.

Steel fabric chain link fence shall be as shown on the plans and as set out above.

Material furnished under this specification shall be covered by a type C

certification in accordance with 916.

1. Tension Wire
1100 Tension wire intended for use on the top or bottom of steel chain link fence or on
the bottom of farm field fence when specified shall be spring coil or crimped steel wire
with an initial diameter of 0.177 ±0.005 of an in., a minimum breaking load of 1,950
lb, and a coating of either zinc or aluminum. The minimum weight (mass) of coating
shall be 0.80 oz/sq ft for galvanized wire and 0.40 oz/sq ft for aluminum coated steel
wire. The weight of aluminum coating shall be determined in accordance with ASTM
A 428.

Material furnished under this specification shall be covered by a type C

certification in accordance with 916.
1110
2. Stretcher Bars, Truss Rods, and Turnbuckles
Stretcher bars shall be 3/16 by 3/4 in. flat bars. These bars, truss rods, turnbuckles,
and necessary fittings shall be of good commercial quality steel, malleable iron, or
wrought iron. They shall be galvanized in accordance with ASTM A 153 after
fabrication. The turnbuckles shall be made from drop forged malleable iron. They shall
have a minimum take up of 4 in. The fittings may be pressed or rolled steel, forged
steel, cast steel, or malleable iron.

3. Braces
1120 Braces shall be made of steel pipe with bolted steel couplings or connections.
Steel pipe shall be in accordance with ASTM F 1083. They shall be galvanized as set
out therein. Fabrication or manipulation that causes minor damage to the galvanized
coating shall be corrected by approved application of a high zinc dust-zinc oxide paint
conforming to the requirements of Federal Specification TT-P-641 type II or Military
Specifications DOD-P-21035. When spray paints are used, two coats shall be applied.
Damaged braces will be rejected.

4. Barbed Wire
Barbed wire used at the top and bottom of farm field fence, or as otherwise
1130 specified, and in accordance with 603 shall be in accordance with applicable
provisions of ASTM A 121. It shall be composed of No. 12 1/2 gauge (2.5 mm)
galvanized or aluminum coated steel wire with four round 14 gauge (2.0 mm) barbs at
approximately 5 in. spacing. The galvanized coating shall be in accordance with class
3 in Table 2. The minimum aluminum coating shall be in accordance with class 60 for
the line wire and class 20 for the barb wire. The weight of coating shall be determined
in accordance with ASTM A 428. The use of aluminum barbs, in accordance with

1015
 910.18

ASTM B 211, alloy 5052-H38, nominal diameter No. 14 gauge (2.03 mm), will be
allowed.

1140 The use of barbed wire with No. 15 1/2 gauge (1.70 mm), high tensile strength
line wires, and No. 16 1/2 gauge (1.47 mm) barbs will be allowed. The barbs shall be
round with four points and spaced at approximately 5 in. intervals. The barbed wire
shall be in accordance with ASTM A 121. The galvanized coating shall be in
accordance with class 3 in Table 2.

Material furnished under this specification shall be covered by a type C

certification in accordance with 916.

5. Bridge Railing Pedestrian Fence

1150 Fence posts and horizontal rails shall be in accordance with 910.13(b)1. The zinc-
coating weight shall not be less than 2 oz/sq ft.

Base plates shall be steel in accordance with ASTM A 709, grade 36 or 50.
Galvanization shall be in accordance with AASHTO M 111. The zinc-coating weight
shall not be less than 2 oz/sq ft.

The chain link fabric shall be coated wire of 9 gauge, with a mesh size of 2 in.
The zinc-coating weight of fabric shall not be less than 2 oz/sq ft. The zinc-coating
weight of brace bands, fabric ties, fence post loop caps, fence post caps, horizontal rail
1160 end cups, tension bands, and tension bars shall not be less than 1.2 oz/sq ft.

Material furnished under this specification shall be covered by a type C

certification in accordance with 916.

(c) Aluminum Fabric Chain Link Fence

This fence shall be in accordance with the applicable requirements of 910.18(b)
except for composition of materials. Requirements for the various component parts of
aluminum fence shall be as shown in Table 1.

1170 Table 1
Additional
Item ASTM Reference Alloy
Information
Alclad 5056 or
Fabric B 211
6061-T94
Barbed Wire - Line B 211 5062-0, H38, 2-strand dia. 0.110 in.
or 6061-T89 4-pt barb. dia. 0.080 in.
Barbs B 211 5052-H38 5 in. space
Alclad 5056 or
Tension Wire B 211 Dia. 0.192 in.; Note 1
6061-T94
Hog Ring Fasteners B 211 6061-T94 Dia. 0.110 in.
Wire Ties B 211 1100-H18 Dia. 0.148 in.
Flat Band Ties B 211 3003-H14 1.2 in. wide; 0.06 in. thick

1016
 910.18

3/4 in. by 1/4 in.; square

Stretcher Bars B 211 6063-T6
edges
Truss and Brace Rods B 211 or B 221 6061-T6 Dia. 3/8 in.
B 26 (cast parts), 356.0-T6
Turn Buckles
B 211 (wrought) 6061-T6
Bands B 221 6063-T6 1/8 in. by 1 in. beveled edge
Bolts B 211 or B 221 2024-T4 ASA B 18.2 hexagon threads
Nuts B 211 or B 221 6061-T6 class 2, 2A, or 2B
1.695 in. ID by 0.078 in.;
Expansion Sleeves B 210 3003-H18 wall drawn type. 6 in. long;
self centering
Post Tops, Rails and Fabricated in permanent
B 26 or B 108 356.0T6
Brace Ends molds or sand castings
Top and Brace Rails B 241 and B 429 6063-T6 1 1/4 in. pipe; Note 2
Barbed Wire Fabricated as for post tops;
B 26 or B 108 356.0T6
Extension Arms sheet castings
Line Posts B 241 and B 429 6063-T6 2 in. pipe; Note 2
Corner Posts B 241 and B 429 6063-T6 2 1/2 in. pipe; Note 2
Note 1: Aluminum coated steel wire in accordance with 910.18(b) may be used.
Note 2: ANSI schedule 40 pipe, plain ends.

(d) Gates
Gate posts sizes shall be as follows:

ANSI Nominal Swing Gate Opening, (inclusive)

Pipe Size Single Gate Double Gate
2 1/2 in. Up to 6 ft Up to 12 ft
3 1/2 in. 7 to 13 ft 13 to 26 ft
6 in. 14 to 18 ft 27 to 36 ft
8 in. 19 to 32 ft 37 to 64 ft

1. Steel Gates
Steel gate posts shall be standard weight, galvanized, steel pipe in accordance with
ASTM F 1083 and furnished with all necessary fittings. Post sizes shall be as set out
above. The gate frames shall be of standard weight, galvanized, steel pipe in
1180 accordance with ASTM A 53; of 1 1/2 in. (38.1 mm) nominal size; and shall have
welded joint or riveted construction using galvanized pressed steel or malleable
fittings. Areas welded after galvanizing shall be coated with a material conforming to
the requirements of Federal Specification TT-P-641, type II or Military Specifications
DOD-P-21035. When spray paints are used, two coats shall be applied. Fabric
coverings for gates shall be in accordance with 910.18(a) or 910.18(b). These gates
shall be furnished with necessary fastenings, hinges, center stops, and locking devices
galvanized after fabrication in accordance with ASTM A 153.

1017
 910.19

2. Aluminum Gates
1190 Aluminum gate post sizes shall be in accordance with 910.18(d). They shall be
ANSI schedule 40 pipe and in accordance with ASTM B 241 or B 429, alloy 6063-
T6. Gate frames shall consist of 1 1/2 in. schedule 40 pipe assembled by welding or
with fittings. Pipe shall be in accordance with ASTM B 241 or B 429, alloy 6063-T6.
Welding material and procedures shall be in accordance with the applicable AWS
provisions. Formed sheet fittings shall be in accordance with ASTM B 209, alloy
6061-T6. Gate hinges may be offset type wrought aluminum, ASTM B 209, alloy
6061-T6, or galvanized malleable iron. Fabric shall be in accordance with 910.18(c).

910.19 Overhead Sign Structures

1200 The complete structure with signs in place shall be able to withstand wind pressure
in accordance with AASHTO Standard Specifications for Structural Supports for
Highway Signs, Luminaires and Traffic Signals. The structure shall be designed to
resist fatigue of the material in accordance with the AASHTO specifications.

All prefabricated structural units shall be packed so that there is no injury or

defacement during transportation to the point of destination.

All bolts, nuts, and washers for bridge bracket assemblies shall be stainless steel
in accordance with ASTM F 738M.
1210
Strain poles for cable span signs shall be in accordance with 922.10(a). Each strain
pole shall include three band-type attachments for span wire clamps. Such attachments
shall be galvanized in accordance with ASTM A 153. Cable shall be in accordance
with 922.10(e)2. Each cable shall include three wire rope clips at each end. Anchor
bolts shall be in accordance with 922.10(c)5. All sign mounting hardware except for
the extruded aluminum bar shall be galvanized in accordance with ASTM A 153.

Gratings for the walkway shall be of aluminum in accordance with ASTM B 221,
alloy 6061-T6 or 6063-T6. Cross bars and bent connecting bars shall be of aluminum
1220 in accordance with ASTM B 221, alloy 6061, 6063 or 3003 conforming to ASTM B
210.

Material furnished under this specification shall be covered by a type C

certification in accordance with 916.

(a) Aluminum Trusses for Overhead Sign Structures, Box Truss and
Dynamic Message Sign Structure Truss
Extruded tubes and other shapes shall be of aluminum in accordance with ASTM
B 221, B 241, or B 429, alloy 6061-T6. All other castings shall be of aluminum in
1230 accordance with ASTM B 26, alloy 356.0-T6. Gusset, flange and stiffner plates shall
be of aluminum in accordance with ASTM B 209, alloy 6061-T6. Plates shall be free
of sharp edges and irregularities.

1018
 910.19

Bolts, nuts, screws, and flat washers shall be passivated type 304 stainless steel.
Bolts and screws shall be in accordance with ASTM A 193, grade B8. Hexagon nuts
and washers shall be in accordance with ASTM A 194, grade 8. High strength bolts,
nuts and washers for chord splice connections, with matching lock nuts having steel
inserts, shall be in accordance with 910.02(g) and shall be galvanized in accordance
with AASHTO M 232, class C or D.
1240
Neoprene pads shall be ultraviolet rated and shall conform to the requirements in
915.04.

Welding material and procedures shall be in accordance with 803 and applicable
AWS provisions.

Certified proof of the qualifications for a minimum of two welders shall be

presented after the contract is awarded and before fabrication is started. This
certification shall be from a commercial or public testing laboratory and qualifications
1250 shall be based on welding of aluminum alloy, 6061-T6 with consumable electrode type
welding using aluminum alloy ER5356 filler material. Welders shall qualify by
passing the requirements set out in 803.04.

Welding shall be checked by visual inspection. Poor welding workmanship shall

be rejected.

Each complete structure shall be free from any misfits or structural deficiencies
prior to shipment.

1260 (b) Steel Overhead Sign Structures, Cantilever, Monotube, Tri-Chord,

Bridge Attached, and End-Supports for Box Truss and Dynamic Message Sign
Structure
End-support members for box truss and dynamic message sign structure shall be
fabricated from constant cross-section tubular steel or extruded steel shapes as
indicated on the drawings. Sections used for end-support columns, diagonal and
horizontal members shall be constant cross-section tubular members in accordance
with ASTM A 53, type E or S, grade B, minimum yield strength of 35,000 psi.
Constant cross-section tubular steel with greater yield strength may be used with
written approval, however, structural dimensions shall remain as shown on the plans.
1270 Sections used for cross support beams shall be constant cross-section extruded W-
shapes in accordance with ASTM A 709, grade 36. Base plates shall be in accordance
with ASTM A 36. Base plates for columns shall develop the full strength of the
columns. Structures shall be galvanized after fabrication in accordance with ASTM A
123.

Support columns for the cantilever structure shall be fabricated from constant
cross-section tubular steel as indicated on the drawings. Column sections shall be in
accordance with ASTM A 53, type E or S, grade B as shown on the plans. Members
shall have minimum yield strength of 35,000 psi. Constant cross-section tubular steel

1019
 910.19

1280 with greater yield strength may be used, with written approval, however, structural
dimensions shall remain as shown on the plans. Base plates shall be in accordance with
ASTM A 36. Base plates shall develop the full strength of the columns.

Cantilever arms shall be either double arms or quadri-chord trusses as shown on

the plans.

Cantilever arms shall be fabricated from octagonal tubular member with 0.14 in./ft
taper and in accordance with ASTM A 595 or ASTM A 572, grade 50. Quadri-chord
arms shall be of constant cross-section tubular members in accordance with ASTM A
1290 53, type E or S, grade B as shown on the plans. Members shall have minimum yield
strength of 35,000 psi. Steel with greater yield strength may be used, with written
approval, however, structural dimensions shall remain as shown on the plans.
Structures shall be galvanized after fabrication in accordance with ASTM A 123.
Plates shall be free of sharp edges and irregularities.

High strength bolts, nuts and washers for chord to column connections, with
matching lock nuts having steel inserts, shall be in accordance with 910.02(g) and shall
be galvanized in accordance with AASHTO M 232, class C or D.

1300 Bolts, U-bolts, nuts, screws, and flat washers shall be passivated type 304 stainless
steel. Bolts and screws shall be in accordance with ASTM A 193, grade B8. Hexagon
nuts and washers shall be in accordance with ASTM A 194, grade 8.

Bridge attached structures shall be fabricated from constant cross-section tubular

steel in accordance with ASTM A 53, type E or S, grade B with a minimum yield
strength of 35,000 psi. Constant-cross section tubular steel with greater yield strength
may be used, with written approval. However, structural dimensions shall remain as
shown on the plans. Structures shall be galvanized after fabrication in accordance with
ASTM A 123.
1310
Tri-chord truss structures shall be made of constant cross-section tubular members
in accordance with ASTM A 53, type E or S, grade B minimum yield strength of
35,000 psi. Monotube structures shall be made of tapered tubular members in
accordance with either ASTM A 595 or ASTM A 573, grade 50. Structures shall be
galvanized after fabrication in accordance with ASTM A 123.

The J hook shall consist of one 3/8-in. steel bar in accordance with ASTM A 307.
It shall be spot welded to the inside of the end-support member. The J hook shall be
hot-dip galvanized prior to welding or in the final assembly with the support column.
1320
Anchor bolts, nuts, and washers shall be in accordance with ASTM F 1554, grade
36. A hexagon nut, leveling nut, and flat washer shall be furnished with each anchor
bolt. Top ends of anchor bolts and associated hardware as shown on the plans, shall
be coated in accordance with ASTM A 153 or be mechanically galvanized and

1020
 910.19

conform to the coating thickness, adherence, and quality requirements of ASTM A

153, class C.

Base plate skirts shall be 10 gauge galvanized steel.

1330 Welding material and procedures shall be in accordance with 711.32 and
applicable AWS provisions.

Welding shall be checked by visual inspection. Poor welding workmanship shall

be rejected.

Each complete structure shall be free from any misfits or structural deficiencies
prior to shipment.

Strain poles shall be anchor bolt type complete with hand-holes and pole top or
1340 cap. They shall meet the requirements set out above for cantilever sign structures. Each
pole is to include three band-type attachments for span wire clamps. The band shall be
from material in accordance with ASTM A 572, grade 50; ASTM A 606; or approved
equal. The bands shall not be of the U-bolt type. The poles shall have maximum
deflections as shown below when loaded 18 in. from the top with a 100 lb load.

Pole Size Deflection

15 in. by 30 in. 0.16 in.
14 in. by 26 in. 0.12 in.

The steel flanges at the center of the cross beam and at the ends of the horizontal
arms shall be fastened to the tapered or straight sections by means of two
circumferential welds. One of the circumferential welds shall weld the outside of the
1350 flange firmly to the tube. The flange connection shall develop fully the strength of the
tubular sections being joined together by means of the flange connections.

Gusset, flange, and base plates shall be in accordance with ASTM A 36 and shall
be galvanized after fabrication in accordance with ASTM A 123. Base plates for
upright poles shall develop the full strength of the poles. Castings for the vertical pole
top and horizontal arm and cap shall be in accordance with ASTM A 126 and shall be
galvanized with a minimum coating of 2 oz/sq ft. Bolts and nuts, except anchor bolts,
shall be in accordance with ASTM F 3125, grade A 325, Type 1. Two nuts for use in
plumbing upright poles shall be furnished with each anchor bolt. Anchor bolts for
1360 overhead steel structures shall be in accordance with 910.19(a). Steel bolts, nuts,
washers, and the top ends of anchor bolts shall be coated in accordance with ASTM A
153 or be mechanically galvanized and conform to the coating thickness, adherence,
and quality requirements of ASTM A 153, class C. Welding shall be in accordance
with 711.32.

Beam clamp details and sign support assemblies shall be galvanized in accordance
with ASTM A 153. Clamps shall be fabricated of high strength, low alloy steel in

1021
 910.20

accordance with ASTM A 242, ASTM A 606, or approved equal. Stainless steel U-
bolts may be used in lieu of the clamps for the attachment of the sign hangers to the
1370 arms of double arm cantilevers. The U-bolts shall be in accordance with 910.19(a) for
stainless steel hardware.

910.20 Steel Bridge Railing Components

Materials for steel bridge railing components shall be in accordance with the
following:

(a) Railing and posts tubing shall be in accordance with ASTM A

500, grade B.

1380 (b) Posts, connection plates, splice bars, base plates, and anchor
channel bars shall be in accordance with ASTM A 709, grade
36. High strength steel posts and connection plates shall be in
accordance with ASTM A 709, grade 50.

(c) Steel bolts, nuts, and cap screws shall be in accordance with
ASTM A 307.

(d) Railing end caps shall be steel castings in accordance with

ASTM A 27, grade 70-36.
1390
(e) Threaded rods, nuts, and washers shall be in accordance with
ASTM F 3125, grade A 325.

(f) Steel washers shall be standard round cut or lock washers, as

shown on the plans.

(g) Cap screws shall be stainless steel in accordance with ASTM A

276, type 304, 305, or 430.

1400 (h) Anchor bolts shall be galvanized and in accordance with

910.02(g)2. Threads may be cut or rolled.

(i) Railing tubing, posts, connection plates, splice bars, base plates,
anchor channel bars, and railing end caps shall be galvanized
after fabrication in accordance with AASHTO M 111.

Bolts, nuts, cap screws, washers, and lock washers shall be

galvanized after fabrication in accordance with AASHTO M
232.
1410
(j) Anchor bolts furnished under this specification shall be covered
by a type A certification in accordance with 916. All other

1022
 910.22

components furnished under this specification shall be covered

by a type C certification in accordance with 916.

910.21 Steel Sheet Piling

Steel sheet piling shall be in accordance with ASTM A 328, ASTM A 1011, or
ASTM A 653.

1420 910.22 Grating for Grated Box End Sections

(a) Type I Grated Box End Sections

Steel pipe and steel tubing for grating shall be in accordance with ASTM A 53,
type E or S, grade B or ASTM A 501, electric-resistance welded or seamless. Such
pipe and tubing shall be galvanized in accordance with ASTM A 123. All other related
hardware shall be galvanized in accordance with ASTM A 153.

Pipe with a 4 in. outside diameter and in accordance with ASTM A 513, type 5,
may be used as an alternate to the 4 in. outside diameter pipe specified. The pipe used
1430 as an alternate shall have a minimum wall thickness of 5/16 in. and a minimum yield
strength of 50,000 psi. Steel tube of 4 in. by 4 in. by 3/8 in. and in accordance with
ASTM A 500, grade B, will also be allowed as an alternate to the 4 in. outside diameter
pipe specified.

(b) Type II Grated Box End Sections

Structural steel grates shall be ASTM A 36 for end sections having widths less
than or equal to 3 ft and shall be ASTM A 572, grade 50 for widths greater than 3 ft.

Pipe, tubing, tube, and grates furnished as described herein shall be covered by a
1440 type B certification in accordance with 916. The typical values of the tests listed below
shall be provided on the type B certification.

Welding, as shown on the plans, shall be in accordance with 711.32 and AWS
D1.1.

Test ASTM
Tensile Strength, Yield Strength, Outside Diameter, A 53, type E or S,
Wall Thickness, Galvanization Coating Thickness grade B
Tensile Strength, Yield Strength, Wall Thickness,
Outside Diameter (Round) or Unit Weight A 501
(Square/Rectangular), Galvanization Coating Thickness
Tensile Strength, Yield Strength, Bar Dimensions A 36
Tensile Strength, Yield Strength, Bar Dimensions A 572, grade 50
Wall Thickness, Outside Diameter, Yield Strength A 513, type 5
Tensile Strength, Yield Strength, Tube Dimensions,
A 500, grade B
Wall Thickness

1023
 911.01

SECTION 911 – WOOD MATERIALS

911.01 Untreated Lumber

(a) General
Untreated lumber is a saw mill product which may be further manufactured by
sawing, resawing, passing lengthwise through a standard planing machine, drying,
cross cutting to length, and machining but is not treated with preservatives.

10 1. Boards
Yard lumber less than 2 in. thick and more than 1 in. wide is a board.

2. Dimension Lumber
Lumber from 2 in. to but not including 5 in. thick and 2 in. or more wide is
dimension lumber.

3. Structural Lumber
Lumber that is 2 in. or more thick and 4 in. or more wide intended for use where
working stresses are required is structural lumber. The grading of structural lumber is
20 based on the strength and use of the entire piece. The grade of lumber shall be as shown
on the plans or as otherwise specified.

4. Sawn Timbers
Solid sawn pieces with a nominal dimension of 5 in. or more in the least dimension
is timber. Timbers may be classified as beams, stringers, posts, caps, sills, girders, or
purlins. Timber for structural purposes shall be no less than 6 in. in width or thickness.
Dimensions and grade of lumber shall be as shown on the plans or as otherwise
specified.

30 5. Timbers, Round
These timbers are used in the original round form, such as poles, posts, and mine
timbers. Round timbers, such as posts and poles, shall be entirely peeled. All limbs
and knots shall be trimmed flush. Unless otherwise approved or shown on the plans,
no minus tolerances will be allowed on the specified diameter.

6. Yard Lumber
Lumber of all sizes and patterns that is intended for general building purposes is
yard lumber. The grading of yard lumber is based on the intended use of the particular
grade and is applied to each piece with reference to its size and length when graded
40 without consideration to further manufacture.

7. Surfaced or Dressed Lumber

This is lumber that is dressed by running it through a planer.

8. Rough Sawn Lumber

This is lumber that has been sawn, edged, and trimmed, but not dressed.

1024
 911.01

(b) Species and Grade

Only Coastal Douglas-fir, red oak group, redwood, southern yellow pine, and
50 white oak group will be allowed, except as set out elsewhere herein. Redwood lumber
shall not be used in bridges where it is a permanent part of the structure.

Except as otherwise provided, all lumber furnished under these specifications

shall be of the species and grades specified.

Softwood lumber shall be graded in accordance with grade rules which conform
with the basic provisions of the American Softwood Lumber Standard PS 20. It shall
be grade marked and shall be in accordance with the applicable grading rules or
specifications of the following agencies for the species indicated.
60
Coastal Douglas-fir – West Coast Lumber Inspection Bureau
Southern Yellow Pine – Southern Pine Inspection Bureau
Redwood – Redwood Inspection Service

Red and White Oak Group, Hardwood Lumber, shall be grade marked and shall
be in accordance with the applicable grading rules of the National Hardwood Lumber
Association.

If lumber is not to be graded as provided above, it may be green or seasoned, but

70 shall be sound, free from excessive wane, unsound loose or hollow knots, knot holes,
shakes, or other defects which would impair strength or durability for the use intended.
Pin holes, shot holes, or occasional grub holes in oak are not classified as defects. If
approved and if the proposed use of the material is stated on the purchase order, grade
markings may not be required on native red or white oak groups furnished from local
sources or on emergency orders or small orders of Coastal Douglas-fir and southern
yellow pine.

Lumber for temporary bridges or other temporary structures may be of any species
and grade which meets approval.
80
(c) Inspection
All lumber regardless of grade markings may be inspected for grades and quality
at the point of origin or final destination. If, during inspection of a lot of lumber, it
becomes apparent that the quantity of rejections exceed 20%, the entire lot may be
rejected.

(d) Tolerances
Tolerances for rough sawn, or dressed lumber shall be in accordance with the
National Lumber Grades Authority Grade Rule standards for each species.
90
(e) Untreated Piling
Untreated piles shall be in accordance with ASTM D 25 and the following. All

1025
 911.02

piling shall be cut from white or red oak, dense southern yellow pine, fir, or cypress,
preferred in the order listed. They may be of other species, subject to approval, which
can withstand driving without showing excessive brooming or splitting.

The butts and tips shall be sawn square with the axis of the pile. Alternatively, the
tips may be tapered to a point of not less than 16 sq in. with the tip so formed that the
centerline of the pile passes through the tip.
100
Unless otherwise specified, all piles shall be clean-peeled before driving. No strip
of the inner bark remaining on the pile shall be more than 3/4 in. wide. There shall be
at least 1 in. of bark free surface between two such strips. Not less than 80% of the
surface shall be clean wood. All knots shall be trimmed flush with the body of the pile.

After peeling, piles shall have diameters as indicated below unless otherwise
approved or required.

Diameter, inches
Length of Pile
Tip, min. 3 in. from Butt, min. Butt, max.
Less than 20 ft 8 11 20
20 ft and less than 40 ft 8 12 20
40 ft and less than 60 ft 7 13 20
60 ft and more 6 13 20

110 911.02 Treated Lumber

(a) General
Treated lumber shall be preservative-treated by pressure processes in accordance
with AWPA Standards T1 and U1 or AASHTO M 133. Other AWPA Standards
applying to specific items are set out in 911.02(b), 911.02(c), 911.02(e), and 911.02(g).
Lumber to be treated shall be in accordance with 911.01, except as modified in
911.02(b), 911.02(c), and 911.02(e). The lumber may be inspected at the treating plant.
Preservatives shall be in accordance with 911.02(h). Wherever ammoniacal or alkaline
copper quat azole or wherever copper preservative is utilized, only stainless steel or
120 hot dipped galvanized fasteners and hardware shall be used. Galvanizing for fasteners
shall be in accordance with ASTM A 153. Galvanizing for hardware shall be in
accordance with ASTM A 653, coating designation G185. Fasteners and hardware in
contact with one another shall be of the same base material and coating if applicable,
and shall be used consistently throughout the treated wood article or structure.

(b) Bridge Lumber

This shall be southern yellow pine or Coastal Douglas-fir. There shall be no
heartwood requirements and the amount of sapwood shall not be limited. Wane will
not be allowed on any treated plank for flooring and may be excluded elsewhere when
130 so specified. Lumber for bridges shall be treated with a preservative in accordance
with applicable provisions of AWPA Standards T1 and U1, Commodity Specification
A: Sawn Products, use category UC4B.

1026
 911.02

(c) Piling
Timber piling, before treatment, shall be in accordance with 911.01(e) except
piles shall be southern yellow pine or Coastal Douglas-fir. The outer and inner bark
shall be removed before treatment. Unless otherwise specified, piling shall be treated
with a preservative in accordance with the applicable requirements of AWPA
Standards T1 and U1, Commodity Specification E: Round Timber Piling, use category
140 UC4C.

(d) Blank

(e) Sign Posts

Wood sign posts shall be cut from southern yellow pine, Coastal Douglas-fir, or
other species as specified. Posts shall be surfaced four sides.

Dimensions shall be in accordance with the plans. There will be a length tolerance
of ±2 in. Both butt and top ends shall be sawn square. All outer and inner bark shall
150 be removed. One way sweep, not exceeding 1 in. between the top and butt, will be
acceptable. Short crooks will not be allowed.

The posts shall be sound timber. No splits, shakes, excessive cracks, loose
decayed or hollow knots will be allowed. Occasional pin, shot, or grub holes in oak,
or bird pecks in other timbers, will not be considered defects. All posts shall be entirely
treated with preservatives in accordance with all applicable provisions of AWPA
Standards T1 and U1, Commodity Specification A: Sawn Products, use category
UC4A.

160 (f) Sawn Timber Posts and Blockouts

The requirements for posts and blockouts prior to treatment shall be in accordance
with AASHTO M 168 and as modified below.

1. Species and Grades

Timber posts shall be of the species listed, and shall be in accordance with the
grading requirements specified in Table A. Timber blockouts shall be of the species
listed, and shall be in accordance with the grading requirements specified in Table B.
Timber posts and blockouts shall have the cross section and length dimensions as
shown on the plans.
170
Table A
Special and Grading Requirements for Sawn Timber Guardrail Posts
Species Posts and Timbers Grade Grading Rules Agenciesa
Softwoods
Coastal Douglas-fir No. 1 or better WWPA or WCLIB
Southern Pine No. 1 or better SPIB
a
WWPA (Western Wood Products Assoc.); WCLIB (West Coast Lumber
Inspection Bureau); and SPIB (Southern Pine Inspection Bureau).

1027
 911.02

Posts and blockouts shall be graded in accordance with grading rules based on
principles and methods specified in ASTM D 245. Where there is a conflict between
AWPA and ASTM standards, AWPA will prevail. Where there is a conflict between
either AWPA or ASTM standards and this specification, this specification will prevail.

All material shall show the approved grading agency stamp indicating mill origin,
species, and grade.
180
Table B
Species and Grading Requirements for Sawn Timber Guardrail Blockouts
Species Posts and Timbers Grade Grading Rules Agenciesa
Softwoods
Coastal Douglas-fir No. 2 or better WWPA or WCLIB
Southern Pine No. 2 or better SPIB
a
WWPA (Western Wood Products Assoc.); WCLIB (West Coast Lumber
Inspection Bureau); and SPIB (Southern Pine Inspection Bureau).

2. General Requirements
Posts and blockouts shall be in accordance with the following general
requirements.

a. Decay
Posts and blockouts shall be free from decay before treatment.

190 b. Unsound Wood

Posts containing unsound wood will be rejected. Blockouts may contain small
spots of unsound wood provided they are well scattered.

c. Grounds for Rejection

Posts and blockouts shall be sound. No sapwood rot will be allowed. Ring shake
will not be allowed. Grub holes in the butt, 1/2 in. or less in diameter, are not
considered defects. Posts or blockouts containing ant holes will not be accepted. Any
post or blockout which contains any defect which is detrimental to the post or blockout
will be rejected.
200
d. Dimensional Tolerances
Posts and blockouts shall be sawn square to within -1/2 in. of the specified cross-
sectional dimensions. A tolerance of ±2 in. will be allowed on the specific length of
the posts. A tolerance of -1/2 in. will be allowed on the specified length of the
blockouts.

3. Pressure Treating Posts and Blockouts

Pressure treating posts and blockouts shall be in accordance with the following
requirements and AWPA Standards T1 and U1, Commodity Specification A: Sawn
210 Products, use category UC4B.

1028
 911.02

a. Machining
Posts and blockouts shall be sawn to their final shape and holes bored prior to
treatment.

b. Inspection Before Treatment

The treater shall be responsible for ensuring that the material has the required
approved grading agency stamp before treatment is commenced. The stamp or
marking shall be applied on a wide face at the trimmed end. The stamp shall be applied
220 such that it remains readable after treating. Material that has been air dried or kiln dried
shall be inspected for moisture content in accordance with AWPA Standard M2.

c. Preservative Treatment
All posts and blockouts shall be treated with a preservative as specified herein.

d. Material for Preservative Treatments

The preservative used for treating posts and blockouts shall be in accordance with
the appropriate AWPA or AASHTO Standards.

230 e. Treatment Methods

Timber for guardrail posts and blockouts shall be treated to be in accordance with
AWPA Standard T1, and the requirements specified herein.

f. Sorting and Spacing

The material in a charge shall consist of the same species or consist of species
within one group shown in table C. The material shall have similar moisture content
and be of similar form and size. Blockouts and posts may be treated in the same charge.

Table C
Species Groupings for Treatment in Same Charge
Group Species
A Southern Pine
B Coastal Douglas-fir
240
g. Conditioning
Conditioning shall be in accordance with AWPA Standard T1.

h. Inspection During Treatment

The treater shall determine that the preservatives used are in accordance with the
requirements herein. The minimum frequency of the preservation analysis shall be
each charge for the occasional single charge inspected. The minimum frequency for
consecutive treatments from the same working tank shall be the first and at least one
of every five additional charges, selected at random. Preservative samples shall be
250 taken as appropriate so as to be representative of the solution in the treating cylinder.

1029
 911.02

i. Retentions
The minimum retentions shall be in accordance with AWPA Standards T1 and
U1.

j. Penetration
The penetration requirements shall be in accordance with AWPA Standard T1,
table B6.

260 k. Inspection After Treatment

Following treatment, the charge shall be physically inspected in accordance with
AWPA Standard M2, section 4. All treated material shall bear the quality mark of the
inspection agency. All inspections shall be completed at no cost to the Department.
All non-compliant material shall be removed from the remaining acceptable material
before shipment.

l. Branding
All post and blockouts shall be clearly and permanently branded or marked on
one of the wide faces. The brand shall be within 12 in. of the top of the post. The brand
270 shall show the treater’s identification, the plant designation, and the year of treatment.
The month may also be included. The brand shall also show the species, the
preservative type, and retention, all in accordance with AWPA Standard M6.

m. Conformance
The treating plant supplying the material shall be responsible for and will be
required to supply a certificate indicating the species, grade, preservative type,
retention, year, and name of treater. The certificate shall also include all of the other
information which is listed in AWPA Standard M2, section 6.2.

280 n. Records
Copies of treating records, analysis records, and other records which may be
necessary to determine accordance with specifications shall be made available to
Department personnel or their designated representatives upon their request. Required
information shall be that which is listed in AWPA Standard M2, section 6.2. These
records shall be retained by the treating plant for five years from the date of material
shipment.

o. Independent Inspections
The Department may inspect the material or call for a non-Departmental
290 inspection to verify that it is in accordance with all specifications.

4. Field Treatment of Posts and Blockouts

Cuts, holes, or injuries to the surface of posts and blockouts which occur after
pressure treatment shall be field-treated with copper naphthenate in accordance with
AWPA Standard M4.

1030
 911.02

5. Rejection for Degrade After Treatment

Guardrail posts or blockouts developing the following degrade prior to installation
will be rejected regardless of prior approvals.
300
a. single checks greater than 3 in. deep or checks opposite
each other totaling more than 3 in. deep, measured with
a probe not more than 1/16 in. thick;

b. single checks 1/4 in. wide or wider measured at the

widest point, and extending more than 1/3 of the length
of the post or blockout;

c. single checks greater than 3/8 in. wide measured at the

310 widest point;

d. splits greater than 3 in. long which are in the plane of

the bolt hole;

e. crooks or bows exceeding 1 in. per 10 ft length; and all

twists;

f. combinations of checks, splits, or shakes which are

otherwise in accordance with the specifications but
320 which may cause the post or blockout to separate into
several pieces.

(g) Recreational Applications

Lumber and timber that will be used in facilities where human contact will occur,
such as handrails, pedestrian facilities including decking and picnic tables, shall be
treated in accordance with AWPA Standards U1 or UC4A, or AASHTO M 133.
Material furnished under this specification shall be covered by a type C certification
in accordance with 916.

330 (h) Preservatives

Preservatives shall be in accordance with current AWPA or AASHTO M 133
Standards as modified by EPA regulation.

Waterborne preservatives shall be in accordance with AASHTO M 133 or AWPA

Standards.

1031
 912.01

SECTION 912 – CONCRETE CURING MATERIALS AND ADMIXTURES

912.01 Curing Materials

Curing materials shall be in accordance with the following requirements.

(a) Burlap Cloth made from Jute or Kenaf

This material shall be new, or reclaimed and thoroughly vacuum cleaned burlap.
Burlap from sugar, salt, or fertilizer bags shall not be used. The burlap shall weigh no
less than 10 oz/sq yd and shall be in strips of not less than 40 in. or more than 120 in.
10 wide and no less than 2 ft longer than the width of the pavement being cured.

(b) Waterproof Paper Blankets

These blankets shall be in accordance with ASTM C 171.

(c) White Polyethylene Sheeting, Film

The sheeting shall be in accordance with ASTM C 171.

(d) White Burlap Polyethylene Sheet

These sheets shall be in accordance with ASTM C 171.
20
(e) Liquid Membrane Forming Compounds
These compounds shall be in accordance with ASTM C 309, type 2, except the
drying time requirement will be determined on a glass surface.

(f) Polyethylene Film

The sheeting shall be in accordance with ASTM C 171.

912.02 Curing-Sealing Materials

Curing-sealing materials are single application curing and sealing products for
30 portland cement concrete.

A list of approved Curing-Sealing Materials will be maintained by the

Department. The list will identify pre-approved products, specify the manufacturer
and product designation, and include application instructions.

In order to have a product added to the list of approved Curing-Sealing Materials,

the manufacturer shall furnish to the Office of Materials Management a type A
certification in accordance with 916. Such certification shall state that the product is
in accordance with the requirements of NCHRP 244 Series IV Southern Climate
40 Weathering Test, and ASTM C 309, type 1.

(a) The certification shall be in accordance with the applicable

requirements of 916, and shall include a dated test report. The
test report shall substantiate full compliance with the
specifications and establish when the testing was started. Test

1032
 912.03

reports older than seven years on January 1 of the approval year

will not be accepted.

(b) If irregularities are found in the results required for such

50 certification, copies of the original data may be required prior
to reconsideration of the certification.

(c) Tests shall be conducted by a state highway agency testing

laboratory or a testing laboratory regularly inspected by CCRL.
Proof of such inspection shall be furnished with the test report.

After a product has been approved, it will be added to the list of approved or
Prequalified Materials. The product will remain on the list until test results on file are
seven years old, provided that there are no changes in raw materials, formulation, or
60 procedures for manufacture. Results more than seven years old or products in which
there has been a change in raw materials, formulation, or procedures for manufacture
shall be recertified in order to remain on the list.

A curing-sealing material that performs unsatisfactorily in the field will be

removed from the approved list.

912.03 Admixtures for Use in Concrete

Admixtures for use in PCC shall be selected from the Department’s list of
approved Admixtures for PCC. An admixture may be added to the approved list by
70 completing the requirements in ITM 806, Procedure D. Admixtures containing
chloride added as an ingredient of manufacture are unacceptable.

(a) Air Entraining Admixtures

Air entraining admixtures are materials to be added to PCC mixtures at the mixer
for the purpose of entraining air.

(b) Chemical Admixtures for Concrete

Chemical admixtures are materials to be added to PCC mixtures at the mixer for
the purpose or purposes indicated below.
80
1. Type A
Type A is a water reducing admixture that reduces the quantity of mixing water
required to produce concrete of a given consistency.

2. Type B
Type B is a retarding admixture that retards the setting of concrete.

3. Type C
Type C is an accelerating admixture that accelerates the setting and early strength
90 development of concrete.

1033
 912.03

4. Type D
Type D is a water reducing and retarding admixture that reduces the quantity of
mixing water required to produce concrete of a given consistency and retards the
setting of concrete.

5. Type E
Type E is a water reducing and accelerating admixture that reduces the quantity
of mixing water required to produce concrete of a given consistency and accelerates
100 the setting and early strength development of concrete.

6. Type F
Type F is a high range water reducing admixture, HRWR, that reduces the
quantity of mixing water required to produce concrete of a given consistency by 12%
or greater.

7. Type G
Type G is a high range water reducing and retarding admixture, HRWRR, that
reduces the quantity of mixing water required to produce concrete of a given
110 consistency by 12% or greater, and retards the setting of concrete.

8. High Range Water Reducing Admixture System

HRWR admixture system is a combination of admixtures that act as a type F
mixture within a concrete mixture. The system consists of chemical admixtures and
an air entraining admixture. One of the components shall be a type F admixture.
Components shall be in accordance with 912.03 for their respective types.

9. High Range Water Reducing and Retarding Admixture System

HRWRR admixture system is a combination of admixtures that act as a type G
120 admixture within a concrete mixture. The system consists of chemical admixtures and
an air entraining admixture. One of the components shall be a type F or a type G
admixture. One of the components shall retard the setting of the concrete. Components
shall be in accordance with 912.03 for their respective types.

(c) Test Report

Testing shall be performed by a recognized laboratory in accordance with
ITM 806.

1. Air entraining admixtures shall be in accordance with

130 AASHTO M 154.

2. Chemical admixtures shall be in accordance with

AASHTO M 194 for their respective types.

3. Test reports shall not be more than five years old on

January 1 of the approval year. New submittals of test
reports more than five years old will be accepted, if all

1034
 912.05

subsequent five year limited retest reports, are submitted.

Subsequent limited retest results shall comply with the
140 dating and age requirements specified above and shall
include the following tests as a minimum requirement for
compliance:

a. infrared analysis, residue by oven drying, and specific gravity;

b. water content and time of setting;
c. flexural strength at 3, 7, and 28 days;
d. relative durability.

912.04 Latex Modifiers

150 The latex modifiers are an admixture to be added to the concrete mixture at the
continuous mixer. The latex shall be one of the latex modifiers in the list of approved
Admixtures for Portland Cement Concrete.

The formulated latex admixture shall be a non-toxic, film forming, polymeric

emulsion in water to which all stabilizers have been added at the point of manufacture
and shall be homogeneous and uniform in composition. A type B certification shall be
furnished in accordance with 916.

Physical properties of the latex modifier shall be in accordance with the following:
160
Polymer Type ................................................ Styrene Butadiene
Stabilizers ......................................... Anionic and Nonionic Surfactants
Antifoaming Agent ........................................ Polydimethylsiloxane
Percent Solids, % by Mass ............................ 46.0 minimum
Mass Per Gallon ............................................ 8.4 lb at minimum
pH (as shipped) .............................................. 9.0 - 11.0
Freeze/Thaw Stability .................................... 5 Cycles, -15° to 25°C
Shelf Life ....................................................... 2 Years, minimum
Color .............................................................. White
170
912.05 Foaming Agent
Foaming agents used in making preformed foam for cellular concrete grout shall
be in accordance with ASTM C 869. A type C certification shall be furnished in
accordance with 916.

1035
 913.01

SECTION 913 – SOIL TREATMENT MATERIALS

913.01 Water
Water used in mixing or curing shall be reasonably clean and free of oil, salt, acid,
alkali, sugar, vegetable, or other substance injurious to the finished product. The
following water properties will be tested in accordance with the test methods listed in
a table below. The results of the water properties shall be as follows:

Property Test Method Result

pH ASTM D 1293 6 to 8
Chloride Ions ASTM D 512 less than 300 ppm
Sulfate (SO4) ASTM D 516 less than 500 ppm
Total Solids ASTM C 1603 less than 1,500 ppm

10 In addition, water containing algae will be unacceptable for use in concrete. Water
known to be of potable quality may be used without test. Where the source of water is
relatively shallow, the intake shall be so enclosed as to exclude silt, mud, grass, or
other foreign materials.

913.02 Calcium Chloride

Calcium chloride shall be in accordance with AASHTO M 144 and shall be:

(a) Type S, grade 1, class A

(b) Type S, grade 3, class A or B
20 (c) Type L

913.03 Sodium Chloride

Sodium chloride shall be in accordance with AASHTO M 143. Rock salt shall be
used for de-icing purposes. Either rock salt or evaporated salt may be used for
stabilization.

913.04 Lime
Lime shall be a hydrated lime when used in masonry or a hydrated lime,
quicklime, or lime by-product when used for soil modification.
30
(a) Hydrated Lime for Masonry
Hydrated lime used in masonry shall be in accordance with ASTM C 207, Type N.

(b) Lime for Soil Modification

Hydrated lime, quicklime, or lime by-product used for soil modification shall be
approved in accordance with ITM 806, Procedure P and shall meet the following
requirements.

1. Hydrated Lime and Quicklime

40 Hydrated lime and quicklime shall be in accordance with AASHTO M 216.

1036
 914.01

2. Lime By-Products
Lime by-products shall be hydrated lime or quicklime by-products in accordance
with ASTM C 25 having the following requirements.

a. The lime by-products shall contain a minimum of 60%

total calcium and magnesium oxides (non-volatile
basis).

50 b. Available calcium hydroxide plus magnesium oxide

calculated as calcium hydroxide shall be a minimum of
30%.

c. Soluble sulfate shall not be more than 5%.

d. Sieve analysis shall be performed in accordance with

ASTM C 110. The lime by-products gradation shall be
as follows:

Sieve % Retained (Max.)

No. 4 (4.75 mm) 5
No. 30 (600 µm) 10
No. 100 (150 µm) 25
60
913.05 Blank

913.06 Bentonite Grout

Bentonite grout shall be untreated, sodium bentonite, finely ground with not more
than 5% retained on the No. 200 (75 µm) sieve. It shall be free of lumps and materials
that can prevent mixing into a fluid free of lumps of unmixed bentonite. Calcium
bentonite will not be accepted.

The grout shall be proportioned at 2 lbs of pure bentonite powder per gal. of
70 potable water. Deviations from these proportions shall be subject to approval.

SECTION 914 – ROADSIDE DEVELOPMENT MATERIALS

914.01 Special Topsoil for Roadside Development

This topsoil shall consist of loose friable soil, free of refuse, stumps, large roots,
rocks over 2 in. in diameter, brush, weeds, or other material which would be
detrimental to the proper development of vegetative growth. It shall be capable of
supporting normal vegetation as demonstrated by the growth of healthy vegetation on
it. It shall not be taken from a source known to contain any of the noxious weeds
defined as such in the Indiana State Seed Law, IC 15-4-1.
10

1037
 914.02

Topsoil shall have a pH value of 6.2 to 7.4. Testing for pH value shall be
performed in accordance with AASHTO T 289. Agricultural limestone may be added
to topsoil in order to raise the pH to meet specification requirements. The addition of
agriculture limestone shall be determined based on tests performed by a laboratory
approved by the Office of Geotechnical Services. Topsoil shall not be incorporated
into the work until it is approved.

914.02 Temporary Seed

Temporary seed will be approved for use by visual inspection of the Engineer.
20 Temporary seed may be purchased from any commercial source provided the seed’s
package is clearly marked and labeled by the manufacturer as to its content and weight.

914.03 Fertilizer
Fertilizer shall be standard commercial fertilizer with an analysis of 12-12-12.

Tests will not be required, but fertilizer standards shall be governed by the rulings
of the Indiana State Seed Commissioner.

914.04 Grass and Legume Seed

30 Grass and legume seed in the quantities and varieties required shall be furnished
full-tagged and delivered in properly designated packages or bags as directed. Seeds
shall be in accordance with the following requirements.

Seed of warm season grasses, forbs, or aquatic species shall be delivered to the
project site individually packaged by species. Warm season grass and forb seed shall
be purchased from lots for which test results are provided. Testing will not be required
for aquatic species. When normal germination testing is not practical for forb species,
a tetrazolium test shall be conducted to determine seed viability.

40 Seeds shall contain none of the noxious weeds listed herein or any that are listed
in the Acts of the General Assembly of the State. Noxious weeds are Canada Thistle,
Field Bindweed, Johnson Grass, Perennial Peppergrass, Perennial Sowthistle, Quack
Grass, Russian Knapweed, and Wild Garlic.

Clover shall be free from dodder with no tolerance allowed. Lespedeza will be
allowed no more than 90 dodder/lb and 45 giant foxtail per lb.

Requirements noted above are minimum and trade allowances will not be
allowed.
50
Seed shall be purchased from sources of supply that have been sampled, tested,
and reported by the State Seed Commissioner, Purdue University, West Lafayette,
Indiana, and found to be satisfactory. Seed of warm season grasses shall be tested by
the State Seed Commissioner or an independent laboratory. Seed of forbs shall be
tested by an independent laboratory. Test results by independent laboratories shall be
signed by a Registered Seed Technologist. Test results shall be submitted to the State

1038
 914.04

Seed Commissioner, and a copy to the Office of Materials Management. This report
is required before seed is sown. Such test report shall be no more than nine months old
at the time seed is used and the use of the seed shall be subject to approval.
60
Seed which has been tested by the State Seed Commissioner may be used without
further testing provided each bag of seed bears a tag showing the various seeds and
their respective percentage in the bag. Each bag of seed used on the contract shall be
accompanied by a copy of the State Seed Commissioner’s letter for acceptance in
accordance with 916.02(e).

Seed which meets the weed seed tolerance, but does not comply with the purity
or germination requirements, or both, may be used provided the percentage of purity
or the percentage of germination is not more than 10% below the minimum specified
70 and that the result obtained from the following formulae does not exceed the maximum
percent of weed seeds allowed.

W x P x G = M or less

P = Minimum Specified Purity

Actual Purity

G = Minimum Specified Germination

Actual Germination
80
W = Actual percent of weed seeds
P = Purity Factor
G = Germination Factor
M = Maximum percent of weed seeds allowed.

If such seeds are selected for use, the amount to be used shall be increased in
accordance with the following formula except the amount used shall not be less than
that specified.

90 Amount to be used = Amount specified x P x G

Percentages of Weed Seed Content

Variety % (not more than)
Alfalfa Medicago sativa 0.5
Alkaligrass Puccinellia distans 0.5
Alsike Clover Trifolium hybridum 0.5
Birdsfoot Trefoil Lotus corniculatus 0.5
Chewings Fescue Festuca rubra (var. fallax) 0.5
Creeping Bentgrass Agrostis stolonifera 0.5
Creeping Red Fescue Festuca rubra spp. rubra 0.5
Fowl Manna Grass Glyceria striata 1
Kentucky Bluegrass Poa pratensis 0.5

1039
914.04

Korean Lespedeza Lespedeza stipulacea 0.75

Sericea Lespedeza Lespedeza sericea 0.75
Ladino Clover Trifolium repens (var. latum) 0.5
Lemons Alkali Grass Puccinellia airoides (Lemons) 0.5
Orchard Grass Dactylis glomerata 0.5
Perennial Rye Grass Lolium perenne 0.5
Red Clover Trifolium pratense 0.5
Red Fescue Festuca rubra 0.5
Red top Agrostis gigantea 0.75
Rice Cut Grass Leersia oryzoides 1
Rough Stalked Meadowgrass Poa trivialis 0.5
Rye, Agricultural Secale cereale 0.5
Rye, Annual Lolium multiforum 0.5
Sheeps Fescue Festuca orina 0.5
Smooth Brome Grass Bromus inermis 0.95
Sweet Clover-white (Scarified) Melilotus alba 0.5
Sweet Clover-yellow (Scarified) Melilotus officinalis 0.5
Tall Fescue Festuca arundinacea 0.5
Timothy Phleum pratense 0.5
Virginia Wild Rye Elymus virginicus 1
White Dutch Clover Trifolium repens 0.75

Percentages of Purity
Variety % (not less than)
Alfalfa Medicago sativa 99
Alkaligrass Puccinellia distans 90
Alsike Clover Trifolium hybridum 97
Birdsfoot Trefoil Lotus corniculatus 98
Chewings Fescue Festuca rubra (var. fallax) 97
Creeping Bentgrass Agrostis stolonifera 98
Creeping Red Fescue Festuca rubra spp. rubra 95
Fowl Manna Grass Glyceria striata 95
Kentucky Bluegrass Poa pratensis 85
Korean Lespedeza Lespedeza stipulacea 98
Sericea Lespedeza Lespedeza sericea 98
Ladino Clover Trifolium repens (var. latum) 98
Lemons Alkali Grass Puccinellia airoides (Lemons) 85
Orchard Grass Dactylis glomerata 85
Perennial Rye Grass Lolium perenne 95
Red Clover Trifolium pratense 98
Red Fescue Festuca rubra 95
Red top Agrostis gigantea 90
Rice Cut Grass Leersia oryzoides 98
Rough Stalked Meadowgrass Poa trivialis 85
1040
 914.04

Rye, Agricultural Secale cereale 99

Rye, Annual Lolium multiforum 95
Sheeps Fescue Festuca orina 97
Smooth Brome Grass Bromus inermis 85
Sweet Clover-white (Scarified) Melilotus alba 98
Sweet Clover-yellow (Scarified) Melilotus officinalis 98
Tall Fescue Festuca arundinacea 98
Timothy Phleum pratense 90
Virginia Wild Rye Elymus virginicus 90
White Dutch Clover Trifolium repens 97

Percentages Actual Germination

Variety % (not less than)
Alfalfa Medicago sativa 85*
Alkaligrass Puccinellia distans 80
Alsike Clover Trifolium hybridum 85*
Birdsfoot Trefoil Lotus corniculatus 80*
Chewings Fescue Festuca rubra (var. fallax) 75
Creeping Bentgrass Agrostis stolonifera 85
Creeping Red Fescue Festuca rubra spp. rubra 80
Fowl Manna Grass Glyceria striata 90
Kentucky Bluegrass Poa pratensis 80
Korean Lespedeza Lespedeza stipulacea 80*
Sericea Lespedeza Lespedeza sericea 80*
Ladino Clover Trifolium repens (var. latum) 85*
Lemons Alkali Grass Puccinellia airoides (Lemons) 80
Orchard Grass Dactylis glomerata 80
Perennial Rye Grass Lolium perenne 90
Red Clover Trifolium pratense 90*
Red Fescue Festuca rubra 85
Red top Agrostis gigantea 80
Rice Cut Grass Leersia oryzoides 80
Rough Stalked Meadowgrass Poa trivialis 75
Rye, Agricultural Secale cereale 80
Rye, Annual Lolium multiforum 90
Sheeps Fescue Festuca orina 75
Smooth Brome Grass Bromus inermis 80
Sweet Clover-white (Scarified) Melilotus alba 85*
Sweet Clover-yellow (Scarified) Melilotus officinalis 85*
Tall Fescue Festuca arundinacea 85
Timothy Phleum pratense 85
Virginia Wild Rye Elymus virginicus 70
White Dutch Clover Trifolium repens 90*
* including not more than 25% hard seeds.

1041
 914.05

For all other seed indicated to be used but not shown in the charts above, that seed
shall be placed at the indicated rate and be 100% pure live seed.

100 914.05 Mulch

(a) Mulch for Seeding

Mulch for seeding may consist of straw; excelsior mulch; wood cellulose fiber
mulch; excelsior blanket; paper mat; or straw mat. All mulch shall be reasonably free
from primary noxious weeds in accordance with 914.04.

1. Excelsior Mulch
Excelsior mulch shall consist of wood fibers cut from sound green timber. The
average length of the fibers shall be 4 in. to 6 in. The cut shall be made in such a
110 manner as to provide maximum strength of fiber, but at a slight angle to the natural
grain of the wood so as to cause splintering of the fibers when weathering in order to
provide adherence to each other and to the soil.

2. Wood Cellulose Fiber

Wood cellulose fiber mulch shall be made from wood chip particles manufactured
particularly for discharging uniformly on the ground surface when disbursed by a
hydraulic water sprayer. It shall remain in uniform suspension in water under agitation
and blend with grass seed, and fertilizer when allowed, to form a homogeneous slurry.
The mulch fibers shall intertwine physically to form a strong moisture holding mat on
120 the ground surface. The mulch shall be heat processed so as to contain no germination
or growth inhibiting factors. It shall be non-toxic and colored green. The percent of
moisture content shall be determined in accordance with 621.14(c), except material
containing more than 15% will be rejected. The ash content shall not exceed 1.5%.
One hundred grams of oven dried material saturated in water, drained, and weighed
shall hold a minimum of 1,000 grams of water.

3. Excelsior Blanket
Excelsior blanket shall consist of a machine produced mat of wood excelsior with
80% of the fibers to be 6 in. or longer. The wood from which the excelsior is cut shall
130 be properly cured to achieve curled and barbed fibers. The blanket shall have a
consistent thickness, with the fibers evenly distributed over the entire area of the
blanket. The excelsior blanket shall be covered on the top side with a 3 by 1 in. leno
weave, twisted kraft paper yarn netting having a high wet strength, or a biodegradable
extruded plastic mesh netting having an approximate minimum opening of 5/8 by 5/8
in. to an approximate maximum opening of 2 in. by 1 in. The netting shall be entwined
with the excelsior mat for maximum strength and ease of handling. The minimum roll
width shall be 4 ft. The mass of the material shall be not less than 0.7 lb/sq yd, constant
mass, air dry. The rolls shall be packaged with suitable protection for outdoor storage
on the project site in a manner which protects them from biodegradation prior to use.
140

1042
 914.05

4. Paper Mat
Paper mat shall consist of a knitted construction of photodegradable,
polypropylene yarn with uniform openings interwoven with strips of biodegradable
paper. The rolls shall be packaged with suitable protection for outdoor storage at a
construction site in a manner which protects them from biodegradation prior to use.
The mass of the paper shall be a minimum of 0.125 lb/sq yd. Roll sizes shall have a
minimum width of 5 ft.

5. Straw Mat
150 Straw mat shall consist of a machine produced mat consisting of at least 90% of
the total dry mass being clean straw from agricultural crops, with the exception that
up to 30% of the total dry mass may be coconut fibers in lieu of an equal percentage
of straw. Paper or paper related products shall not be allowed as component in the
straw mat. The straw shall be evenly distributed throughout the mat to form a thickness
of 1/2 in. ±1/8 in. The top side of the mat shall be covered with a photo-
degradable/biodegradable plastic mesh which shall be substantially adhered to the
straw by a knitting process using photodegradable/biodegradable thread. The rolls
shall be packaged with suitable protection for outdoor storage at a construction site in
a manner which protects them from biodegradation prior to use. The average dry mass
160 of the straw shall not be less than 0.7 lb/sq yd. The minimum roll width shall be 6 ft.

6. Compost Mulch
Compost mulch shall consist of well-composted vegetable matter, leaves, yard
trimmings, food scraps, composted manures, paper fiber, wood bark, class A bio-solids
as defined in Title 40 of the Code of Federal Regulations at 40 CFR Part 503, or any
combination thereof. Compost shall be produced using an aerobic composting process
in accordance with 40 CFR Part 503 regulations, including time and temperature data
indicating effective weed seed pathogen, and insect larvae kill. Compost shall be well
decomposed, stable, and weed free. Compost shall be refuse free by less than 1% by
170 weight. Compost shall be free of any contaminants and materials toxic to plant growth.
Inert materials shall not exceed 1% by dry weight, pH of 5.5 to 8.0. Carbon-nitrogen
ratio shall not exceed 100. Moisture content shall not exceed 45% by dry weight.
Variable particle size of the compost shall be a maximum dimension of 3 in. in length
1/2 in. in width, and 1/2 in. in depth. Compost mulch shall not be used in storm water
runoff channels or where concentrated flow is anticipated.

(b) Mulch for Plants

Mulch for plants shall consist of broken corncobs, wood chips, chopped bark, size
No. 5 gravel, or crushed stone in accordance with 904.02(e), except 0% to 5% may
180 pass the No. 200 (75 µm) sieve, or other approved materials. The particles of wood
chips, chopped bark, and corncobs shall contain no more than 10% passing the 1/2 in.
screen and 100% shall pass the 3 in. screen. Wood chips shall be from green, hardened,
deciduous trees. Broken corncobs shall be no longer than 4 in.

1043
 914.06

914.06 Leguminous Inoculants

The inoculants for treating leguminous seeds shall be standard pure culture of
nitrogen fixing bacteria. They shall be no more than one year old at the time of use
and shall be subject to approval. Directions of the manufacturer on containers of
inoculants shall be followed when inoculating seed.
190
914.07 Sod
Sod shall consist of fibrous, well rooted, bluegrass, fescue, or other approved
grass cut to a height of 2 to 3 in. Edges of sod shall be cut cleanly, either by hand or
machine, to a uniform minimum thickness of 3/4 in. or more. The roots shall be
exposed in the sod strip to allow the sod to be handled without undue tearing or
breaking. The sod strip shall be of a uniform width of no less than 16 in. and no less
than 2 ft in length. Sod shall be free from all primary noxious weeds in accordance
with 914.04. Acceptance in the field before cutting shall not preclude rejection when
delivered to the work if such contamination is found.
200
Nursery sod shall meet applicable requirements as set out above and shall be a
variety or blend of Kentucky bluegrass or fescue. It shall comply with nursery
inspections and plant quarantine regulations of the states of origin and destination as
well as with Federal regulations governing interstate movement of nursery stock.
Material furnished under this specification shall be covered by a type C certification
in accordance with 916.

914.08 Plant Materials

If the plant material is shown on the Schedule of Pay Items as plant, the Contractor
210 shall submit its source of supply for each plant material for approval prior to delivery
to the project site. This plant list shall include the name of the source of supply and
the location where the plants were grown. A certification that the plants are available
at this source, that the plants were grown at the prescribed location, and that there is a
firm commitment for their purchase at the time of certification shall be provided. These
procedures shall be followed for approval of alternate sources when the originally
approved source is unable to furnish plants at the time when needed. Plants shall be in
accordance with the requirements set out herein. Unless otherwise specified, all plant
material shall be acquired from zones 4, 5, or 6. However, plant material shall be
acquired from zones no further than 1/2 zone south of the zone in which the project is
220 located. Hardiness zones shall be determined from the Plant Hardiness Zone Map,
Miscellaneous Publications No. 1475, Agricultural Research Service, United States
Department of Agriculture, published by the U. S. Government Printing Office,
Washington, D.C. The Contractor shall have a copy of this map.

If the plant material is shown on the Schedule of Pay Items as seedlings, the
Contractor shall choose a source which is shown on the approved list of sources that
is maintained by the Department. This list will specify the sources that are currently
on an immediate use basis. If the source is not on the list, then the same procedure
shall be followed as stated above for plants to obtain approval.
230

1044
 914.08

(a) Quality of Plant Material

All plants shall be first class and representative of the normal species or varieties,
true to type, and standard form. Unless otherwise specified, all plants shall be nursery
grown stock that had been transplanted or rootpruned two or more times according to
the kind and size of plant. The root system shall be vigorous and well developed. The
branch system shall be developed normally. All plants shall be free from disfiguring
knots, sun-scald, injuries, abrasions of the bark, dead or dry wood, broken terminal
growth, or other objectionable disfigurements.

240 (b) Plant Names

Plants shall be true to name, following standard botanical and common
nomenclature as adopted by the American Joint Committee on Horticultural
Nomenclature given in the current edition of Standardized Plant Names. All trees
delivered shall be tagged legibly with the names and sizes of the trees.

All delivered shrubs shall be tagged legibly with the name and size of the shrub
when “Tag Each” is indicated on the summary list. Otherwise, each bundle shall be
tagged. If shrubs are separated individually when delivered, 20% of each species shall
be tagged. A tag with the name and size of the shrub printed thereon shall be used for
250 each species. A 1 in. band of non-toxic paint shall be applied to the stem of seedlings
or “whips”, prior to delivery, in lieu of tags. If tags are required, they shall remain
attached to shrubs for the duration of the contract.

(c) Substitutions
Substitutions of plants in size and kind shall be made only after proper execution
of a change order in accordance with 109.05 and then only when sufficient evidence
has been shown that the specified stock could not be secured.

(d) Grading Standards

260 Grading of plants shall be in accordance with the American Association of
Nursery Horticultural Standards of the current ASNS, ANSI Z 60.1 as revised herein
and on the plans.

(e) Nursery Inspection and Plant Quarantine

All plants shall be free from plant diseases and insect pests. Shipments of plants
shall be in accordance with nursery inspection and plant quarantine regulations of the
states of origin and destination as well as with Federal regulations governing interstate
movement of nursery stock. A valid copy of the certification of inspection shall
accompany each package, box, bale, or carload shipped or otherwise delivered.
270
(f) Balled and Burlapped Plants
Balled and burlapped plants shall be dug so as to retain as many fibrous roots as
possible and shall come from soil which forms a firm ball. The soil in the ball shall be
the original and undisturbed soil in which the plant was grown and shall be free of
noxious weeds and weed seeds. The plant shall be dug, wrapped, transported, and
handled in such a manner that the soil in the ball will not be loosened enough to cause

1045
 914.08

stripping of the small and fine feeding roots or cause the soil to drop away from such
roots. Any indication of manufactured earth balls or mishandling of the plant will be
cause for rejection. The shape and size of the ball shall be as specified in the ASNS as
280 revised herein and shown on the plans.

(g) Container Grown Plants

Plants which are furnished in containers shall be well rooted and established in
the container in which they were shipped. An established container grown plant shall
be a plant transplanted into a container and grown in that container sufficiently long
for the new fibrous roots to have developed so that the root mass retains its shape and
holds together when removed from the container.

(h) Bare Rooted Plants

290 The minimum root system of bare rooted trees or shrubs shall be in accordance
with the standards stated in the ASNS. Bare rooted plants shall be dug only when the
air temperature exceeds 35°F. Particular attention shall be given to the fibrous roots.
The maximum time lapse between loading for shipment and delivery to the work or
approved storage site shall be four days unless other shipping arrangements are
approved.

(i) Collected Plants

Collected plants, when specified in connection with any species or variety, shall
not be nursery grown, but shall have been grown under natural conditions at the
300 location from which they were procured. They may be balled and burlapped or bare
roots as specified in the plant list on the plans. In either case, the collected material
shall be in accordance with the applicable requirements given in the current issue of
ASNS for quality, size, ball, and grade.

(j) Forms, Shapes, and Condition of Plants

Vines and groundcover plants shall be in accordance with grades and
specifications shown in the ASNS unless otherwise specified.

Plants which have been cut back from larger grades to meet specifications will
310 not be acceptable. Plants designated on the plans as street trees, specimen, extra heavy,
clump, or of other like import shall be in accordance with the standards as given in the
ASNS for the special type specified.

Trees shall have straight trunks, be well branched, and have symmetrical tops.
There shall be no cuts of limbs over 3/4 in. in diameter which have not completely
healed over. Each tree shall have the top and root characteristics of its variety and
growth that are typical of such trees in this region. Deciduous trees, unless otherwise
specified, shall have branching between 1/4 and 1/2 of the distance of their height from
the ground. Street trees, if so specified, shall be of uniform branching height. Bush
320 form, when specified, shall be branching at the base of the plant or within 12 in. of the
base. Clumps, when specified, shall have three or more main leaders or trunks starting
at the ground. At least two of these shall be of the caliber specified.

1046
 914.09

(k) Inspection
Plant materials shall be subject to inspection at any time during the life of the
contract. Such inspection shall not be construed as final acceptance of the plants
involved. Any stock which is not in accordance with these specifications will be
rejected and shall be removed from the project.

330 Balled and burlapped plants may have the ball opened for inspection, at the option
of the Department, to determine if the root system is sufficient to ensure plant growth.
If after breaking open, the ball is found to be acceptable, payment for the destroyed
plant will be made at 50% of the contract price for the plant involved.

Nursery stock may be inspected at the nursery before digging or shipping and
sealed with Department seals. If not inspected and sealed at the nursery, it shall be
done at a final collecting point at or adjacent to the project and prior to planting, unless
otherwise specified in writing. Notification shall be made a minimum of three days in
advance of delivery of unsealed plants. Large quantities of small plant material such
340 as shrubs, seedlings, vines, and groundcovers shall be sealed in a satisfactory manner.
Sealing of plants shall not be considered as final acceptance and shall not waive the
responsibility to furnish, plant, and maintain material that complies with the
specifications.

(l) Shipment
All precautions that are customary in good trade practice shall be taken to ensure
the arrival of the plants in good condition. Plants shall be packed or covered in such a
manner as to ensure adequate protection against damage while in transit. The roots of
bare root plants shall be protected with wet straw or other suitable material to ensure
350 the arrival at destination with the roots in a moist condition. When shipment is made
in an enclosed vehicle, the vehicle shall be adequately ventilated to prevent over
heating of the plants in transit.

(m) Certification
Certifications from all plant supply sources shall be furnished certifying that all
plants furnished are in accordance with 914.08. These certifications shall be submitted
monthly and shall contain the information as indicated on the suggested form in ITM
804.

360 914.09 Miscellaneous Material

(a) Water
Water used in the planting or care of vegetation shall be free from oil, acids,
alkalis, salts, or any substance injurious to plant life. Water from streams, lakes, ponds,
or similar sources shall not be used unless approved.

1047
 914.09

(b) Stakes for Bracing and Anchoring

Wood stakes for bracing or supporting trees shall be of rough cypress, cedar,
locust, oak, or other approved wood free from knots, rot, cross grain, or other defects
370 that would impair the strength of the stake for which it is to be used. Wood stakes shall
be a minimum of 2 in. by 2 in. square in cross section and of adequate length. The
wood bracing stakes shall be painted or stained dark green. Delineator posts in
accordance with 910.15 may be used except they shall be painted dark green.

An alternate staking and bracing method using a solid rubber support cord with
metal hooks and stakes, and plastic stake disk system, may be used.

(c) Tree Wound Dressing

Dressing for treating tree wounds or cuts shall be either:
380
1. an approved black asphaltum base antiseptic paint;

2. an approved black paint consisting of Bordeaux Mixture,

raw linseed oil, and lampblack; or

3. an approved black paint consisting of zinc oxide, raw

linseed oil, and lampblack.

(d) Porous Material

390 Porous material for tree root protection may be gravel, crushed stone, slag, or
other porous material varying in size from 1 to 3 in. and shall be approved before being
used.

(e) Pipe
Pipe for underdrains shall be in accordance with 907 or 908. The size and type
shall be as specified.

(f) Staples
Wire staples shall be made from No. 11 gauge (3 mm) or heavier wire, 1 or 2 in.
400 wide at the throat and 6 in. from top to bottom after bending. Biodegradable staples
shall be in accordance with ASTM D 6400 and be 4 in. or longer with a head suitable
for securing the fabric in place. The staples shall be packaged in cartons.

(g) Plastic Net

Plastic net shall consist of photodegradable, longchain synthetic polymer plastic
yarn, either extruded oriented or woven into a net with the yarns fixed at each
intersection such that they retain their relative positions with respect to each other. The
plastic net shall have a square mesh opening of approximately 3/4 in. by 3/4 in. The
plastic net shall have a minimum tensile strength of 20 lb over a 3 in. width in the
410 machine direction and 15 lb over a 3 in. width in the transverse direction. The plastic
net shall have a nominal mass of 2.8 ±0.4 lb per 1,000 sq ft. The plastic net shall be
furnished in rolls which can be easily handled and the rolls shall be packaged in a

1048
 915.01

suitable protection for outdoor storage at a construction site, which protects the
material from degradation prior to use. Roll sizes shall have a minimum width of 6 ft.

Material furnished under this specification shall be covered by a type C

certification in accordance with 916.

(h) Filter Sock

420 Filter socks for sediment control applications shall use a continuous tubular
knitted mesh netting with 3/8 in. openings and constructed of 500 denier
polypropylene. They shall be set in place using hardwood stakes of 1 by 2 in. or stakes
of equivalent strength.

Where using socks with compost soil bark mixture as a filler, the Contractor shall
use a continuous knitted mesh netting with 3/8 in. openings and constructed of 5 mil
thickness of photodegradable HDPE.

Filler particle size shall not be greater than 3 by 1/2 by 1/2 in. and shall be capable
430 of staying within the sock.

SECTION 915 – BRIDGE PILES AND BEARINGS

915.01 Steel Pipe Piles and Epoxy Coated Steel Pipe Piles

(a) General Requirements

Steel pipe piles and epoxy coated steel pipe piles, as designated herein, shall
consist of fluted steel, or rounded straight seamed, spiral seamed, or seamless steel
pipes which, after being driven are filled with class A concrete. The steel pipe shall be
uncoated unless an epoxy coating, in accordance with 915.01(d) is specified.
10
Pipe piles shall be of the diameter and minimum wall thickness shown on the
plans. All sections shall be one cylindrical integral piece except as otherwise required
for end sections of the outside diameter specified. All pipe piles shall be of sufficient
strength to withstand driving to the required penetration depth and nominal driving
resistance.

If necessary to facilitate handling, pipe piles may be furnished in sections to be

welded in the field to form the final integral lengths required.

20 The manufacturer shall provide a mill certification showing heat numbers and test
results for the specified tests. Each pipe pile shall be stenciled to show the diameter,
wall thickness, and heat numbers for the verification of the certifications. The
certifications shall be delivered before the pipe piles are driven.

1049
 915.01

The end of pipe piles shall be equipped with conical pile tips or flat end plates.
The welding used to attach the conical pile tips or flat end plates to the end of pipe
piles shall be done by a welder qualified in accordance with 711.32.

1. End Plates
30 If end plates are used, they shall be flat, non-reinforced and a minimum thickness
of 3/4 in. for pipe piles 12 in. outside diameter or smaller, and 1 in. thick for pipe piles
greater than 12 in. outside diameter up to and including 14 in. For pipe piles larger
than 14 in. outside diameter, the end plates shall be designed to complement the size
of the pipe pile. End plates shall have a diameter approximately 1/2 in. greater than
the outside diameter of the pipe pile and be fillet welded to the pipe pile, using two
passes or beads.

2. Conical Pile Tips

Conical pile tips shall be of sufficient dimensions to ensure adequate joint and
40 driving strength. The end of the pipe pile shall have full bearing on the face of the pile
tip or against a shoulder inside the pile tip. Unless otherwise approved, the pile tip
shall be conical with a 60 to 90° angle between faces. The pile tip shall be substantially
of the same diameter as the end of the pipe pile and butt welded to the end of the lowest
section.

(b) Fluted Steel Pipe Piles

Fluted steel pipe piles shall have a minimum tensile strength of 50,000 psi when
tested in accordance with ASTM A 370. Test specimens for determination of tensile
strength shall be taken longitudinally adjacent to the crest of the flute. The diameter of
50 fluted steel pipe piles shall be measured from crest to crest of flutes.

A sufficient taper will be allowed to enable no less than 6 in. telescoping at the
joints. The lowest section shall taper approximately 1 in. in 4 ft from an 8 in. tip to the
specified diameter of the upper end. Fluted steel pipe piles with a taper of 1 in. in 7 ft
on the lowest section of long piles may be used provided a minimum of approximately
5 ft of the top of the pile below cutoff elevation is the full diameter as shown on the
plans.

(c) Rounded Steel Pipe Piles

60 Rounded steel pipe piles, except for end finish, shall be in accordance with ASTM
A 252, grade 3. Welded pipe may be welded with straight or spiral seams.

(d) Epoxy Coating for Piles

Only powdered epoxy resin from the Department’s list of approved Coating
Materials shall be used for the epoxy coating of steel pipe piles and steel H piles.

The patching or repair material shall be compatible with the coating and shall be
made available by the coating manufacturer. The material shall be suitable for repairs
made to coated areas damaged during fabrication or handling.
70

1050
 915.01

The coating color shall contrast with the color of iron oxide. All coated piles
furnished for a structure shall be the same color. The patching or repair material shall
also be the same color as the original coating material.

1. Prequalification of Organic Coatings for Steel Piles

The coating product shall be a 100% solids, heat curable, thermosetting, dry
powdered epoxy coating. Coating manufacturers who request to have their product
added to the Department’s list of approved Epoxy Coatings for steel shall supply the
information as follows.
80
a. Product Data Sheet
A product data sheet which shall specify the method of surface preparation, the
thermal treatments before and after coating application, the coating application
procedure, and the product name and description of the patching material shall be
provided.

b. Fingerprint
The fingerprint shall include the method of test, such as infrared spectroscopy or
thermal analysis, and a generic description of the product.
90
c. Materials Safety Data Sheet
Current materials safety data sheets shall be supplied for the product and the
patching material.

d. Laboratory Report
A dated laboratory report shall be provided which substantiates full compliance
with the following test requirements.

(1) Tensile Strength and Elongation

100 The tensile strength and elongation of the coating material shall be tested in
accordance with ASTM D 2370 with a rate of elongation of 10% to 20% per minute.
The minimum tensile strength shall be 8,000 psi. The minimum elongation shall be
5%.

(2) Impact Resistance

The impact resistance of the coating shall be tested in accordance with ASTM
G 14 using a 5/8 in. diameter tip, and a 12 mil minimum coating thickness of a 1/8 in.
thick panel at 73°F. Three tests shall be performed. The minimum acceptable value
shall be 80 lbf·in. of impact with no visible breaks in the coating.
110
(3) Abrasion Resistance
The abrasion resistance of the coating shall be tested in accordance with the
Annex to ASTM A 972.

1051
 915.01

(4) Salt Fog

The weathering resistance of the coating shall be tested by means of a salt spray
cabinet following ASTM B 117 for 1,000 h. The coating shall not blister or exhibit
corrosion, discoloration, or loss of adhesion away from the scribed area.

120 2. Application
The application of the epoxy coating shall be at an enclosed plant, equipped with
environmental controls and automated blasting equipment. This equipment shall
facilitate surface preparation and coating application in accordance with the
manufacturer’s recommendations and in accordance with additional requirements set
out herein. The application process shall be performed by a continuous, balanced
system where cleaning of the surface and application of the coating are performed at
the same rate.

a. Surface Preparation
130 The pile surface shall be blast cleaned in conformance with SSPC-SP-10, Near
White Metal Blast. The cleaning media shall produce an anchor pattern profile of
2 mils minimum. All raised slivers, scabs, laminations or bristles of steel remaining
on the newly cleaned surface shall be removed by means of abrasive sanders. All traces
of grit and dust from the blasting shall be removed.

b. Coating Application
The coating shall be applied immediately to the cleaned surface and before visible
oxidation of the surface occurs. The coating shall be applied in accordance with the
manufacturer’s recommendations. The recommendations shall address the equipment
140 required for proper application, the number of coats of epoxy, cure time between coats,
cure time before placing in service, and all other information needed by the
Department to ensure proper performance of the material.

(1) Thickness
Thickness of the cured coating shall be measured on a representative number of
piles from each production lot by the same method required by ASTM G 12 for
measurement of film thickness of pipeline coatings on steel. The minimum coating
thickness for fusion bonded epoxy shall be 8.0 mils for individual measurements and
12 mils for the average.
150
(2) Cure
The coating film shall be cured and post cured in accordance with the
manufacturer’s recommendations. A representative proportion of each production lot
shall be checked by the coating applicator using a method found most effective for
measuring cure to ensure that the entire production lot is in a fully cured condition.

(3) Continuity of Coating

After cure, the epoxy coating shall be checked by the applicator for continuity of
coating and shall be free from holes, voids, contamination, cracks, and damaged areas.
160 There shall not be more than two holidays, which are pinholes not visually discernable,

1052
 915.03

in any linear foot of the coated pile. A holiday detector in accordance with ASTM A
972 shall be used in accordance with the manufacturer’s instructions to check the
coatings for holidays.

3. Certification
Material furnished under this specification shall be covered by a type C
certification in accordance with 916. In addition, a certificate of compliance prepared
by the applicator shall be furnished for each shipment of coated piles. The certificate
of compliance shall state that the piles have been coated in accordance with the
170 manufacturer’s requirements; that thickness, continuity, and flexibility tests of the
coating have been performed; and that the test results are in accordance with the
requirements outlined herein. Test results shall be retained by the applicator and made
available for inspection upon request for a period of seven years.

915.02 Steel H Piles and Epoxy Coated Steel H Piles

Steel H piles and epoxy coated steel H piles shall be of the shape and dimensions
shown on the plans or as otherwise specified. The steel shall be in accordance with
ASTM A 572, grade 50. Steel H piling shall be handled in the same manner as required
in 711.56. The piles shall be uncoated unless an epoxy coating, in accordance with
180 915.01(d), is specified.

The manufacturer shall provide a mill certification showing heat numbers and test
results for the specified tests. Each H pile shall be stenciled to show the manufacturer’s
name, the specifications, size and mass of section, and heat numbers for verification
of the certification. The certification shall be submitted at the time of delivery of the
piles.

915.03 Pile Shoes

Steel H pile shoes furnished shall be covered by a type C certification in
190 accordance with 916. Pile shoes shall be cast-in-one-piece steel in accordance with
ASTM A 148, grade 80-50 and shall be fastened to the piles by welding in accordance
with the manufacturer’s recommendations. They shall have sufficient flange and
continuous web vertical back-ups to assure proper alignment and fitting to the pile.
Either the pile shoe or the outside of each flange of the pile shall be beveled 45°.
E70XX welding rods shall be used. All welds shall be made in the flat position and
the welder shall be qualified in accordance with 711.32.

Timber pile shoes furnished shall be covered by a type C certification in

accordance with 916. Pile shoes shall be cast-in-one-piece steel in accordance with
200 ASTM A 27, grade 65-35, class 2 or grade 70-36, class 2 and shall be fastened to the
piles in accordance with the manufacturer’s recommendations.

The soil or rock bearing surfaces of the shoes shall be sloped downward towards
the web a minimum of 15° but not to exceed 45° to the horizontal under the flanges.
The sloped surfaces of the shoes shall terminate so as to form a flat surface not

1053
 915.04

exceeding 1/3 of the flange width. The surfaces may have individual or continuous
cutting teeth.

915.04 Elastomeric Bearings

210
(a) Description
Elastomeric bearings as herein specified shall include plain bearings, consisting
of elastomer only, and laminated bearings, consisting of layers of elastomer restrained
at their interfaces by bonded laminates. The bearing type shall be as shown on the
plans.

(b) Materials

1. Elastomer
220 Elastomeric bearing pads shall be made from elastomeric materials and shall be
steel reinforced as shown on the plans. They shall be in accordance with Articles 18.1
and 18.2 of the AASHTO LRFD Bridge Construction Specifications and AASHTO M
251 with the exception that Table X1 is not applicable. The elastomer portion of the
elastomeric compound shall be 100% virgin natural polyisoprene known as natural
rubber, or 100% virgin polychloroprene known as neoprene. The cured compound
shall be in accordance with Table A for natural rubber, or Table B for neoprene,
depending on which type is furnished.

1054
 915.04

TABLE A
230 POLYISOPRENE, OR NATURAL RUBBER, QUALITY CONTROL TESTS

PHYSICAL PROPERTIES
ASTM D 2240 Hardness (Shore A Durometer) 55 ±5
Tensile Strength, Min., ksi 2.25
ASTM D 412
Ultimate Elongation, Min. % 425
HEAT RESISTANCE
Change in Durometer Hardness,
10
Max. Points
ASTM D 573, Change in Tensile Strength,
-25
70 h, @ 158ºF Max. %
Change in Ultimate Elongation,
-25
Max. %
COMPRESSION SET
ASTM D 395,
22 h @ 158ºF, Max. % 25
Method B
OZONE
25 ppm ozone in air by volume,
20% strain, 100ºF ±2ºF, 48 h
ASTM D 1149 No Cracks
mounting procedure, D 518,
Procedure A
LOW-TEMPERATURE BRITTLENESS
ASTM D 746, Grades 0 and 2
Procedure B Grade 3, Brittleness @ -40ºF No Failure
INSTANTANEOUS THERMAL STIFFENING
Grades 0 and 2, Tested @ -32ºC Stiffness at test temperature shall
ASTM D 1043 not exceed four times the stiffness
Grade 3, Tested @ -40ºF
measured at 74ºF.
LOW-TEMPERATURE CRYSTALLIZATION
Stiffness at test time and
temperature shall not exceed four
times the stiffness measured at 74ºF
with no time delay. The stiffness
shall be measured with a quad shear
test rig in an enclosed freezer unit.
The test specimens shall be taken
Quad Shear Test from a randomly selected bearing. A
Grade 3, 14 Days @ -15ºF
as Described ±25% strain cycle shall be used. A
complete cycle of strain shall be
applied within a period of 100 s. The
first 0.75 cycle of strain shall be
discarded. The stiffness shall be
determined by the slope of the force
deflection curve for the next 0.50
cycle of loading.

1055
915.04

TABLE B
POLYCHLOROPRENE, OR NEOPRENE, QUALITY CONTROL TESTS

PHYSICAL PROPERTIES
ASTM D 2240 Hardness (Shore A Durometer) 55 ±5
Tensile Strength, Min., ksi 2.25
ASTM D 412
Ultimate Elongation, Min. % 375
HEAT RESISTANCE
Change in Durometer Hardness, Max.
15
ASTM D 573, Points
70 h, @ 212ºF Change in Tensile Strength, Max. % -15
Change in Ultimate Elongation, Max. % -40
COMPRESSION SET
ASTM D 395,
22 h @ 212ºF, Max. % 35
Method B
OZONE
25 ppm ozone in air by volume, 20%
ASTM D 1149 strain, 100ºF ±2ºF, 48 h mounting No Cracks
procedure, D 518, Procedure A
LOW-TEMPERATURE BRITTLENESS
ASTM D 746,
Grade 3, Brittleness @ -40ºF No Failure
Procedure B
INSTANTANEOUS THERMAL STIFFENING
Stiffness at test temperature shall
ASTM D 1043 Grade 3, Tested @ -40ºF not exceed four times the
stiffness measured at 74ºF.
LOW-TEMPERATURE CRYSTALLIZATION
Stiffness at test time and
temperature shall not exceed four
times the stiffness measured at
74ºF with no time delay. The
stiffness shall be measured with a
quad shear test rig in an enclosed
freezer unit. The test specimens
shall be taken from a randomly
Quad Shear Test
Grade 3, 14 Days @ -15ºF selected bearing. A ±25% strain
as Described
cycle shall be used. A complete
cycle of strain shall be applied
within a period of 100 s. The first
0.75 cycle of strain shall be
discarded. The stiffness shall be
determined by the slope of the
force deflection curve for the next
0.50 cycle of loading.

1056
 915.04

The bond strength, determined in accordance with ASTM D 429, Method B, shall
be at least 40 lb/in.

The adhesion failure, determined in accordance with ASTM D 429, Method B,

240 shall be at least R-80. The adhesion-failure requirement will be waived if the bond
strength is at least 80 lb/in.

2. Structural Steel
Structural steel spacer plates, top and bottom load plates, and other steel
components, including anchor bolts, exposed to the environment shall be galvanized
in accordance with AASHTO M 111, zinc metallized with a coating of 7 mils in
accordance with SSPC-CS 23.00, or painted with the structural steel coating system in
accordance with 619.09(a). The finish coat for painted steel shall be in accordance
with 909.02(d). The color shall be in accordance with SAE-AMS-STD-595, color No.
250 20045.

When stainless steel load plates are specified, the material shall be in accordance
with ASTM A 240, type 304.

3. Internal Steel Shims

Internal steel shims shall be rolled hot and cold steel and shall be in accordance
with AISI 1015 through 1025, ASTM A 1008, or ASTM A 1011 grade 36 or higher.
Shims shall be of the thickness specified with a tolerance of ±0.015 in.

260 4. Threaded Stud

Threaded studs, where required, shall be in accordance with ASTM A 307 and
mechanically zinc coated in accordance with ASTM B 695, class 50.

5. Side Retainer
Side retainers shall be made from plates or rolled mild steel in accordance with
ASTM A 36.

(c) Manufacturing Requirements

Plain bearings may be molded individually, cut from previously molded strips or
270 slabs, or extruded and cut to length. Cut edges shall be at least as smooth as ANSI
B 46.1 No. 250 finish. Unless otherwise shown on the plans, all components of a
laminated bearing shall be molded together into an integral unit. Air bubbles within
the elastomeric material shall be cause for rejection.

Laminated elastomeric bearings shall be individually molded to the required size.

Corners and edges may be rounded with a radius at the corners not exceeding 3/8 in.
and a radius at the edges not exceeding 1/4 in.

Steel shims shall be sandblasted and cleaned and protected against contaminants
280 until fabrication is completed.

Bearings designed as a single unit shall be built as a single unit.

1057
 915.04

Each reinforced bearing shall be marked with indelible ink or flexible paint. The
marking shall consist of the orientation, the order number, lot number, bearing
identification number, and elastomer type and grade number. Unless otherwise
specified, the marking shall be on a face that is visible after erection of the bridge.

(d) Appearance and Dimensions

290 The edges of the embedded steel laminates, including around holes, shall be
covered with 1/8 to 1/4 in. of elastomer. All other dimension tolerances shall be in
accordance with AASHTO M 251.

(e) Quality Assurance

The mechanical properties of the materials and of the finished bearing shall be in
accordance with the AASHTO LRFD Bridge Construction Specifications, Article
18.2.5, and AASHTO M 251, with the exception that the tables in 915.04(b)1 shall be
used.
1. Compressive strain of any layer of an elastomeric bearing
300 shall not exceed 7% at 800 psi average unit pressure or at
the design dead load plus live load pressure if so indicated
on the plans.

2. The shear resistance of the bearing shall not exceed 40 psi

for 55 durometer, table A compounds; or 75 psi for 55
durometer, table B compounds at 25% strain of the total
effective rubber thickness after an extended four-day
ambient temperature of -20°F.

310 (f) Certification

Material furnished under this specification shall be covered by a type B
certification in accordance with 916. The results of the following tests shall be
provided on the type B certification.

ASTM, or INDOT Standard

TEST
Specifications
Ultimate Tensile Strength D 412
Ultimate Elongation D 412
Hardness (Durometer) D 2240
Tensile Strength and Elongation on
D 573 and D 412
Oven-aged Material
Hardness on Oven-aged Material D 573 and D 2240
Compression Set D 395, Method B
Ozone Resistance D 1149
Adhesion D 429, Method B
Brittleness D 746, Procedure B
Compressive Strain 915.04(e)1
Shear Resistance 915.04(e)2

1058
 915.05

When steel components are incorporated into elastomeric bearings, a mill

certification, galvanization certification, if applicable, and a Buy America
Certification in accordance with 106.01(c) will be required.

320 In addition, one bearing pad from each type to be furnished for the structure will
be required for laboratory testing. However, if shapes A and B of a given type are
required, only shape A need be furnished for testing. The material may be sampled
prior to shipment to the project, provided suitable arrangements can be made through
the Office of Materials Management. Materials not previously sampled and approved
for use shall be sampled after delivery to the project site. Samples shall be furnished
at least 30 days before date of use.

915.05 Bearing Assemblies with Polytetrafluoroethylene, PTFE, Sliding

Surfaces
330 A copy of the manufacturer’s design manual shall be submitted for approval when
directed.

All steel components shall be in accordance with ASTM A 709, grade 36 unless
otherwise shown on the plans. Where these assemblies are to be used in conjunction
with a self-weathering steel bridges, the steel components shall be in accordance with
ASTM A 709, grade 50W. Stainless steel mating surfaces shall be 14 gauge minimum
ASTM A 240, type 304 sheets with a maximum surface roughness of 20 Rms.

The PTFE shall be 100% virgin unfilled polymer or 15% glass filled and etched
340 on the bonding side. The properties of the PTFE shall be in accordance with the
following:

Requirement Test Method Value

Tensile Strength, minimum ASTM D 638 2,500 psi
Elongation, %, minimum ASTM D 638 200
Specific Gravity ASTM D 792 2.1 to 2.3

PTFE, where required, shall be bonded to grit blasted steel. The PTFE guides shall
be bonded and mechanically fixed into place. The bonding compound used to bond
PTFE or elastomeric pads to steel plates shall be in accordance with ASTM D 429,
Method B.

All steel surfaces exposed to the environment shall be zinc metalized and shall be
350 7 mils thick in accordance with SSPC-CS 23.00, or painted in accordance with
619.09(a). The finish coat for painted steel shall be in accordance with 909.02(d). The
color shall be in accordance with SAE-AMS-STD-595, color No. 20045.

All required materials shall be covered by a type B certification in accordance

with 916.

1059
 916.01

SECTION 916 – MATERIALS CERTIFICATIONS

916.01 General
Materials certifications will be required for certain materials in accordance with
various sections of these specifications and other contract documents. Unless
otherwise specified or directed, one copy of each certification shall be submitted prior
to use of the material. All certifications shall be signed by a person having legal
authority to bind the company preparing the certification.

10 The contract number, name of the Contractor, destination to which the material
covered by the certification is consigned, and name and quantity of material
represented shall be shown on all copies of the certification. Identifying information
such as alloy, grade, type, class, or other similar designation shall also be shown when
applicable.

Any material received on the project for which certification has been furnished
may be sampled and tested. If the results of the tests are in disagreement with the
certification, the test results shall prevail and further acceptance by certification from
the manufacturer of the material concerned may be suspended.
20
916.02 Types of Certifications
Certifications shall be type A, type B, type C, type D, or as required under other
types. When specified, the type of certification provided for a material shall be in
accordance with the Frequency Manual except as otherwise specified. Specific
information and test results required in type A, type B, and other types of certifications
will be listed in the material specifications. Sample forms for type A, type B, type C,
and type D certifications are shown in 916.03. Sample forms for other type
certifications are shown in 916.03 or ITM 804.

30 (a) Type A
Type A certification shall be prepared by the manufacturer. It shall consist of a
certified copy of a laboratory report which lists results of the specified tests and shall
certify that the materials furnished comply with the specifications. The applicable
specification shall be referred to in the certification. The tests may be conducted in the
laboratory of the manufacturer or in another qualified laboratory. Such tests shall have
been conducted on samples obtained from the lot or lots of material in the shipment.

(b) Type B
Type B certification shall be prepared by the manufacturer. It shall show the limits
40 of test values for the specified tests and shall certify that the materials furnished
comply with the specifications. The applicable specification shall be referred to in the
certification. The tests may be conducted in the laboratory of the manufacturer or in
another qualified laboratory.

(c) Type C
Type C certification shall be prepared by the manufacturer and shall certify that

1060
 916.03

the materials furnished are in accordance with the specifications. The applicable
specification shall be referred to in the certification.

50 (d) Type D
Type D certification shall be prepared by the Contractor and shall certify that the
materials furnished are in accordance with the specifications. The applicable
specification shall be referred to in the certification. A type D certification shall be
used for product identification. It may be required to certify that the material is in
accordance with minimum trade standards.

(e) Other Types

Types of certifications other than type A, B, C, and D are specified for selected
materials. The requirements for a certification are described in the material’s
60 specification.

(f) Requirements for Small Quantities of Materials

Where circumstances warrant and previously approved material is not available,
small quantities may be accepted either by a type D certification or by an affidavit
from the supplier stating that the material offered is equal to that specified.

(g) Buy America Requirement

All steel and cast iron materials and products used in the contract shall be certified
to be in accordance with 106.01(c).
70
916.03 Sample Forms

(a) For Buy America Requirement

BUY AMERICA CERTIFICATION

In accordance with Indiana Department of Transportation Specification

106.01(c), I hereby certify that all steel and cast iron materials and products were
produced and manufactured in the United States of America or territories subject to its
80 jurisdiction.

CONTRACT NUMBER

PROJECT NUMBER

CONTRACTOR’S NAME

MANUFACTURER’S NAME

90 B/L or INVOICE NUMBER

MATERIAL DESTINATION

1061
 916.03

This is to certify that for the contract described above, the materials
supplied are as follows:

**Material Name Quantity

____________________ _____________________
____________________ _____________________
100
____________________ _____________________
Date Company of Manufacture
_____________________
*Signature of Company Official/Title

____________________ _____________________
Date Contractor
______________________
Signature of Contractor Official/Title
110
* This Certification shall be prepared by the manufacturer of the material being
supplied for this contract.
** Identifying information such as Alloy, Grade, Type, Class, or other similar
designation shall also be shown when appropriate.

(b) Sample Type A Certification Form

120 INDIANA DEPARTMENT OF TRANSPORTATION

TYPE A CERTIFICATION OF COMPLIANCE

CONTRACT NUMBER

PROJECT NUMBER

CONTRACTOR’S NAME

130 MANUFACTURER’S NAME

B/L or INVOICE NUMBER

MATERIAL DESTINATION

This is to certify that for the contract described above, the materials
supplied are as follows:

1062
 916.03

**Material Name Quantity

140 ____________________ _____________________
____________________ _____________________

***Conform to: ______________________________________________

The materials listed above comply with the following Test Methods and
are within the acceptable limits of said Test Methods:

TEST METHOD LIMITS OF TEST VALUE ACTUAL TEST RESULTS

_____________ ______________________ _______________________
150 _____________ ______________________ _______________________
_____________ ______________________ _______________________

____________________ _____________________
Date Company of Manufacture
_____________________
*Signature of Company Official/Title

* This Certification shall be prepared by the manufacturer of the material being

supplied for this contract.
160 ** Identifying information such as Alloy, Grade, Type, Class, or other similar
designation shall also be shown when appropriate.
*** Applicable material specification reference shall be listed.

(c) Sample Type B Certification Form

INDIANA DEPARTMENT OF TRANSPORTATION

170 TYPE B CERTIFICATE OF COMPLIANCE

CONTRACT NUMBER

PROJECT NUMBER

CONTRACTOR’S NAME

MANUFACTURER’S NAME

180 B/L or INVOICE NUMBER

MATERIAL DESTINATION

This is to certify that for the contract described above, the materials
supplied are as follows:

1063
 916.03

**Material Name Quantity

____________________ _____________________
____________________ _____________________
190
***Conform to: ______________________________________________

The materials listed above comply with the following Test Methods and
are within the acceptable limits of said Test Methods.

TEST METHOD LIMITS OF TEST VALUE

__________________ _______________________
__________________ _______________________
200 __________________ _______________________

____________________ _____________________
Date Company of Manufacture
_____________________
*Signature of Company Official/Title

* This Certification shall be prepared by the manufacturer of the material being

supplied for this contract.
** Identifying information such as Alloy, Grade, Type, Class, or other similar
210 designation shall also be shown when appropriate.
*** Applicable material specification reference shall be listed.

(d) Sample Type C Certification Form

CONTRACT NUMBER

PROJECT NUMBER
220
CONTRACTOR’S NAME

MANUFACTURER’S NAME

B/L or INVOICE NUMBER

MATERIAL DESTINATION

This is to certify that for the contract described above, the materials
230 supplied are as follows:

1064
 916.03

**Material Name Quantity

____________________ _____________________
____________________ _____________________

***Conform to: ______________________________________________

____________________ _____________________
240 Date Company of Manufacture
_____________________
*Signature of Company Official/Title

* This Certification shall be prepared by the manufacturer of the material being

supplied for this contract.
** Identifying information such as Alloy, Grade, Type, Class, or other similar
designation shall also be shown when appropriate.
*** Applicable material specification reference shall be listed.

250

(e) Sample Type D Certification Form

CONTRACT NUMBER

PROJECT NUMBER

MANUFACTURER’S NAME

260 MATERIAL DESTINATION

This is to certify that for the contract described above, the materials
supplied are as follows:

**Material Name Quantity

____________________ _____________________
____________________ _____________________

***Is in accordance with: _______________________________________

270
____________________ _____________________
Date Contractor
______________________
*Signature of Contractor Official/Title

* This Certification shall be prepared by the Contractor.

** Identifying information such as Alloy, Grade, Type, Class, or other similar
designation shall also be shown when appropriate.

1065
 916.03

*** Applicable material specification reference shall be listed. Otherwise, a

280 statement shall be provided that the material supplied is in accordance with
minimum trade standards.

(f) Sample Asbestos Exclusion Letter

Prior to acceptance of work and final payment, the Contractor shall submit to the
Engineer for each building or bridge, on the Contractor’s letterhead, a signed, dated
copy of the following letter. The Engineer will be responsible for the distribution of
the letter.
290
ASBESTOS EXCLUSION LETTER

____________
Date

_____________________________________________________
work address of Engineer for Indiana Department of Transportation

ATT: ______________________________
300 Name, Project Engineer/Supervisor

Re: Asbestos Exclusion

Location/Description ___________
Contract Number ___________
Bridge Structure Number ___________
Contractor’s Name ___________

Dear Engineer:

310 I hereby certify that to the best of my knowledge no asbestos containing material
was used as a building material in this project.

Very truly yours,

________________________________
Signature of Contractor official

________________________________
Title of Contractor official
320
cc: District Bridge Inspection Engineer
Environment, Planning and Engineering Division Chief
Project File

1066
 917.03

SECTION 917 – QUALITY ASSURANCE AGGREGATE CERTIFICATION

917.01 General Requirements

An aggregate source will be authorized to ship products in the status of a Certified
Aggregate Producer who is in accordance with the required standards of ITM 211.
This will consist of a program which will require the aggregate source to make a
commitment to product quality management. Approval to participate in the program
will be based on the following criteria.

10 (a) existence of suitable materials in the deposit being mined;

(b) facilities capable of consistently processing uniform materials

in accordance with the specification requirements; and

(c) a source Quality Control Plan which will ensure that the mineral
aggregates have a 95% assurance of being in accordance with
the Department’s quality and uniformity requirements.

Specific details of this program are contained in ITM 211. Sampling and testing
20 details are found in the Inspection and Sampling Procedures for Fine and Coarse
Aggregates manual. A Certified Aggregate Producer shall operate in accordance with
the requirements of both publications.

917.02 Quality Control Plan

An aggregate source will not be approved as a Certified Aggregate Producer until
it has prepared a Quality Control Plan and the plan has been approved. The plan shall
encompass all details of production starting with the extraction of the indigenous raw
materials and concluding with material shipped from the plant. The Quality Control
Plan shall be prepared in accordance with the requirements of ITM 211.
30
917.03 Source Approval Requirements
The Office of Materials Management shall be notified in writing that the
aggregate source wants to become a Certified Aggregate Producer. The aggregate
source shall identify the specific products for which approval is sought. Such list shall
include all of the products to be produced at the source regardless of whether the
products are for Department or other uses.

An aggregate source may not be considered for entry into the certification
program until the preliminary source investigation has been completed in accordance
40 with ITM 203.

The following procedure will be used to establish an aggregate source as a

Certified Aggregate Producer.

1067
 917.04

(a) Step 1
The source shall enter the coordinated testing phase of ITM 211. Coordinated
testing shall be performed in accordance with ITM 211. During this phase, the
producer shall be required to develop a Quality Control Plan to establish demonstrated
mean test values and standard deviations.
50
(b) Step 2
The aggregate source shall enter the trial phase. The producer shall also operate
in accordance with ITM 211 and the Quality Control Plan. The Quality Control Plan
shall be refined as may be necessary.

(c) Step 3
The aggregate source will become an approved Certified Aggregate Producer
following satisfactory performance during the trial phase. Achieving such status shall
be accompanied by the inherent responsibility to operate within the tenets of ITM 211.
60 The Certified Aggregate Producer shall produce material at a compliance requirement
of effectively 95% of the appropriate specifications. The Department will monitor such
compliance through the use of periodic in-depth inspections of the production site.
Continuing approval is contingent upon the effectiveness of the producer’s Quality
Control Plan as evidenced by the quality and uniformity of the products which are
prepared in accordance with the appropriated specifications and ITM 211.

917.04 Removal from Certified Producer Status

The Office of Materials Management will be responsible for the review and
removal of an aggregate source from being an approved Certified Aggregate Producer.
70 A Certified Aggregate Producer shall operate so as to avoid a need for the Department
to exercise this action. However, removal from Certified Aggregate Producer status
may be necessary for situations such as:

(a) the statistical probability of the product compliance has fallen

below 90%;

(b) the product has a 90% to 95% probability of compliance but the
producer has failed to take corrective action to restore 95%
probability;
80
(c) the Certified Aggregate Producer has failed to take immediate
corrective action relative to deficiencies in the performance of
the approved Quality Control Plan;

(d) evaluation of data has demonstrated an inability of the Certified

Aggregate Producer to consistently be in accordance with
Department requirements;

(e) the Certified Aggregate Producer has deliberately shipped

90 aggregate material which is not in accordance with the
specifications, or has falsified records; or
1068
 918.02

(f) the production site has not been operated in accordance with the
Summary of Production or Ledge Quality Results letter.

Notice of removal from Certified status will be in written form, will be issued by
the Office of Materials Management, and will identify the reasons for the removal.
Effective immediately upon receipt of such notification, no further aggregate
shipments shall be made on a certified basis.
100
917.05 Appeals
The producer shall have the right to appeal removal from Certified Producer status
to the Engineer. The appeal shall be in written form, shall state the reason or reasons
on which the appeal is based, and shall be received within 14 calendar days of receipt
of the removal notice.

SECTION 918 – GEOSYNTHETIC MATERIALS

918.01 General Requirements

Geosynthetics are polymer based products used for separation, filtration,
reinforcement, liquid containment, soil and aggregate confinement and many other
soil related purposes within many conventional civil engineering structures. When
appropriate, the Department will require the use of geosynthetics meeting the
categories and characteristics indicated below.

10 A manufacturer requesting that a geosynthetic be added to the approved materials

list shall submit the required documents in accordance with ITM 806 to the Office of
Materials Management.

918.02 Geotextile
The geotextile shall be either non-woven or woven and consist of at least 85%
long-chain synthetic polymers. The geotextile shall contain stabilizers or inhibitors
added to the base polymer mix to make the filaments and yarns resistant to
deterioration caused by ultraviolet radiation exposure. The geotextile shall be
produced such that the yarns and fibers retain their relative positions. The non-woven
20 geotextile shall be needle punched, heat bonded or resin bonded.

All damaged geotextile shall be replaced for the entire width of the roll. The
Contractor shall furnish the product labeled that clearly indicates the manufacturer’s
or supplier’s name, product identification, lot number, manufactured date and roll
dimensions. Geotextiles used for Department projects shall be NTPEP listed and shall
be in accordance with AASHTO M 288 and the Department’s Approved Materials
List. Geotextiles will be placed and maintained on the Department's list in accordance
with ITM 806.

30 The geotextile shall meet the following requirements:

1069
 918.02
(a) Geotextile Properties for Riprap and Revetment Applications

Requirements(1)
Test Method, ASTM Type 1A Type 1B Type 2A Type 2B Type 3
Grab Tensile Strength, min. D 4632 200 lbs 200 lbs 250 lbs 300 lbs 250 lbs
Grab Elongation D 4632 > 50% < 50% > 50% < 50% < 50%
CBR Puncture Strength, min. D 6241 500 lbs 600 lbs 625 lbs 1000 lbs 875 lbs
Trapezoid Tear Strength, min. D 4533 80 lbs 75 lbs 100 lbs 150 lbs 60 lbs
UV Degradation Resistance D 4355
70% 70% 70% 70% 90%
500 hrs, min. D 6637
≤ No. 80 sieve, ≤ No. 40 sieve, ≤ No. 100 sieve, ≤ No. 40 sieve,
for soils ≥ 40% for soils < 40% for soils ≥ 40% for soils < 40% ≤ No. 70
Apparent Opening Size, AOS D 4751
passing the No. passing the No. passing the No. passing the No. sieve
200 sieve 200 sieve 200 sieve 200 sieve
Permittivity D 4491 ≥ 1.2 sec -1 ≥ 2.1 sec -1 ≥ 0.80 sec -1 ≥ 0.90 sec -1 0.28 sec -1
Note:
(1) All values are minimum average roll values (MARV) as determined in accordance with ASTM D 4354 in the weaker principal direction,
except AOS size is based on maximum average roll value.

1070
 (b) Geotextile Properties for Underdrains and Drainage Applications

Requirements(1) (2)
Test Method, ASTM Type 1A Type 1B Type 2A Type 2B Type 3
Grab Tensile Strength, min. D 4632 80 lbs 200 lbs 160 lbs 200 lbs 200 lbs
Grab Elongation D 4632 > 50% < 50% > 50% < 50% < 50%
CBR Puncture Strength, min. D 6241 175 lbs 600 lbs 410 lbs 750 lbs 1100 lbs
UV Degradation Resistance D 4355
70% 70% 70% 70% 90%
500 hrs, min. D 6637
≤ No. 50 sieve, ≤ No. 40 sieve, ≤ No. 70 sieve, ≤ No. 30 sieve,
for soils ≥ 40% for soils < 40% for soils ≥ 40% for soils < 40% ≤ No. 40
Apparent Opening Size, AOS D 4751
passing the No. passing the No. passing the No. passing the No. sieve
200 sieve 200 sieve 200 sieve 200 sieve
Permittivity, min. D 4491 ≥ 1.2 sec¯¹ ≥ 2.1 sec¯¹ ≥ 0.8 sec¯¹ ≥ 1.5 sec¯¹ 0.90 sec¯¹
Notes:
(1) All values are minimum average roll values (MARV) as determined in accordance with ASTM D 4354 in the weaker principal direction,
except AOS size is based on maximum average roll value.
(2) Type 3 value is a maximum average roll value (Max ARV) as determined in accordance with ASTM D 4354.

918.02
1071
 918.02
(c) Geotextile Properties for Pavement or Subgrade Stabilizations
40
Requirements(1)
Test Method, ASTM Type 1A Type 1B Type 2A Type 2B
Grab Tensile Strength, min. D 4632 200 lbs 300 lbs 350 lbs 400 lbs
Wide Width Tensile , @ 5% Strain D 4595 n/a n/a 1200 2400
Grab Elongation D 4632 ≤ 50% < 50% ≤ 50% < 50%
CBR Puncture Strength, min. D 6241 175 lbs 600 lbs 410 lbs 750 lbs
Trapezoid Tear Strength, min. D 4533 75 lbs 110 lbs n/a n/a
UV Degradation Resistance D 4355
70% retained 70% retained 70% retained 70% retained
500 hrs, min. D 6637
Apparent Opening Size, AOS, min. D 4751 sieve No. 50 sieve No. 40 sieve No. 30 sieve No. 30
Soil Retention, Pore Size, O50/O95, min. D 6767 n/a n/a 290/380 320/460
Permittivity, min. D 4491 0.05 sec -1 0.050 sec -1 0.60 sec -1 0.40 sec -1
Notes:
(1) All values are minimum average roll values (MARV) as determined in accordance with ASTM D 4354 in the weaker principal
direction, except AOS size is based on maximum average roll value.

1072
(d) Geotextile Properties for Silt Fence

Requirements(1)
Test Method, ASTM Wire Fence Supported Self Supported
Grab Strength D 4632 90 lbs 90 lbs
Elongation @ 45 lbs D 4632 50% max.
Apparent Opening Size (2) D 4751 No. 20 sieve No. 20 sieve
Permittivity (2) D 4491 0.01 sec-1 0.01 sec-1
Ultraviolet Degradation at 500 hrs D 4355 70% strength retained 70% strength retained
(1) The value in the weaker principal direction shall be used. All numerical values will represent the minimum
average roll value. Test results from a sampled roll in a lot shall be in accordance with or shall exceed the
minimum values shown in the above table. The stated values are for non-critical, non-severe conditions. Lots
shall be sampled in accordance with ASTM D 4354.
(2) The values reflect the minimum criteria currently used. Performance tests may be used to evaluate silt fence
performance if deemed necessary by the Engineer.
Note:
1. All values are minimum average roll values (MARV) as determined in accordance with ASTM D 4354.

918.02
1073
 918.03

918.03 Geomembrane
This material shall consist of a geomembrane fabricated from high density
polyethylene, HDPE, consisting of strong, rot resistant, chemically stable long-chain
50 synthetic polymer materials, dimensionally stable with distinct and measurable
openings. The manufactures shall submit the tests for the intended use to the
Department.

Geomembrane shall be selected from the Department's Approved Materials List.

Geomembrane will be placed and maintained on the Department's list in accordance
with ITM 806.

The geomembrane shall meet the following requirements:

Test Method Requirements

Density, min. ASTM D 1505 55 pcf
Sheet Thickness ASTM D 5199 30 mils
Tear Resistance ASTM D 1004 22 lbs
Resistance Soil Burial ASTM D 3083 90% retained
pH AASHTO T 289 Durability between 3 to 12
Roll Width Calibered 20 ft
60
918.04 Geocell Confinement System
Geocell confinement system is a lightweight, flexible mat that consists of high
density polyethylene strips. The mat shall be perforated and the strips shall be
ultrasonic bonded together to form a strong configuration. Cell seam strength shall be
uniform over full depth.

Geocell shall be selected from the Department's Approved Materials List. Geocell
will be placed and maintained on the Department's list in accordance with ITM 806.

70 The geocell shall meet the following requirements:

Properties Material/Test Method Unit Value

Sheet Thickness ASTM D 5199 mils 50
Environmental Stress Crack
ASTM D 1693 hours 3,500
Reduction, min.
Short-Term Seam Peel
ASTM D 6392 lbs/ft 350
Strength for 4 in. depth
Percent Open Area COE-02215 % 12.6
Nominal Expanded Cell Size Calibered in. 12.6 x 11.3
Note:
Carbon Black shall be minimum 1.5% by weight in accordance with ASTM 5199.

1074
 918.05

918.05 Geogrid
Geogrid shall be biaxial or multi axial of a regular network of connected polymer
tensile elements with aperture geometry sufficient to enable significant mechanical
interlock with the surrounding material. The material shall be polypropylene, ASTM
D 4101 (97% minimum) and Carbon Black, ASTM D 1603 (0.5% minimum). The
geogrid structure shall be dimensionally stable and shall be able to retain its geometry
under construction stresses. The geogrid structure shall have a resistance to damage
80 during construction, ultraviolet degradation, and all forms of chemical and biological
degradation encountered in the soil being placed.

Geogrid shall be in accordance with the property requirements as specified in the

Geosynthetic Research Institute, GRI, Standard Test Methods GG1, GG3, GG4,
ASTM D 5262, and ASTM D 6637.

During periods of shipment and storage, the geogrid shall be protected from
temperatures greater than 140°F, mud, dirt, dust, and debris. Each geogrid roll shall be
labeled or tagged to provide product identification. The manufacturer’s
90 recommendations shall be followed with regard to protection from direct sunlight. At
the time of installation, the geogrid will be rejected if it has defects, tears, punctures,
flaws, deterioration, or damage incurred during manufacture, transportation, or
storage. All damaged portions of geogrid shall be replaced for the entire width of the
roll. All of the geogrid shall meet the requirements of ASTM D 4873. The Contractor
shall furnish the product labels that clearly show the manufacturer’s or supplier’s
name, product identification, lot number, manufactured date, roll dimension and
provide a document that the material is in accordance with manufacturer’s or
supplier’s certificate.

100 Only geogrids selected from the Department’s list of approved Geogrids shall be
used. Geogrids will be placed and maintained on the Department’s list in accordance
with ITM 806, Procedure S.

The geogrid shall be in accordance with the property requirements for the type
specified as follows:

1075
 918.05

(a) Type IA and Type IB

Type IA Type IB
Property Test Method Unit
Value, Min. Value, Min.
Aperture Area Calibered Sq. in. 1.3 1.3
Open Area COE, CW02215 % > 50.0 ≤ 80.0 > 50.0 ≤ 80.0
Junction Strength ASTM D 7737 lbs/ft ----- 788
Tensile Modulus, ASTM D 66371,2,3
machine direction lb/ft 10,000 10,000
cross machine direction lb/ft 10,000 10,000
Ultimate Strength, ASTM D 66372,3
machine direction lb/ft 800 800
cross machine direction lb/ft 800 800
Ultraviolet Stability ASTM D 4355 ----- ----- 70% at 500 hrs
1
Secant modulus at 5% elongation.
2 Results for machine direction, MD, and cross machine direction, CMD, are required.
3
Minimum average roll values shall be in accordance with ASTM D 4759.

110 (b) Type II

Property Test Method Unit Value, Min.

Open Area COE, CW02215 % > 50.0 ≤ 80.0
Tensile Modulus, machine direction ASTM D 66371,2 lb/ft 49,300
Ultraviolet Stability ASTM D 4355 70% at 500 hrs
Creep Limited Strength, machine
ASTM D 5262 lb/ft 1,090
direction at 5% strain
1
Secant modulus at 2% elongation.
2 Minimum average roll values shall be in accordance with ASTM D 4759.

(c) Type III

Geogrid material shall be of high-density polyethylene, HDPE; polypropylene,
PP; or polyester, PET, polymers and have the following properties:

Property Test Method Unit Value, Min.

Open Area COE, CW02215 % > 50.0 ≤ 80.0
Ultraviolet Stability ASTM D 4355 70% at 500 hrs
Ultimate Strength, machine direction ASTM D 6637 lb/ft 1,500
Long-Term Design Strength,
GRI-GG4 lb/ft 1,000*
Allowable, LTDS, machine direction
* Minimum Average Roll Value, MARV: Property value calculated as average minus
two standard deviations.

1076
 919.01

T
LTDS
RF RF RF
Where:
120
Tult = Ultimate strength
RFCR = Reduction factor for creep
RFIR = Reduction factor for installation damage
RFD = Reduction factor for durability

The minimum reduction factors are as follows:

RFCR = 2.6 for HDPE, 4.0 for PP, 1.6 for PET
RFIR = 1.10
RFD = 1.10

918.06 Fabric for Waterproofing

Fabric for waterproofing shall be treated cotton in accordance with ASTM D 173,
130 woven glass in accordance with ASTM D 1668, or glass fiber mat in accordance with
ASTM D 2178. Material furnished under this specification shall be covered by a type
C certification in accordance with 916.

SECTION 919 – TRAFFIC SIGNS

919.01 Traffic Signs

Traffic signs shall be in accordance with the MUTCD.

Panel sign fabrication shall not utilize overlapping or butt splicing of reflective
sheeting. Roll splices, as supplied on the roll of sheeting by the sheeting manufacturer,
are allowed subject to the following conditions.

10 (a) a maximum of one roll splice per panel, and

(b) a maximum of three roll splices per sign.

Exit panels are considered a part of the signs to which they are attached when
fabricated under the same contract. If the exit panels are made for separate installation,
only one roll splice is allowed on the entire sign.

Overlap splices on sheet signs will be allowed only because of insufficient

sheeting width on signs whose smaller dimension exceeds 48 in. The overlap splice
shall be installed in a shingle type manner using a horizontal lap. The lap width shall
20 be a minimum of 1/4 in. Butt splices shall not be used. Roll splices are allowed on
sheet signs but shall not exceed one splice per sign.

All signs shall be packed for shipment and handled during construction in
accordance with the manufacturer’s recommendations. All sign or sign face damaged
prior to acceptance shall be replaced or repaired. Damaged sheet signs shall be
1077
 919.01

replaced in their entirety. Damaged panel signs shall have the affected panels replaced
or repaired in accordance with the manufacturer’s recommendations.

Repaired areas on panel signs shall not be larger than 3 in. by 3 in. Repaired areas
30 1 in. by 1 in. or less shall be limited to a maximum of three per panel and a maximum
of six per panel sign. Repaired areas larger than 1 in. by 1 in. shall be limited to one
per panel and a maximum of three per panel sign. The maximum number of repaired
areas shall be three on a panel or six on a panel sign. No more than 20% of the total
number of panel signs may be patched. Panels with sheeting cracked at the bend
around the panel edge shall be replaced.

A sign with the metal face damaged greater than superficial deformation shall be
replaced.

40 (a) Backing Material

Fabrication, including cutting and punching of holes but excluding holes for
demountable copy, shall be completed prior to surface treatment. Material shall be cut
to size and shape and shall be free from buckles, warp, dents, cockles, burrs, and
defects resulting from fabrication. The surface shall be a plane surface.

Metal sign base material shall be cleaned and prepared to receive the sheeting
material in accordance with the sheeting manufacturer’s recommendation.

1. Sheet Signs
50 The backing material for permanent sheet signs shall be sheet aluminum in
accordance with ASTM B 209, alloy 5052H38, or alloy 6061-T6.

The minimum thickness of the sheet shall be as shown for the appropriate sign
width.

Width, in. Thickness, in.

Up to 30 0.080
31 to 60 0.100
61 and Over 0.125

Backing material for temporary ground mounted signs shall be aluminum, steel,
fiberglass, reinforced plastic, or plywood, unless otherwise approved.

60 2. Panel Signs
Extruded aluminum panels shall be in accordance with ASTM B 221, alloy 6063-
T6, and be 12 in. in width. Extruded aluminum panels shall be flat and straight within
tolerances established by the aluminum industry. The weight for panels shall be 2.48
lb/ft.

Trim molding shall be of the same material and thickness as the panels to which
it is attached.

1078
 919.01

Panel bolts, flat washers, and lock-nuts shall be in accordance with ASTM B 211,
70 alloy 2024-T4. Panel bolts shall be 3/8 in. by 3/4 in. standard hex head. Lock-nuts
shall be standard hex head.

3. Demountable Letters, Numbers, and Symbols

Backing material for letters, numbers, and symbols shall be 0.040 in. thick
aluminum sheets in accordance with ASTM B 209, alloy 3003-H14. Borders shall be
0.032 in. thick aluminum sheet in accordance with ASTM B 209, alloy 6061-T6.

(b) Sheeting Material

Only sheeting materials from the Department’s list of approved Sign Sheeting
80 Materials shall be used. Type IV or higher sheeting shall be used for highway signs.
The sheeting type for the sign copy and border shall be the same type or higher than
the sheeting type used for the background. Sheeting materials will be placed and
maintained on the Department’s approved list in accordance with ITM 930.

1. Reflective Sheeting
Reflective sheeting used for signs, channelizing and delineation devices shall be
in accordance with ASTM D 4956.

For contracts let on or after September 1, 2019, type IV or higher white and
90 fluorescent orange reflective sheeting shall be used for drums utilized on interstate
routes and ramps.

For contracts let on or after September 1, 2020, Type IV or higher white and
fluorescent orange reflective sheeting shall be used on all drums, tubular markers,
vertical panels, and 42 in. cones.

Type V or higher reflective sheeting shall be used on delineators, except for

barrier delineators which shall be Type III or higher.

100 Reboundable reflective sheeting shall be used on plastic drums, flexible delineator
posts, and other flexible channelizers.

The reflective sheeting shall include an adhesive backing Class 1 or Class 2 in

accordance with ASTM D 4956.

2. Non-reflective Sheeting
Non-reflective sheeting shall be in accordance with ASTM D 4956 except that the
sheeting shall not incorporate optical elements. The color shall be black in accordance
with SAE-AMS-STD-595, color No. 17038.
110
3. Transparent Sheeting
Transparent sheeting shall be a material recommended by the background
sheeting manufacturer.

1079
 919.01

(c) Letters, Numbers, Symbols, and Accessories

Letters, numbers, symbols, and accessories shall be demountable.

The reflective sheeting shall be of the same type as used on the background and
mechanically applied to the properly prepared aluminum in a manner prescribed by
120 the sheeting manufacturer.

Each demountable legend unit, supplemental panel, and border frame shall be
supplied with mounting holes and shall be secured to the sign face with aluminum
rivets with aluminum mandrels. Adhesives that, when removed, may damage the sign
face, legend unit, or border shall not be used to hold the unit in place.

(d) Fasteners

1. Sheet Signs
130 The bolts, steel flat washers, and lock-nuts used to attach sheet signs to posts shall
be stainless steel in accordance with ASTM A 276, or type 304 carbon steel in
accordance with ASTM A 307, grade A. Carbon steel hardware shall be galvanized in
accordance with ASTM A 153. Lock washers and hex nuts shall be used in lieu of the
lock-nuts when carbon steel hardware is furnished.

The bolts shall be 5/16 in. by 3 in. hex head, full threaded. The steel flat washers
shall be size no. 1/4, 0.738 in. outside diameter, 0.317 in. inside diameter, and 0.051
to 0.08 in. thick and in accordance with Military Specifications MS 15795-811. Nylon
flat washers shall be 7/8 in. outside diameter, 0.317 in. inside diameter, and shall be
140 0.032 in. thick.

2. Panel Signs and Temporary Panel Signs

The aluminum post clips shall be in accordance with ASTM B 26 or ASTM B
108, alloy 356.0-T6 and as shown on the plans. Aluminum post clip bolts shall be as
shown on the plans and in accordance with ASTM B 211, alloy 2024-T4. Lock-nuts
shall be in accordance with ASTM B 211, alloy 2017-T4. Flat washers shall be in
accordance with ASTM B 209, alloy Alclad 2024-T4.

3. Aluminum Rivets
150 Aluminum rivets shall be determined by character size and shape but shall not be
more than 8 in. on center. All rivets shall be color matched to the legend or
supplemental panel being installed.

(e) Basis for Use

Materials furnished under this specification, except those used for temporary
construction signs, temporary traffic signs, and temporary panel signs, shall be covered
by a type C certification in accordance with 916.

1080
 920.01

SECTION 920 – HIGHWAY ILLUMINATION MATERIALS

920.01 Highway Illumination Materials

All luminaires, lamps, fuse kits, wire and cable, and major equipment shall be
approved new material bearing the UL seal of approval or meet their standards.

Descriptive and technical literature shall be furnished for approval on all

equipment prior to purchase and incorporation into the work.

10 Warranties for all major equipment shall be in accordance with 807.02.

(a) Lighting Standards and Mast Arms, under 80 ft

1. General Requirements
Conventional lighting standards shall be aluminum or steel and shall be in
accordance with AASHTO Standard Specifications for Structural Supports for
Highway Signs, Luminaires, and Traffic Signals.

For conventional light standards, design wind velocity shall be 80 mph. The
20 maximum horizontal deflection of the pole under maximum loading conditions shall
not exceed a deflection angle of 1° 10" from the vertical axis of the pole for any 1 ft
section of the pole along the entire length of the pole. The maximum stress shall be
80% of the AASHTO Standard Specifications for Group I-DL loads. Vibration
dampers shall be furnished as recommended by the manufacturer. The manufacturer
may use drag coefficients based on actual wind tunnel tests; otherwise, they shall use
the drag coefficients in Table 1.2.5c of Group I loads.

Conventional light standards shall be designed to support a 53 lb luminaire with

an effective area of 2.4 sq ft. When larger luminaires are specified, the light standards
30 shall be designed to support the larger luminaires and this shall be shown on the light
standard working drawings.

Conventional poles shall have a 4 in. by 8 in. reinforced handhole centered 18 in.
above the base of the pole and a cover attached with a minimum of two stainless steel
hex head bolts. The pole shall have a removable pole cap and a wire support hook to
support the vertical drop of the wire by a service drop clamp attached to the cable. A
wiring hole with a 1 in. inside diameter grommet shall be provided where the arm is
attached. Pole bases shall be designed for mounting on anchor bolts equally spaced on
an 11 1/2 in. or 14 1/2 in. diameter anchor bolt circle. Anchor bolt covers shall be
40 furnished.

Hardware shall be type 304 or 305 stainless steel in accordance with ASTM
A 276, except where otherwise specified.

For conventional poles, a 1/2 in. by 13 UNC threaded grounding nut or other
approved method shall be provided near the bottom of and shall be accessible through

1081
 920.01

the handhole for attaching the ground wire. The ground wire shall be No. 6 AWG soft-
drawn, solid copper in accordance with ASTM B 3.

50 Mast arms less than 8 ft in length shall either be single member or truss type,
except that mast arms on bridge deck light standards shall be truss type. Single member
arms shall be a tapered tube oval shaped at the pole end with the long dimension in the
vertical plane, welded to a pole plate and bolted or clamped to the shaft with a
minimum of four 1/2 in. bolts. Mast arms 8 ft and over in length shall be truss type.
The upper member shall be a tapered tube oval shaped at the pole with the long
dimension in the horizontal plane. The lower member may be standard pipe. Both
members shall be welded to a pole plate and bolted or clamped to the pole. A minimum
of four 1/2 in. bolts at the upper member and a minimum of two 3/8 in. bolts at the
lower member shall be used if a pole plate configuration is used to attach the mast arm
60 to the pole. Mast arms that are clamped to the pole shall have a minimum of four 1/2
in. bolts per clamp. Mast arms shall provide an enclosed raceway for the wiring and
shall be free of burrs and rough edges. Each arm shall be furnished with a 2 in. nominal
pipe size slipfitter. The maximum rise of the truss style arm shall be as set out in the
table and shall be measured vertically from the centerline of the free end of the truss
to a plane through the centerline of the upper arm bracket after loading.

Mast Arm Length, ft Maximum Rise, ft

9 or less 4
10 to 14 5
15 to 19 5.5
20 to 25 6
26 to 30 8

Light standards shall be constructed to provide a nominal luminaire mounting

height above the roadway pavement as shown on the drawings. The elevations of
70 foundations above or below the edge of the pavement shall be controlled by existing
roadside conditions. The proper shaft length shall be determined by field measurement
prior to placing an order for the poles.

A variation in the nominal mounting height of ±1 ft is allowed so that the

“Effective Mounting Height”, foundation to luminaire, of the light standards may be
supplied for 40 ft nominal mounting height.

Elevation of Foundation Top with Effective Mounting Height,

Respect to the Near Road Edge, ft Foundation to Luminaire, ft
+7.00 to +5.01 34
+5.00 to +3.01 36
+3.00 to +1.01 38
+1.00 to -1.00 40
-1.01 to -3.0 42
-3.01 to -5.00 44
-5.01 to -7.00 46

1082
 920.01

The effective mounting heights for other nominal mounting heights deviate from
80 the table by the difference in the nominal heights.

2. Aluminum Lighting Standards

a. Round Seamless
The pole and mast arm shall be in accordance with ASTM B 241, alloy 6063-T4,
and of sufficient diameter and wall thickness to withstand the design loads. The pole
shall be tapered full length or tapered in the middle with the top or bottom
approximately 1/3 of the pole of constant cross section. The minimum wall thickness
for poles on breakaway couplings and steel slip bases shall be 0.219 in. Poles on
90 transformer bases or shoe anchor bases installed without breakaway devices are
exempted from this minimum wall thickness requirement. An inner tube extension, or
sleeve, fitted inside the main tube shaft, is permissible to increase the wall thickness
of the shaft starting at the bottom of the shoe base and extending upward towards the
top of the pole. The sleeve or tube extension shall be no less than 3 ft in length,
fabricated from aluminum alloy 6063-T4 and heat treated to produce a T6 temper after
placing in the shaft. The minimum wall thickness of the combination of shaft and
sleeve shall be 0.219 in. Attaching plates or clamps for aluminum mast arms shall be
in accordance with ASTM B 241, alloys 6061-T6, 6063-T6, 356.0-T6, or 5052-H32.
The bottom end of the shaft shall be welded to a one-piece cast aluminum shoe anchor
100 base of 356.0-T6 aluminum alloy in accordance with ASTM B 26 for sand castings or
ASTM B 108 for permanent mold castings or equal and provided with four slotted
holes for anchor bolts and the shaft’s full length shall be heat treated to produce a T6
temper. The top of the shaft shall be provided with a removable aluminum pole cap.
The shaft shall have no longitudinal welds. After fabrication, the shaft shall be cleaned
to a satin finish and wrapped for protection during shipping and handling.

b. Single Longitudinal Welded

The material for these lighting standards shall be round, tapered structural marine
aluminum sheet in accordance with ASTM B 209, alloy 5086-H34, and of sufficient
110 diameter and wall thickness to withstand the design loads. The minimum wall
thickness for poles on breakaway couplings and steel slip bases shall be 0.219 in. Poles
on transformer bases or shoe anchor bases installed with no breakaway devices are
exempted from the minimum wall thickness requirement. The anchor base shall be
one-piece cast aluminum in accordance with ASTM B 26, alloy 356.0-T6. The base
casting for the formed and welded shaft shall be designed to be inserted a minimum of
12 in. into the shaft and bonded to the shaft with a weatherproof structural epoxy
adhesive that fully develops the required strength as specified by the design criteria.
After fabrication, the shaft shall be cleaned to a satin finish and wrapped for protection
during shipping and handling.
120
3. Stainless Steel Lighting Standards
Stainless steel lighting standards shall be fabricated from stainless steel in
accordance with ASTM A 666, type 201, that has a minimum yield point of 68,000 psi.

1083
 920.01

Welds other than spot welds shall be performed with conventional welding equipment
and with stainless steel welding rods. Welds shall be free of cracks and pores. The wall
thickness and diameter of the pole shall be sufficient to withstand designed loads.
Exposed surfaces of the standard shall be smooth and free from marks or
imperfections. During shipment, the poles and mast arms shall be protected with a
non-staining protective material to preserve the finish.
130
4. Galvanized Steel Lighting Standards
The pole and base plate shall be fabricated from steel in accordance with ASTM
A 572, A 595, or A 1011 with a minimum yield strength of 50,000 psi. Single member
mast arms and the upper members of truss type mast arms shall be fabricated from
steel in accordance with ASTM A 572 or A 595 with a minimum yield strength of
50,000 psi. The lower member of truss type arms may be fabricated from standard
steel pipe in accordance with ASTM A 53 with a minimum yield strength of 36,000
psi. After fabrication, the pole and mast arm shall be thoroughly cleaned and
galvanized in accordance with ASTM A 123.
140
Steel standards shall be tapered 0.14 in./ft and shall be round, octagonal, or
dodecagonal. The design load shall be used to determine the pole diameter and wall
thickness. The pole shall have one longitudinal electrically welded joint. A steel base
plate shall be welded to each pole and provided with four slotted holes for the anchor
bolts.

All welds on steel standards shall be performed at the factory. Base plate welds
shall be 100% penetration. Circumferential welds shall be backed-up welds with 100%
penetration. Longitudinal welds shall be a minimum of 60% penetration. The 100%
150 penetration welds shall be ultrasonically inspected and all other welds shall be
inspected by magnetic particle. Welding shall be performed in accordance with
711.32.

5. Timber Pole Lighting Standards

Timber poles for highway lighting standards shall be in accordance with
922.10(b).

6. Frangible Breakaway Bases

All light standards, except high mast towers and those protected by bridge end
160 bents or retaining walls, shall be installed on breakaway devices. All breakaway
devices on a contract shall be of the same type and manufacturer.

Breakaway devices shall be in accordance with AASHTO Standard Specifications

for Structural Supports for Highway Signs, Luminaires, and Traffic Signals as
modified in 920.01(a)1.

A certification from the manufacturer shall be furnished with the shop drawings
stating the breakaway devices conform to the breakaway criteria of the AASHTO
Standard Specifications for Structural Supports for Highway Signs, Luminaires, and
170 Traffic Signals.
1084
 920.01

a. Cast Aluminum Transformer Base

The anchor bolts for transformer bases shall be in accordance with 920.01(a)7.
The anchor bolt circle for transformer bases shall be 15 in. The bolt holes in the
transformer base may be slotted. The pole shall be bolted to the transformer base with
four 1 in. diameter galvanized steel bolts.

An approved handhole in the transformer base may be substituted for the 4 in. by
8 in. handhole specified in 920.01(a)1.
180
b. Breakaway Coupling
Breakaway couplings may be used with aluminum poles with mounting heights
up to 50 ft and with steel poles that weigh 600 lb or less. The couplings shall be
furnished with necessary hardware including a two-piece cover. Couplings shall be
installed in accordance with the manufacturer’s instructions and recommended
clearance between the top of the foundation and the bottom of the breakaway coupling.

7. Anchor Bolts
Anchor bolts shall be 1 in. with 8NC rolled threads in accordance with ASTM A
190 307. The minimum length of threads shall be 6 in. Mean diameter of rod stock shall
be 0.918 in. ±0.011 in. and out-of-round tolerance shall be ±0.012 in. The top 10 in.
of the bolt shall be galvanized in accordance with ASTM A 153. Anchor bolts shall be
in accordance with 910.19(b). The bolts shall be a minimum of 36 in. in length for
poles 8 in. outside diameter or less and 48 in. in length for poles 9 in. or 10 in. outside
diameter. In addition to the minimum length, the bolt shall have a 4 in. right angle
bend at the unthreaded end. The anchor bolts in bridge structures shall be as shown on
the plans.

(b) High Mast Standards of 80 ft and Over

200 The high mast pole, base, anchor bolts, lowering device, installed fixtures, and
associated appurtenances shall be designed to withstand a minimum wind speed of
90 mph, gust of 117 mph, using applicable design criteria in accordance with
AASHTO Standard Specifications for Structural Supports for Highway Signs,
Luminaires, and Traffic Signals. Minimum design criteria for each fixture shall be an
effective projected area of 2.8 sq ft and a weight of 85 lb. If larger fixtures are used,
the actual size and weight shall be used in the design of the pole.

The Contractor shall be responsible for the accuracy of the dimensions and the
proper fit of all material and equipment furnished with the pole. The Contractor shall
210 provide all applicable manufacturers’ warranties for material and workmanship.
External lowering devices shall be designed to attach to the pole as shown on the plans.
The pole shall include the mounting accommodations as shown on the plans.

1. High Mast Poles

The poles shall be tapered shafts having poly-sided or circular cross sections. The
pole shaft sections shall be slip fitted and shall provide at least 1 in. radial clearance
from all interior devices.
1085
 920.01

All tower shaft components shall be fabricated from high strength, low alloy, steel
220 in accordance with AASHTO M 270; ASTM A 595, grade A or B; ASTM A 572,
grade 55; ASTM A 1011; ASTM A 606, or ASTM A 656, with a minimum yield
strength of 50,000 psi.

Sections which are slip fitted shall have slip joints with a minimum overlap of 1.5
times the diameter of the bottom of the upper section at the slip joint. Towers having
slip joint construction shall be match marked at the factory and shall be shipped
disassembled for assembly at the work site. Slip joints shall be marked to ensure that
the 1.5 times diameter insertion is provided.

230 All steel used in the base plate and shaft shall meet an impact property of 15 ft·lbs
at 40°F in the longitudinal direction using the Charpy V-Notch test. This shall be an
average of three tests per mill heat with no test below 10 ft·lbs. A copy of the certified
mill test reports for this steel and the Charpy V-Notch test results shall be submitted.
Sufficient information shall be furnished to demonstrate that this material is traceable
to the mill heat number shown on the test report.

All tower shaft hardware including hardware for the handhole door, and the latch
mechanism shall be stainless steel in accordance with ASTM A 276, type 304 or 305,
except where otherwise specified.
240
After fabrication, the pole shall be cleaned and galvanized. Galvanized steel
towers, including the handhole, handhole door, base plate, mounting plate, and all
other elements welded to the shaft shall be hot-dip galvanized in accordance with
AASHTO M 111.

2. Welding
The welding symbols and all information regarding location, type, size, welding
sequence, and welding procedure specifications shall be shown on the working
drawings.
250
Welds shall be smooth and cleaned of flux and spatter in accordance with AWS
procedure. Minimum preheats for welds shall be 100°F for seams, and 225°F for
circumferential welds.

All welds shall be performed at the factory. Circumferential welds shall be

backed-up welds with 100% penetration. Longitudinal welds shall have a minimum of
60% penetration except within 2 ft of either side of the circumferential joint, the welds
shall be backed-up and of 100% penetration. Base plate welds shall be 100%
penetration. Circumferential welds and 100% penetration longitudinal welds shall be
260 100% ultrasonically inspected. The 60% penetration longitudinal welds shall be 100%
ultrasonically or radiographically inspected for soundness. Welding shall be
performed in accordance with 711.32. Weld filler shall provide Charpy V Notch equal
to or greater than 20 ft·lbs at 0°F.

1086
 920.01

a. Inspection
The manufacturer shall provide quality control, QC, inspection. The inspector
shall be an AWS CWI, in accordance with AWS D1.1. The NDT inspector shall be an
independent non-destructive-testing inspector, certified as level II in RT, UT, or MT,
or all as applicable. Copies of the inspection reports and NDT reports shall be provided
270 to the Engineer.

The method for testing full penetration and partial penetration welds by the
independent welding inspector shall be the same as specified above.

b. Blank

3. Handholes
Openings for handholes shall be reinforced to maintain the design strength of the
pole. The handhole shall have a weatherproof gasket made of neoprene or silicone
280 rubber. The gasket shall be formed for a forced fit around the handhole or be attached
by mechanical means. Samples of the gaskets shall be furnished for approval. The door
and hinges shall be the same type steel as the poles. The hinge pins and other securing
hardware shall be stainless steel and tamperproof. The door shall be fabricated to allow
for a padlock, which is not included in the hardware. The hasp used for padlocking
shall be fabricated from stainless steel. Provisions shall be made to bolt the door
securely shut. The door shall include a bugproof and weatherproof aperture with a
minimum opening of 4 sq in. Nylon or non-corrosive screens, or other approved
methods of bugproofing shall be furnished. Two bonding plates shall be furnished
which are accessible through the pole handhole for connecting the ground wires. A
290 connection shall be furnished for an additional ground wire on the outside of the pole
near the base plate.

4. Luminaire Ring Assembly

The ring shall be fabricated from ASTM A 666, type 201 or 304 stainless steel
and shall have a removable raceway cover. The ring shall be fabricated as an enclosed
wire raceway to provide for the symmetrical mounting of the luminaires. All structural
connections shall be made with bolts and nuts.

The luminaire ring shall be supported by means of stainless steel aircraft cables
300 of seven strands with 19 wires per strand with a minimum breaking strength of 3,700
lb.

5. Head Frame Assembly

The head frame shall be made of ASTM A 666, type 201 or 304 stainless steel.
All required pulleys, rollers, or sheaves and shafts shall be constructed from
non-corrosive metallic materials. No component shall be used in the lowering device
in excess of its rating or in violation of the component manufacturer’s
recommendation. This requirement shall be applicable, but not limited to, the
compatibility of the cables and sheaves. There shall be three supports for the

1087
 920.01

310 suspension cables. A roller system or one compatible sheave for the power cable shall
be located mid-point between two of the suspension supports. To prevent the cables
from riding out of the grooves, cable guides shall be provided. The suspension cable
sheaves shall have a minimum pitch diameter of 3 1/2 in. and the power cable sheave
or individual rollers in a roller assembly shall have a minimum pitch diameter of 18
1/2 in. and shall be grooved to fit the power cable.

All components at the top of the pole shall be protected from the weather by a
dome fabricated from steel in accordance with 920.01(b)1, fiberglass, or spun
aluminum.
320
The dome shall be secured to the head frame assembly with at least eight fasteners
around the perimeter of the dome. The dome shall be reinforced at the points of
attachment and it shall be fitted to the head frame assembly so that no visible distortion
occurs to the dome when it is properly installed. The dome attachment shall be
designed to withstand pole vibration, other pole movement, and the design windload.
The fiberglass dome shall be made of material that is not subject to cracking or other
deterioration because of aging.

6. Winch Assembly
330 The winch cable shall be 5/16 in. diameter galvanized steel aircraft cable of seven
strands with 19 wires each strand with a minimum breaking strength of 9,800 lb.

The winch shall have a drum with a minimum diameter of 4 in. and drum flanges
with a minimum diameter of 8 in. The drum shall be supported at each end by a rigidly
mounted permanently lubricated bearing capable of carrying the design load. The
winch drum shall be designed to allow the cable to lay in even consecutive layers.

The winch shall be driven by a self locking, worm gear reducer. The gear reducer
shall be permanently lubricated and totally enclosed in a cast aluminum or cast iron
340 housing. The winch assembly shall be powered by an external drive system.

7. External Drive System

The external drive system shall be powered by a heavy duty reversing NEMA
frame motor with an electromagnetic friction breaking mechanism rated at a minimum
of 6 ft·lb of torque per motor horsepower (746 W). The brake shall be actuated each
time the power to the motor is interrupted. The breaking mechanism shall be an
integral part of the motor housing. The motor operated drive shall have a factory set
torque limiter or clutch. This clutch assembly shall be calibrated to position the ring at
the top of the pole and not exceed 80% of yield strength of the cable.
350
The external drive system shall operate with the 240/480 AC volt power available
at the pole or incorporate a transformer into the system. The external drive system may
use either the luminaire power plug or a separate outlet with a 600 volt, 30 ampere
rating. The external drive system shall be operated from a minimum distance of 25 ft

1088
 920.01

from the pole. The control voltage for any handheld control equipment shall not exceed
120 volts. The handheld control equipment shall be shock proof.

The external drive system shall be capable of operating all high mast pole
installations. Working drawings shall be furnished in accordance with 105.02 and shall
360 include the dimensions and the wiring diagram of the standard connections of the
external drive system. The external drive system shall be mounted on a two-wheel cart
with wheels at least 12 in. in diameter and the weight shall be distributed so that it
presents a balance load.

8. Cable Terminator
The three luminaire ring support cables shall be attached to three stainless steel
helical compression springs incorporated into the cable terminating device. These
springs shall be designed to compensate for inequalities in the cable lengths and to
maintain adequate tension on the support cables through pole and cable thermal
370 expansion and contraction.

The cable terminator shall incorporate a separate eye bolt on the bottom of the
device for the attachment of a cable or chain to hold the luminaire ring in a raised
position while the winch cable or winch assembly is being inspected or repaired. The
cable terminating device shall be designed to prevent the device from catching on the
slip joint of the structure.

9. Lightning Rod Assembly and Grounding System

The lightning rod, air terminal, shall shield the head frame assembly cover and
380 the outer edge of the luminaires within a 45° electrostatic shielded cone. The
grounding system shall include bonding plates, grounding clamps, four 5/8 in.
diameter by 12 ft copperweld grounding rods, a grounding conductor with a minimum
size of 28 strands of 14 gauge bare copper wire in rope lay configuration, 9/16 in.
diameter with a weight of copper of 375 lb per 1,000 ft, air terminal, lightening rod
and other incidental connectors. All hardware shall be stainless steel, brass, copper,
copper alloy, or equally corrosion-resistant metal.

Bonding plates, with a minimum contact surface area of 8 sq in., shall be installed
at locations shown on the plans. The bonding plates shall be welded to the tower shaft
390 during the time of manufacturing. The grounding conductor shall be secured to the
bonding plates by a two-bolt pressure plate clamp connector having a minimum of 4
in. of contact with the copper. At the point of termination the grounding conductor
shall extend beyond the bonding plate a minimum of 3 in.

Each ground rod clamp shall have a minimum of 1 1/2 in. of contact between the
grounding conductor and the ground rod. The grounding conductor shall be continuous
between the bonding plates inside the tower shaft handhole and the grounding rod
termination point.

400 Bends of conductors shall form an angle of 90° or more. Unsupported conductors
shall have a radius of bend 8 in. or greater.
1089
 920.01

10. Anchor Bolts

Anchor bolts for high mast poles shall be furnished in a pre-clustered form and
shall be a hooked deformed reinforcing bar or a hooked smooth bar. The bolts shall be
in accordance with ASTM A 615 modified to a minimum yield strength of 75,000 psi.
The top 12 in. of each anchor bolt, nut, and washer shall be galvanized in accordance
with ASTM A 153 or be mechanically galvanized and in accordance with the coating
thickness, adherence, and quality requirements of ASTM A 153, class C.
410
(c) Wire and Cable
Lighting circuit cables for direct burial shall be enclosed in polyethylene conduit.

1. Polyethylene Conduit
This conduit shall be in accordance with ASTM D 3485 either medium density
type II, class C or high density type III, class C smooth wall, coilable polyethylene
conduit for preassembled wire and cable.

The size of the conduit for different cable conductor sizes shall be as follows.
420
Size
Cable Conductor Conduit
3-1/C No. 4 1 1/4 in.
3-1/C No. 2 1 1/2 in.
3-1/C No. 1/0 2 in.
3-1/C No. 3/0 2 in.

2. Conductors in Cable-Duct
The cable shall consist of three separate electrically insulated conductors installed
in the duct so any one conductor may be easily removed without damage to the other
two. The conductors shall not be cabled or twisted together. The conductors shall be
stranded copper of the AWG size specified. Conductor sizes No. 8 AWG and larger
shall be stranded in accordance with ASTM B 8, class B.

Each conductor shall be insulated with crosslinked polyethylene manufactured in

430 accordance with Insulated Power Cable Engineer Association publication S66-524.
Each conductor shall have the following characteristics: a 600 volt rating; UL listed;
an XHHW conductor temperature rating not to exceed 90°C in dry locations; and not
to exceed 75°C in wet locations.

Each of the three conductors shall be imprinted at regular intervals with the
following description: Type XHHW; 600 volt; UL; the conductor’s AWG size and
metal or alloy; the manufacturer’s name, trademark, or other distinctive marking by
which the product can be readily identified.

440 Identification coding of the conductors shall be accomplished by complete color

coding or by ribbing of the insulation. Color coding of the insulation shall be

1090
 920.01

homogeneous throughout the entire depth and length of the jacket. The colors shall
include one black, one white, and one red. Ribbing shall consist of one non-ribbed
conductor, one single-ribbed conductor, and one double-ribbed conductor. The same
method of conductor identification coding shall be used throughout the project.

3. Lighting Standard Circuit Wiring

This wiring shall consist of two 1/C No. 10 AWG, 600 volt, THWN or MTW
insulation, stranded copper wire.
450
4. Sign and Underpass Wiring
The wiring from the switch box to the last luminaire shall be 3/C copper stranded
No. 10 AWG conductors and shall have imprinted at regular intervals along the length
of the insulation jacket the following designation: No. 10 AWG, type MTW or THHN
or THWN or Gasoline and Oil Resistant II or AWM, 600 volt, UL. The conductor
classifications shall be UL listed and have the following minimum temperature ratings:
MTW 90°C; THHN 90°C; THWN 75°C; and AWM 105°C. It shall be installed in 3/4
in. conduit between the breaker box and luminaires.

460 5. Aerial Cable

This cable shall be triplex secondary distribution cable consisting of two insulated
conductors and a steel reinforced bare copper messenger neutral. The insulated
conductor shall be No. 6 AWG stranded copper with 600 volt, XHHW-XLP type
insulation.

6. High Mast Tower Luminaire Ring Conductors

The wiring from the terminal box on the ring through the last luminaire shall be
in accordance with 920.01(c)4.

470 7. Power Cable-High Mast Poles

The power cable shall be a 4/C No. 10 AWG copper insulated electrical cable type
“SO” modified for a repetitive reeling operation. It shall be in accordance with ASTM
B 3, ASTM B 173, and IPCEA S-19-83. Conductor insulation shall be in accordance
with ASTM D 169 and IPCEA S-19-81, Paragraph 3.12. The sheath or jacket shall
meet or exceed IPCEA S-19-81, Paragraph 7.6.20.1.1. Conductors shall be color
coded.

The power cable shall have a heavy-duty 600 volt, AC 30 amp rated electrical
plug capable of disconnection in a safe manner under load conditions. The electrical
480 plug shall be moisture resistant and waterproof at both transition points.

8. Electrical Connectors
Connectors shall be a compression type of the proper size with only one conductor
per groove in the fitting. They shall be designed specifically for use on aluminum and
copper conductors, prefilled with an oxide inhibitor and installed with a hydraulic tool
according to the manufacturer’s specifications. After installation, the connectors shall
be fully insulated and weatherproofed. The connectors installed in underground
handhole shall be taped and then waterproofed as shown on the plans.
1091
 920.01

490 (d) Luminaires

Underpass, Roadway, and High Mast models shall be selected from the
Department’s list of approved solid state luminaires.

1. General Requirements
Luminaires shall be compatible with the lighting materials specified in this section
and in the plans. Luminaires, including primary fuse protection, surge protection
devices, power drivers, and other major components, shall be rated for a minimum
operational life of 50,000 hours at 77°F.

500 Luminaires shall be a single, self-contained device, not requiring on-site assembly
for installation. Connectors shall be crimp type.

All internal components shall be adequately supported to withstand mechanical

shock and vibration. Luminaires shall be tested in accordance with ANSI C136.31, 2G
loading or ANSI C136.31, 3G loading for luminaires on bridges. Testing about all axes
shall be accomplished with a single luminaire.

Luminaires shall include gasketing that will completely seal out dust, moisture,
and insects from the interior of the optical assembly and retard the formation of an
510 undesirable film from gaseous vapors on the interior of the optical assembly. The
optical assembly shall be rated at IP 66 or better in accordance with ANSI/IEC 60529
while ballasts, power drivers and surge protection devices shall be rated at IP 65 or
better.

Light sources supplied for luminaires shall be electrically compatible with the
luminaires. Luminaires shall include an integrally built in power driver. The luminaire
shall operate satisfactorily in temperatures from -40°F to 122°F with an input voltage
variation of ±10% of the rated operating voltage specified. Power consumption,
wattage, shall not exceed that which is shown on the plans. The luminaire power factor
520 shall be 0.9 or greater. Power drivers shall maintain constant current and have a
minimum Mean Time to Failure of 2,000,000 hrs as determined by Telcordia SR 332,
issue 3 or MIL-HDBK-217F methodology. Total Harmonic Distortion, THD, of the
power driver shall not exceed 20% as verified by ANSI C82.77.

Roadway lighting luminaires shall have a precision-cast aluminum housing with

weatherproof finish.

Refractors or lenses shall be scratch resistant and made from high impact, heat-
resistant, glass or UV inhibited, high impact plastic. If utilized, reflectors shall be
530 detachable and made of highly specular aluminum.

Luminaires shall have seven wire photocontrol receptacle in accordance with

ANSI C136.41 with shorting cap for adaptive lighting control.

1092
 920.01

Luminaires shall exhibit a color temperature in the range of 3500K to 4500K per
ANSI C78.377 and a minimum Color Rendering Index of 70 as verified by the IESNA
LM-79 test.

A Surge Protection Device, SPD, shall be included to protect the luminaire from
540 damage and failure from transient voltage and currents. The SPD shall conform to UL
1449 and shall be tested in accordance with, and survive, the procedure in ANSI/IEEE
C62.41.2 definitions for standard and optional waveform for location category C-
High. Once the surge current has subsided, the SPD shall automatically restore normal
operation and reset to a state ready to receive the next surge.

Luminaires shall comply with Title 47 CFR Part 15, Class A on unlicensed
transmissions in a business, commercial, or industrial environment.

Underpass and post top mounted luminaires shall be protected against salt spray
550 and conform to ASTM B117, 2,000 hrs time horizon.

Luminaires shall include vandal shields when installed on an underpass or signs

on bridge brackets and when otherwise specified. The vandal shield shall be made of
a tough durable plastic, such as Lexan, mounted in a rugged galvanized steel or
aluminum frame, and shall withstand severe impact without being damaged or
allowing the refractor to be damaged. It shall be fastened securely to the luminaire so
it cannot be removed from the outside and shall not interfere with the light distribution
pattern. It shall protect the face of the refractor and if ventilation is necessary, the
ventilating apertures shall be arranged so that they do not admit a probe of a diameter
560 greater than 1/4 in.

a. LED Luminaires
LEDs shall be connected so that the loss of one LED will not result in the loss of
the entire luminaire. LED circuitry shall prevent flickering to the unaided eye at the
voltage specified on the plans and the range indicated herein. LED junction
temperature shall not exceed 158°F.

LEDs shall deliver a minimum of 85% of the initial rated lumens after 50,000
hours of operation at 130°F ambient temperature as indicated by LM-80 lumen
570 maintenance test of the light source as calculated by IESNA TM-21, L85 > 50,000 hrs.

A passive thermal management system to dissipate the heat generated by

operation shall be provided. Fans or other mechanical cooling systems shall not be
used.

b. Light Emitting Plasma Luminaires

Plasma emitters shall deliver a minimum of 70% of the initial lumens after 50,000
hrs of operation.

1093
 920.01

580 c. Metal Halide Luminaires

Metal halide luminaires shall utilize a power driver; external capacitors or igniters
shall not be used. Metal Halide lamps used in high mast luminaires shall be supported
at both ends with mechanical spring grips or other means to hold the lamp secure
against vibration.

2. Roadway Lighting Luminaires

Roadway luminaires shall have a strong, easily operated, positive latch on the
street side of the housing with a hinge and a safety catch that prevents accidental
unhinging on the house side of the refractor or lens holder. They shall include a four
590 bolt slipfitter capable of adapting to a 2 in. mounting bracket that is adjustable ±5° for
leveling.

Luminaires shall be adjustable in the horizontal and vertical directions to meet the
specified IESNA light distribution pattern. Luminaire weight shall not exceed 53 lbs
and its projected area shall not exceed 2.4 sq ft.

3. Sign Luminaires
Sign luminaires shall be LED and operate on no more than 250W of power. Sign
luminaires shall have a shield that blocks the view of the refractor from an approaching
600 motorist. This shall be accomplished by the design of the housing or by a shield
fabricated from sheet aluminum, approximately 0.05 in. thick, and of sufficient size to
be fastened onto the horizontal edge of the refractor holder with self tapping screws
and placed between the refractor and approaching traffic.

Aluminum and steel structural members for luminaire supports shall include
aluminum conduit, conduit clamps, fittings, and stainless steel screws.

(e) Circuit Breakers and Enclosure

All circuit breaker enclosures shall be NEMA 4/5.
610
1. Circuit Breakers for Type II Service Point
The cabinet and hardware shall be weatherproof and rain tight. The enclosure shall
have provisions for pad locking. The fastener and mounting hardware shall be plated
brass, stainless steel, or aluminum. The enclosure shall be made of 14 gauge aluminum
or 14 or 16 gauge stainless steel. The circuit breaker operating handles for manual
tripping shall be concealed inside the enclosure. Computation of branch circuits shall
be based on the National Electrical Code Standard Limitation of loading breakers to
80% of their rated current. Additional details shall be as shown on the plans.

620 2. Circuit Breakers for Sign and Underpass Circuits

Sign and underpass circuit protection shall be provided by two single pole, 240
volt AC, 120 volt for 120/240 volt service, circuit breakers with ampere rating of 200%
of the normal load. The circuit breakers shall have provisions for padlocking
externally. The circuit breaker operating handles for manual tripping shall be
concealed inside the enclosure. The enclosure shall be made of aluminum or stainless
steel. Additional details shall be as shown on the plans.
1094
 920.01

3. Circuit Breakers for High Mast Poles

The enclosure shall be furnished with two single pole, 30 ampere, 480 volt AC
630 circuit breakers with a minimum symmetrical RMS interrupting capacity of 14,000
amperes. The breakers shall be accessible through the pole handhole. The circuit
breaker operating handles for manual tripping shall be external to the enclosure. The
enclosure shall be made of aluminum or stainless steel. Additional details shall be as
shown on the plans.

4. E-Series Magnetic Circuit Breakers

These breakers shall have the following features.

a. capable of 10,000 on-off operations;

640
b. interrupting capacity of 7,500 amperes;

c. temperature stable so as not to be adversely affected by

temperature changes over their operating environment
of -40°F to 185°F;

d. lug range 1/0 - 14 copper and 1/0 - 12 aluminum; and

e. trip on overload, even when handle is forcibly held in

650 the ON position.

(f) Multiple Relay Switches with Photocell Receptacles

Multiple relay switches with photocell receptacles shall have a two-pole relay for
connection to a 120/240 or 240/480 volt, three-wire, single phase, 60 Hz power supply.
The relay switch components shall match the service voltage being supplied. The unit
shall contain two single pole circuit breakers with a minimum rated capacity to
withstand 100% of the rated ampere load. The circuit breakers shall trip at not less
than 125% of the rated load capacity. Control circuit arresters for lighting protection
and a manual control selector switch shall be included within the unit. The enclosure
660 shall be a cast aluminum weatherproof case, with a hinged cover, having provisions
for padlocking and a hanger for pole or wall mounting.

(g) Materials Certification

Unless otherwise specified, materials furnished under this specification require a
type C certification in accordance with 916.

(h) Junction Box

The junction box shall be polymer concrete, of concrete-gray color, with a cover
rating of 20,000 lb.

1095
 921.01

SECTION 921 – PAVEMENT MARKING MATERIALS

921.01 Blank

921.02 Durable Marking Material

Durable marking material shall be thermoplastic, preformed plastic or multi-
component pavement markings. The materials shall not contain any toxic heavy metals
above the limits of the regulatory levels of 40 CFR 261.24, table 1, when tested in
accordance with EPA TCLP, or contain any other material which will require
10 characterization as a hazardous waste when removed from the pavement surface.

(a) Thermoplastic
This material shall be in solid form in accordance with AASHTO M 249 or
supplied in a preformed state and shall not contain lead chromate pigments.

Heat bonded preformed thermoplastic shall be in accordance with AASHTO M

249 with the exception of the application properties outlined in section 5 of AASHTO
M 249 shall not apply. Drying time and short term and long term flowability
requirements are not applicable at time of installation. The material shall be capable
20 of fusing to itself and previously applied thermoplastic pavement markings when
heated. The material shall contain a minimum of 30% beads by weight. The beads
shall be homogeneously blended throughout the material. The marking thickness
throughout its width, before the material is heated up, shall be supplied at a minimum
average thickness of 90 mils.

(b) Preformed Plastic

This material shall consist of a homogeneous preformed plastic film with a width
as specified. Dimensional requirements shall meet one of the following:

30 1. Preformed plastic material shall have a smooth plane surface, with

a minimum thickness of 60 mils throughout the entire cross section,
or

2. Preformed plastic material shall have an embossed patterned surface

with 35% to 65% of the surface area raised. The edges of the raised
areas shall present a near vertical face to traffic from any direction.
The minimum thickness of the raised area shall be 60 mils. The area
between the raised areas shall be a minimum of 20 mils measured at
the thinnest section of the cross section.
40
The material shall have a precoated adhesive. The adhesive shall allow the
preformed plastic material to be repositioned on the pavement surface to which it is
applied before permanently fixing it in its final position with downward pressure.

The material shall be capable of being affixed to either HMA or PCCP by means
of the precoated adhesive and, following the initial application of pressure, shall mold

1096
 921.02

itself to pavement contours, breaks, and faults by traffic action at normal pavement
temperatures.

50 The near vertical faces of patterned preformed plastic shall be coated with a layer
of beads.

A type C certification in accordance with 916 shall be furnished for the marking
materials except materials used for temporary pavement markings.

1. Packaging
Each package shall be marked to indicate the color of the material, specific symbol
or word message, the batch number, the manufacturer’s name, address, and the date of
manufacture.
60
2. Basis For Use
A type C certification in accordance with 916 shall be furnished for the preformed
plastic material except materials used for temporary pavement markings.

(c) Multi-Component
The material shall be for use on both HMA and PCC pavements. The material
shall consist of a pigmented resin system of epoxy. The multi-component pavement
markings shall be ultra-violet light resistant and shall not darken during the heating
conditions of application, chalk, crack, show appreciable degradation or discoloration
70 due to sunlight exposure and aging of the markings. The cured multi-component
pavement markings shall be impervious to salts, grease, oil, fuels, acids, alkalies and
other common chemicals that may be found in or on HMA and PCC pavements. The
pigment in the white material shall contain titanium dioxide in accordance with ASTM
D 476.

The material shall be provided in containers, which are in accordance with current
Federal DOT regulations. Each container shall be labeled in accordance with 29 CFR
1910.1200 and include the trade name or trade mark, formulation or product
identification, date of manufacturer, color, batch or lot number, component
80 identification and mixing instructions.

Multi-component pavement marking material furnished under this specification

shall be covered by a type C certification in accordance with 916.

(d) Snowplowable Raised Pavement Marker and Cast Metal Base

Snowplowable raised pavement marker shall consist of a cast metal base to which
is attached a replaceable prismatic reflector for reflecting light longitudinally along
the pavement from a single or from opposite directions. Both ends of the casting shall
be shaped to deflect a snowplow blade upward.
90

1097
 921.02

The prismatic reflectors and cast metal bases shall be in accordance with ASTM
D 4383. Only prismatic reflectors and cast metal bases from the Department’s list of
approved snowplowable pavement markers shall be used.

A type B certification in accordance with 916 shall be furnished for the epoxy
material.

1. Epoxy Adhesive
The epoxy adhesive shall be in accordance with AASHTO M 237, type IV,
100 Table 3 with respect to composition and performance. A type B certification in
accordance with 916 shall be furnished for the epoxy material.

2. Blank

(e) Pavement Marking Beads

A type C certification in accordance with 916 shall be furnished for the beads.

1. Standard Beads
Beads shall be glass in accordance with AASHTO M 247, Type 1. The beads shall
110 have a moisture resistant coating.

2. Modified Standard Beads

The modified standard beads shall be glass in accordance with AASHTO M 247,
Type 2. These beads shall have a moisture resistant coating and may have an adhesion
promoting coating.

3. Supplemental Beads
The supplemental beads shall be glass in accordance with AASHTO M 247, Type
4 except the beads shall have a minimum roundness of 80% by weight.
120
These beads shall a have a moisture resistant coating and may have an adhesion
promoting coating.

4. Supplemental Elements
These shall be for color, skid resistance, or wet weather retro-reflectivity and may
be used provided they do not exhibit a characteristic of toxicity referenced in
AASHTO M 247. A type D certification in accordance with 916 shall be furnished for
the supplemental elements.

1098
 922.02

SECTION 922 – TRAFFIC SIGNAL MATERIALS AND EQUIPMENT

922.01 Description
Unless otherwise specified, traffic signal materials and equipment shall be in
accordance with the NEMA TS2 2003 Standards Publication, and be compatible with
the Department’s current inventory of signal equipment.

922.02 Traffic Signal Control Equipment

Models shall be selected from the Department’s list of approved Traffic Signal
10 and ITS Control Equipment, unless otherwise specified.

(a) Model Approval

Each model of controller assembly, CA, and all major units, as defined in NEMA
TS2-2.1.1, will be tested and evaluated by the Department’s Logistical Support Center,
and approved prior to use. The CA, as defined by NEMA TS2-1.1.7, as being a
complete electrical unit, shall include major units operational in a TS2 environment.
Major units of the CA are defined as controller unit, CU; malfunction management
unit, MMU; bus interface unit, BIU; cabinet power supply; load switches; vehicle
detector equipment; cellular modems; radio modems, and flasher. The evaluation of a
20 product will be considered when the Department receives the preliminary product
evaluation submittal form. The Department will advise the manufacturer or vendor, of
the date of delivery at which time a presentation of the product will be required
accompanied by the product brochure, the operational manual containing procedures
for all features incorporated in the CU’s design, and the maintenance manual
containing all schematics, pictorial parts layouts, components parts listings, and
documented theory of operation. Certification in accordance with 922.02(d) shall also
accompany the preliminary product evaluation form. If a product has TS2
communicative capabilities, then a data analysis interpretation offered in a decimal
form expressing frames by an SDLC protocol analyzer shall accompany the initial
30 documentation as well. When accuracy of documentation is validated, the evaluation
period may commence. In addition, all computer system software applicable to a
manufacturer’s product shall work with the Department’s current operating systems
so that upgrades will not be needed to recognize the full potential of the product. Any
product under evaluation that has an operational failure occurring during the bench
test procedure will be rejected and returned to the submitter. The product will not be
considered for future evaluation without a cover letter documenting failures
encountered and changes to the design to correct the failures. A presentation by the
manufacturer of the product in question and explanation of why the product failed will
be required. Resubmittal of the original product will be expected for testing,
40 evaluation, and approval. Furthermore, two more rejections of a product submitted for
evaluation will be cause to deny approval of that model permanently.

The controller model shall be fully NTCIP 1202 compliant, and be capable of
logging time-stamped controller event data at 100 ms resolution. The events collected
shall be logged in the Department specified data file format and shall include but are
not limited to, start and termination of all phase green, amber, and red, pattern changes,

1099
 922.02

and all detector actuations and terminations. Data log file shall be accessible for
standard FTP retrieval directly from the controller model’s internal FTP server via the
IP addressable RJ-45 Ethernet port.
50
Continued failures indicative of a trend, repeated random malfunctions, or NEMA
non-compliance of an approved product shall be cause to remove that model from the
Department’s list of approved Traffic Signal and ITS Control Equipment. If the
manufacturer makes any changes to an approved model of a major unit or controller
cabinet terminal/facilities to correct a non-NEMA compliant or safety issue, the
Department shall be notified immediately. The manufacturer shall correct all existing
equipment purchased by the Department either directly, by contract, or through
agreement prior to the change being incorporated at the manufacturer’s production
level.
60
A design change to an approved model of a CA or any major unit shall require a
submittal of documented changes. At the discretion of the Department, resubmission
of the model for testing, evaluation, and approval may be required. The permanent
addition or removal of component parts or wires, printed circuit board modifications,
or revisions to memory or processor software, are examples of items that are
considered to be design changes.

(b) Controller Assemblies or Major Units Furnished and Installed by the

Contractor
70 A CA, as defined by NEMA TS2-1.1.7, shall be provided by the Contractor and
shall be built to the specifications of the intersection design.

Each CA shall be supplied with three documentation packets. The documentation

shall be provided in both paper hard copy and electronically as specified for each
document. Each packet shall consist of:

1. One complete set of wiring and schematic diagrams for all

of the CA’s panels, racks and wiring; the electronic
document shall have a minimum of one indexed page for
80 each paper sheet.

2. A parts list indicating contract number, vendor, category,

manufacturer, model, serial number, software/firmware
version as applicable, and inventory number of all major
units incorporated in the CA; the electronic document
format and the blank worksheet shall be obtained from the
Department’s Logistical Support Center.

3. An 11 by 17 in. intersection design plan.

90
4. A completed Department approved loop tagging table; the
electronic document format and the blank worksheet shall

1100
 922.02

be obtained from the Department’s Logistical Support

Center.

5. Packet number 2 shall also include a paper hard copy and

an indexed and searchable electronic format file of the
instructional programming manual identical in nature to
that approved for use during the evaluation of each product
100 and shall include a TS2 type 2 to TS2 type 1 adapter
harness.

All electronic documents shall be saved to CD in the specified format for each
document. Each packet shall be labeled with the name of the intersection, the contract
number, the commission number and the date of installation. Packet destinations shall
be as per 805.08.

A 60-day burn-in period of traffic control equipment shall be required prior to

acceptance of the contract. The Contractor shall be responsible for all costs associated
110 with vendor or manufacturer warranty service until acceptance of the contract, or
acceptance of that portion of the contract where the traffic control equipment is
installed.

(c) Warranty
The manufacturer’s or vendor’s warranty shall be provided for the following
components: all major units operating in a TS2 environment, light emitting diode,
LED, signal indications, load switches and flashers. Warranty periods shall commence
from the date of field placement of the device or on the date of signal turn-on as shown
on the IC 636A form if purchased through a contracting agent.
120
(d) Certification of NEMA TS2 Traffic Control Equipment
The following certifications shall be furnished.

1. Certification of a Production Run Model

A certification representing each model of approved major unit of a CA shall be
on file with the Department. A certification of a production run model for a CU will
be valid for a maximum period of five years from the date of approval or unless a
significant change is made in the CU. If a significant change is made, a new
certification shall be submitted. A significant change shall be the addition or deletion
130 of any function or feature in the control unit, or any other change as defined in
922.02(a) to the circuitry in the product.

2. Certification of Environmental Testing

A certification shall be furnished with each major unit approval request indicating
it has been tested and is in accordance with the tests from NEMA TS2-2. The
certification shall specify the model and serial number of the product being tested. A
complete log of each test shall be provided to the Department and will be maintained
by the Department. The log shall show which, if any, controller component failed

1101
 922.02

during the test, when it failed, and what steps were taken to repair the controller. The
140 log shall include the date of testing, name and title of person conducting the tests, a
record of conditions throughout the tests, and a temperature and humidity verses time
chart. The maximum report interval of any chart shall be 24 h. The chart shall be from
a recording machine used to monitor the status of the environmental chamber during
testing.

(e) NEMA TS2 Fully Actuated Solid State Controller Unit, CU

The following requirements are the minimum for the design and operation of a 16
channel fully actuated solid state CU. The NEMA TS2 configuration will consist of 2
types of CU’s, type A1 and type A2, as defined in NEMA TS2-3.2.
150
The CU shall be in accordance with NEMA TS2 Standards, all provisions
contained herein, and the Department’s specifications. Manufacturer specific
enhancements are acceptable; however, no function or device shall preclude the
interchangeability of a CU with another CU of like NEMA specification within a
controller assembly.

1. General Requirements
The CU shall be microprocessor based and both versions shall contain a three-
port configuration and shall operate in the NEMA TS2 type A1 environment.
160
The CU shall include provisions for time-of-day programming. The CU shall be
capable of a minimum of 50 programmed events and be in accordance with NEMA
TS2-3.8.

A removable nonvolatile EEPROM module or removable serial, flash-based, non-

volatile data module shall be utilized in each CU to maintain all programmed data. A
real-time clock shall be either battery-backed or powered by a super capacitor and
active during a power outage so as to provide complete time keeping functions and
leap year corrections. A switch or other means shall be provided to turn off or
170 disconnect battery power during storage. This shall be accomplished without physical
removal of the battery. Batteries within the CU shall be turned off or disconnected
during storage and shipment.

Programming and maintenance manuals for approved CU’s shall be identical in

nature to that approved for use during the evaluation period of the CU. The Department
shall be notified of any changes to the manuals.

Serial number and model numbers shall be permanently applied on or near the
front of circuit boards of the CU and viewable without removing or disconnecting the
180 board. Serial number and model number of the main frame shall be permanently
applied externally on top or on the front panel.

2. CU Requirements
The requirements set forth herein refer to a type A1 and A2 CU. Where
differences occur between types, it will be designated.
1102
 922.02

The CU shall have, as a minimum, the internal diagnostics defined by NEMA

TS2-3.9.3.

190 The CU shall monitor and log the status of events as specified in NEMA TS2-
3.9.3.1.5 in non-volatile memory and shall be selectable via program entry and be
retrievable by the system computer via NEMA port 2 or 3. In addition, the CU shall
have the ability to log an MMU fault as it occurs. A minimum of 16 entries shall be
stored in non-volatile memory. When capacity is exceeded, the oldest entry will be
replaced by the newest. Logged entries shall at minimum contain the date and time
denoted in military style with minute resolution, description of the fault as it would
appear on the MMU, and the status of each of the channel inputs at the time the fault
occurred, clearly denoting the presence of activity on a channel.

200 The CU shall be capable of all inputs and outputs listed by controller type in
NEMA TS2-3. Pedestrian timing shall be provided on all phases of a CU. The CU
shall be keyboard programmable to enable initialization in any color and phase.
Initialization shall occur after a recognized power interruption, upon MMU reset, or
upon return from manual or time-of-day flash. The CU shall be programmable from a
closed loop computer system, a laptop computer using the RS232 port, front panel
programming, and by downloading from another like CU through the RS232 port.

Keystroke buttons shall be clearly marked as to function. All programming

buttons and indicators pertinent to the operation of a phase shall be on the front of the
210 CU and shall have programmable phase omitting and phase skipping capabilities.

The TS2 type A2 CU shall be in accordance with all applicable requirements for
a type A2 CU as defined by NEMA TS2-3 and shall contain a full complement of
connectors.

The CU shall have an RJ-45 ethernet port on the front panel and ethernet module
that provide 10/100 base T interface in half or full duplex and which supports auto-
configuration of the link parameters.

220 3. Internal Modules

All plug-in modules shall be equipped for easy removal or installation without the
use of tools and shall be readily accessible for maintenance. All internal module plugs
and edge card plugs shall have the corresponding pin connector position labeled with
the first and last numbers or the first and last letters.

4. CU Enclosure
The enclosure shall be of adequate strength to protect the components during
normal handling. The keypad, liquid crystal display and all interface connectors
required for the operation and standard field adjustments shall be mounted on the front
230 panel. Fusing shall be on the front panel of the CU and shall provide protection from
internal or external overload.

1103
 922.02

The front panel of the controller shall be fastened to the frame such that no special
tools shall be required to remove or replace printed circuit board modules or to gain
access through the front panel. All hinges shall have stainless steel pins.

5. Firmware and Software Revisions

The Department’s Logistical Support Center shall be notified each time an update
or revision of the firmware or software is released, explain the changes, and the
240 benefits of the change. The Department will determine if and to what extent a revision
is to be placed into field operation and may fully re-evaluate the CU with the revision.

(f) NEMA TS2 Cabinet, Auxiliary Equipment, and Terminal and

Facilities, TF, Requirements
These standards define the minimum requirements for a TS2 type A1 cabinet,
both inside and out. The performance and construction of the cabinet shall be in
accordance with the applicable requirements of NEMA TS2 sections 4, 5, 6, and 7.
The serial number and model number of the auxiliary equipment shall be permanently
applied externally on or near the front of the product. Programming and maintenance
250 manuals for approved products shall be identical in nature to that approved for use
during the evaluation period of the product. The Department shall be notified of all
changes to the documentation. Manufacturer specific enhancements are acceptable,
however no function or device shall preclude the interchangeability of an auxiliary
product with another product of like NEMA specification within a controller assembly.

1. Controller Cabinet Requirements

The NEMA TS2 type A1 controller cabinet shall be in accordance with the
following requirements.

260 a. General
The cabinet and the shelves shall be fabricated of aluminum. The cabinet shall be
1/8 in. minimum thickness sheet aluminum or 1/4 in. minimum thickness die-cast
aluminum. The cabinet exterior and interior including shelves shall have a sandblasted,
roughened, or chemically etched finish that reduces gloss, reflection, and glare.

The main cabinet door shall use a Corbin lock No. 2 and each cabinet shall be
furnished with two No. 2 keys. The lock shall open in a counterclockwise motion only.
The door shall be capable of being opened and stopped in at least the following two
ranges of degree opening as measured from the face of the cabinet door on the hinged
270 side: 80 to 100°, and 170 to 190°. The door shall be hinged on the right side of the
cabinet. The main door and the police panel door shall close against a weatherproof
and dustproof gasket seal, which shall be permanently bonded to the cabinet. A
standard police panel key shall be provided with each cabinet.

A rain channel shall be incorporated into the design of the main door panel to
prevent liquids from entering the enclosure. A 1 1/2 in. deep drawer shall be provided
in the cabinet, mounted directly beneath the controller support shelf. The drawer shall

1104
 922.02

have a hinged top cover and shall be capable of accommodating one complete set of
cabinet prints and manuals. This drawer shall support 50 lb in weight when fully
280 extended. The drawer shall open and close smoothly. Drawer dimensions shall make
maximum use of available depth offered by the controller shelf and be a minimum of
24 in. wide.

b. Switches, Auxiliary, and Environmental Feature Requirements

The cabinet shall have a police door and a police control panel within the main
door. The police panel shall have three different switches, one switch for field
indication cutoff, one switch for flashing operation, and one switch for Auto and
Manual with a manual control jack to accept a 1/4 in. monaural phone plug jack. The
switches shall be protected from water when the cabinet door is open.
290
A test switch panel shall be mounted on the inside of the main door. The test
switch panel shall include, as a minimum, the following switches. An auto/flash switch
shall be installed so that when in the flash position, power shall be maintained to the
controller and the intersection shall be placed in flash. A stop time switch shall be
installed so that when in the ‘On’ position the controller shall be stop-timed in the
current interval. A controller equipment power On/Off switch shall be installed which
shall control AC power to the CU, MMU, and cabinet power supply. All switches
mounted on the switch panel on the inside of the main door shall have in place a
mechanism to prevent accidental activation of the switch. “Locking bat” type switches
300 or side switch guards are acceptable. Switch guards, if used, shall be in place for each
switch, shall be made of the same material as the cabinet, and shall enable the operation
of the switch without the use of tools.

All switch functions shall be permanently and clearly labeled. Handwritten

labeling will not be allowed.

The cabinet shall include all required wiring, connectors and adapters to provide
full compatibility and interchangeability with either a TS2 type A1 or type A2
controller.
310
c. Receptacle
The cabinet shall contain one duplex convenience outlet and a lamp receptacle
that is actuated and turns on when the door is open and goes off upon closing of the
door and an internal On/Off switch which can override the preceding. The convenience
outlet shall be duplex, three-prong, NEMA type 5-15R grounding outlet in accordance
with NEMA WD - 6, with ground-fault circuit interruption as defined by the National
Electric Code. These units shall be protected with a 15-ampere cartridge fuse wired
ahead of the multibreakers. An additional outlet shall be provided in each cabinet and
shall be a duplex, three-prong, NEMA type 5-15R grounding outlet wired after the
320 cabinet surge protection. This unit shall be protected with a 10-ampere cartridge fuse.
The additional outlet in master cabinets shall be powered by the 10-ampere circuit
breaker and through a separate power interrupt switch providing separate control of
the master CU power supply.

1105
 922.02

d. Fan and Filter

The cabinet shall contain a thermostatically controlled ventilating fan and a vent
with a commercially classified uniform 1 in. thick filter. The thermostat shall be
manually adjustable from 90 to 115°F. The fan shall be mounted internally at the top
and toward the front of the cabinet to exhaust out the front top lip of the cabinet. The
330 fan shall be rated at a minimum of 100 cu ft per minute as designated by NEMA TS2-
7.9.1. The thermostat shall be located within 6 in. of the fan.

The filter size will be according to the provisions for the type of cabinet as stated
in NEMA TS2-7.9.2.3 and shall be a replaceable pleated air filter with a minimum
efficiency reporting value, MERV, rating of 5 or higher as defined by the ASHRAE
52.2-2007 specification. The cabinet ventilation shall be in accordance with NEMA
TS2-7.9. The diameter of circular openings for cabinet ventilation shall not exceed 3/8
in. The short dimension for slotted openings shall not exceed 3/8 in.

340 Each inductive device, including the fan, shall have a separate power surge
protection.

2. Load Switch and Flasher Requirements

The cabinet shall contain a jack mounted type 3 solid state non-repairable flasher
in accordance with NEMA TS2-6.3 electrical and physical dimensions.

The pedestrian load switch and the signal load switch shall be an approved unit
meeting all electrical and physical dimension requirements in accordance with NEMA
TS2-6. The load switch shall not use a printed circuit board to transmit the 115V AC
350 line input or signal buss output. Each load switch shall offer three indicators, one for
each circuit indicating the status of the input to the load switch.

The load switch signal outputs shall be brought to a separate terminal strip for
hook-up of the signal displays. Load switches inputs shall be capable of being
programmed for flash, overlap, vehicular, or pedestrian phases with the use of a
standard slotted or phillips screwdriver via the cabinet terminal strip. The load switch
input programming of the TS2 type A1 CU shall be accomplished through front panel
data entry of a TS2 type A1 or a TS2 type A2 CU.

360 3. Terminal and Facilities Requirements

a. General Requirements
The TF layout shall be in accordance with NEMA TS2-5.2.7. The cabinet shall
contain a main TF panel complying with NEMA TS2-5 standards. The model number
of the main panel shall be permanently applied to the front of the panel, where it is
easily readable, without removing or disconnecting the panel. Each controller input
and output circuit shall terminate on the main TF panel or on a supplementary panel.
The phase arrangement of the controller shall coincide with the channel arrangement
of the load switches and MMU. All outputs on channels 9 through 12 field connections

1106
 922.02

370 shall have a 1μF capacitor placed at each output terminal on the front of the TF panel.
All TFs within the cabinet shall be readily accessible for field connection without
removing the controller or associated equipment and for maintenance in the cabinet.
All stranded wiring shall be tinned. A 24 volt relay shall be used on the TF to remove
24V DC from the common side of the load switches, effectively taking the mercury
relay out of the circuit when the signal is put in mechanical flash. The TF panel shall
be hinged at the bottom and capable of swinging down, to allow accessibility of the
wiring and terminals at the rear of the panel. The backpanel shall be attached to the
cabinet such that access to the backside of the backpanel, for maintenance purposes,
shall be accomplished without the use of special tools or removal of auxiliary panels,
380 shelving, or other cabinet appurtenances. A bracket extending at least half the length
of the NEMA load switch shall support all load switches.

Terminals shall be consecutively numbered on both sides of the TF panel and shall
be in compliance with the appropriate schematic diagrams. All positions for load
switches, flasher, and mechanical relays shall have reference designators on both sides
of the TF panel. All nomenclature shall be on or adjacent to the component or terminal.
All nomenclature shall be machine produced and not handwritten. Cabinet prints shall
identify the function of each terminal position.

390 CU and MMU harness cables shall be of sufficient length to allow units to be
placed on either shelf or on top of the cabinet while remaining in operational mode.
RS485 port 1 communications cable shall also be of sufficient length to allow any port
1 cable to be utilized with any TS2 unit within the CA. The RS485 harness shall be
constructed of a high quality shielded communications cable. The TF panel shall
contain a resistor/capacitor network circuit which will provide an external restart pulse
to initiate the startup sequence upon initialization from flash.

Remote flashing shall be provided for all signal circuits. Unless otherwise
indicated on the plans, phases 2 and 6 shall be wired to flash yellow. All other phases
400 shall be wired to flash red. Flashing for signal circuits shall be activated on one circuit
for odd numbered phases and on the other circuit for even numbered phases.

b. Power Panel Requirements

A transparent plexiglass cover shall be provided over the CA power supply panel.
The cover shall leave the switches on the breakers exposed as well as leave access to
terminals at the bottom of the panel for wiring purposes. No terminals on the power
panel shall have silicon protectant on them in lieu of the plexiglass cover. The panel
shall contain a multi-breaker with one 10A circuit breaker to provide overload
protection to the CU, MMU, BIU, +12/24V DC cabinet power supply, and detection
410 devices. It shall also contain one main circuit breaker of 35 or 40A, to provide over-
load protection to the signal and flash bus load. All breakers shall have line and load
terminals clearly labeled. The signal bus shall be connected to the incoming AC line
through a mercury contact switch or a solid state control device functionally equivalent
to the NEMA 5.4.2.3 specified contact switch. The terminals for AC + and − input to
the cabinet shall be capable of accepting a No. 6 wire.

1107
 922.02

With the CA 10A and main 35 or 40A circuit breakers ‘Off’ (tripped), all units
inside the cabinet and the intersection display shall be ‘Off’. With the 10A breaker
‘On’ and main 35 or 40A circuit breaker ‘Off’, the signal output shall be ‘Off’ and the
420 major units within the cabinet shall function. With the 10A breaker ‘Off’ and main 35
or 40A circuit breaker ‘On’, the intersection shall be in flash mode and all units within
the cabinet will be ‘Off’.

The cabinet shall contain a 50kA, 8x20μs surge suppressor. The surge suppressor
shall be a 120V AC, 15A, minimum 2-stage parallel/series type device and protect
lines: line-neutral, line-ground and neutral-ground, have a maximum continuous
operating voltage of 140V AC, maximum clamp voltage of 350 volts and device status
indicators of green/good and red/failed. The device shall plug into a NEMA 12
position terminal base wired before and in parallel with the 35 or 40A main signal buss
430 circuit breaker and in series with the 10A circuit breaker for the solid state equipment
and provide for a tool-free replacement of the device. There shall be a minimum of
two electrical receptacles on the equipment side of the device for future auxiliary
equipment. The surge suppressor shall operate between -30 to 165°F. The dimensions
of the unit shall not exceed 4 1/2 in. wide by 7 in. long by 3 1/2 in. deep.

All equipment capable of operating at 12 or 24V DC typically powered by an

individual receptacle type power supply shall have a power cable permanently wired
into the cabinet and the device shall be powered by the cabinet TS2 power supply.

440 4. MMU Requirements

The cabinet shall contain a MMU and shall be in accordance with the standards
of NEMA TS2- 4. The MMU shall be wired to monitor each load switch output.

5. BIU Requirements
All BIU’s shall be in accordance with NEMA TS2 2008, Section 8. Edge mounted
printed circuit boards and rack cards shall not have jumper wire modifications unless
the jumper wires are permanently bonded to the PCB over its entire length. BIU’s shall
be supplied with each cabinet to allow for maximum phase and function utilization for
which the cabinet is designed.
450
6. Loop Amplifier Units and Rack Requirements

a. General
All loop amplifier units shall be in accordance with NEMA TS2-6 and shall follow
type C, two-channel with delay and extend, as stated in NEMA TS2-6.5.2.2.1. All
amplifiers shall be selected from the Department’s List of Approved or Prequalified
materials for each type of amplifier. In addition, loop amplifiers shall have an LCD
display or a RS232 serial data connection and software interface capable of displaying
loop status including but not limited to operating frequency and -ΔL/L, diagnostics,
460 and all amplifier settings and operating parameters. Edge mounted printed circuit

1108
 922.02

boards and rack cards shall not have jumper wire modifications unless the jumper
wires are permanently bonded to the PCB over its entire length.

All detection components including amplifiers, racks, auxiliary BIU, interface

panels, lead-ins, and all connecting harnesses shall provide one count output channel
per lane of each approach within project limits.

All loop amplifiers designated for counting shall meet all requirements as above
and shall additionally transmit channel 1 and 2 count pulses on the edge connection
470 assigned to channels 3 and 4 respectively. Counting amplifiers shall be configured
with count outputs mapped to and recorded in the CU detector logs. The status output
of each active counting channel, 3 and 4, shall be set to logic ground by software
configuration within the amplifier or externally by use of jumper card in the adjacent
slot.

An auxiliary BIU panel may be used strictly for count outputs, channels 3 and 4
only, in this configuration, the status outputs for those count output channels may be
wired to logic ground on the BIU panel. The status outputs for all standard output
channels shall provide accurate status data at all times. All detector input data to the
480 CU shall remain accurate at all times.

All M and P-1 cabinets shall incorporate a 16 channel detector rack, configuration
No. 2, as per NEMA TS2-5.3.4 and shall allow operation of a two- channel detector
in each slot and the capability of operation of a two-channel counting amplifier in each
even-numbered slot with the respective count outputs in each odd numbered slot. The
number of detector racks provided shall be determined by the loop tagging table. All
G cabinets shall incorporate an eight-channel detector rack, configuration No. 1, as per
NEMA TS2-5.3.4.

490 All detector loop panels and detector racks shall be labeled according to the loop
tagging table and as follows.

All detection shall be labeled in such a way that the numbering for any loop is
consistent throughout the cabinet; the loop terminated as Loop or Detector 17 shall be
Detector Channel 17 in the detector rack and Detector Input 17 to the controller.

b. Loop Termination Panel

Each loop lead-in panel shall be labeled on the upper left corner with the loop
numbers that are terminated on that panel as follows: (1-16), (17-32), (33-48), (49-64).
500 Each loop termination point shall be labeled with the corresponding loop number.
Example: For panel 17-32: loops terminated on this panel will start with 17 and end
with 32.

c. Detector Rack
Each detector rack shall be labeled at the bottom of the rack with a continuous
label. The label shall be 1 in. wide, thermal printed black on clear, white or matte

1109
 922.02

polyester tape with permanent adhesive, water, chemical and scratch resistant printed
with 4 lines of Arial, size 10 font. Below the BIU shall be the BIU number and detector
channel numbers that are contained within the rack as follows: (1-16), (17-32), (33-
510 48), (49-64). This area shall also contain the intersection for diamond interchanges
controlled from one cabinet. Each slot shall be labeled below the module with the
corresponding loop tag information; the count output number portion of the
information shall be under the first part of the tag information. For each two-channel
module, channel 2’s label shall be below channel 1’s label.

7. Cabinet Power Supply Requirements

The TS2 cabinet power supply shall adhere to the guidelines of NEMA TS2-5.3.5.
The power supply shall be encased on all sides so that no circuitry is exposed to the
user.
520
(g) Cabinets

1. G Cabinet (Size 3)
The G cabinet shall be pedestal-mounted or pole-mounted. As per NEMA TS2-
5.3, the TS2 type 1 G cabinet, at minimum, shall house an eight-load switch bay
(configuration 2) terminal and facilities panel and shall have 1 adjustable shelf located
12 in. below the top of the cabinet. The bottom of the cabinet shall be reinforced to
ensure a secure pedestal mounting. The G cabinet shall have dimensions of 25 in. wide,
38 in. high, 18 in. deep with a tolerance of + 4 in. in any or all dimensions.
530
A cabinet slipfitter shall be used to attach the cabinet to the pedestal. The slipfitter
shall fit a 4 1/2 in. outside diameter pipe and shall have a minimum of three set screws
equally spaced around the slipfitter.

A vent of adequate size shall be provided. The size of the vent and the filter
requirements shall be in accordance with the manufacturer’s recommendations.

2. M Cabinet (Size 5)
As per NEMA TS2-5.3, the TS2 type 1 M cabinet, at minimum, shall house an
540 eight-load switch bay (configuration 2) terminal and facilities panel and shall have two
adjustable shelves with the first shelf located 15 in. below the top of the cabinet and
the second located 7 in. below the first shelf.

The M cabinet shall be ground-mounted on a concrete foundation at locations and

dimensions as shown on the plans.

The M cabinet shall have dimensions of 30 in. wide, 48 in. high, and 16 in. deep
with a tolerance of ±2 in. in any or all dimensions.

550 Anchor bolts shall be steel in accordance with ASTM A 36. Diameter of the bolt
shall be 1/2 in. or 5/8 in. and the minimum length shall be 15 in. plus 3 in. right angle
hook on the unthreaded end.

1110
 922.02

The top 6 in. of the bolt shall be threaded with 13 NC threads on 1/2 in. bolts and
11 NC threads on 5/8 in. bolts. The hexagon nut, the flat washer, and the threaded end
of the bolt shall be galvanized in accordance with ASTM A 153 or be mechanically
galvanized and in accordance with the coating thickness, adherence, and quality
requirements of ASTM A 153, class C.

560 The cabinet shall include one loop detector rack.

3. P-1 Cabinet (Size 6)

The P-1 cabinet shall be ground mounted on a concrete foundation at locations
and dimensions as shown on the plans with anchor bolts in accordance with
922.02(g)2. As per NEMA TS2-5.3, the TS2 type 1 P-1 cabinet, at minimum, shall
house a 16-load switch bay (configuration 3) terminal and facilities panel and shall
have two adjustable shelves with the first shelf a minimum of 30 in. above the bottom
of the cabinet, the second shelf having a minimum clear opening of 11 in. above the
first shelf.
570
The cabinet shall be 44 in. wide, 52 in. high, and 24 in. deep with a tolerance of
±3 in. in any or all dimensions.

The cabinet shall include two loop detector racks.

4. R Cabinet (Size 7)
The R cabinet shall be ground mounted on a concrete foundation at locations and
dimensions as shown on the plans with anchor bolts in accordance with 922.02(g)2.
As per NEMA TS2-5.3, the TS2 type 1 R cabinet, at minimum, shall house a 16-load
580 switch bay (configuration 3) terminal and facilities panel and shall have three
adjustable shelves with the first shelf located a minimum of 30 in. above the bottom
of the cabinet, the second shelf having a minimum clear opening of 11 in. above the
first shelf and the third shelf having a minimum clear opening of 11 in. above the
second shelf.

The cabinet shall be 44 in. wide, 72 in. high, and 24 in. deep with a tolerance of
±3 in. in any or all dimensions.

The cabinet shall include three loop detector racks.

590
5. Flasher - Two Circuit Alternating Flasher
Two circuit alternating flasher shall be solid state.

a. General
The solid state flasher shall periodically interrupt a source of alternating current
line power. Solid state shall mean electrical circuits, the active components of which
are semi-conductors, to the exclusion of electromechanical devices or tubes.

1111
 922.02

The flasher shall be a type 3 solid state flasher conforming to NEMA TS1-1989.
600 The flasher output circuit carrying the signal load shall consist of opto or photo isolated
solid state power relays and shall be hard wired to the flasher connector.

Three schematic diagrams and three descriptive parts lists shall be furnished with
each flasher.

Two circuit flashers shall be plug-in design. The flasher design shall not allow the
unit to be inserted improperly into the plug-in base. The flasher shall have heavy-duty
plugs and jacks capable of handling the rated load current. The rate of flash shall be
50 to 60 flashes per minute.
610
The flasher shall operate between 95V and 135V AC 60 Hz. No degradation of
performance shall be experienced in environmental changes from -20 to 165°F and 0
to 90% relative humidity.

b. Cabinet Requirements
The cabinet shall be weatherproof and fabricated from cast aluminum or
aluminum sheeting with a minimum thickness of 1/8 in. The cabinet door shall be the
entire front of the cabinet and shall be hinged on the right or left side of the cabinet. A
Corbin No. 2 lock and two No. 2 keys shall be furnished. The lock shall be located
620 near the center of the door on the side opposite the hinge.

Minimum dimensions for the cabinet shall be 12 in. deep, 12 in. wide and 12 in.
high. The maximum dimensions shall be 18 in. deep, 15 in. wide and 18 in. high.

The cabinet shall have two pole plates for stainless steel band mounting of the
cabinet on a pole with a minimum diameter of 4 in. and a maximum diameter of 18 in.
Two blank cover plates shall be provided. Two hub plates for 1 in. diameter conduit
shall be provided with gaskets, eight bolts at four bolts per plate, nuts, and washers for
attaching the hub plates to the cabinet. The cabinet shall be drilled for the mounting of
630 the pole plates or hub plates as shown on the plans.

It shall have a screened vent in the bottom with a minimum size of 1 3/4 sq in.,
and a minimum of one louvered and screened vent towards the top of the cabinet.

The panel in the cabinet shall be capable of being removed and reinstalled with
simple hand tools. A 25 ampere radio interference filter and surge arrestor wired ahead
of a 15 ampere circuit breaker shall be mounted on the panel. A terminal block capable
of the following electrical connections shall be mounted on the panel:

640 Circuit 1 - for connection of field signals (flash circuit 1)

Circuit 2 - for connection of field signals (flash circuit 2)
Circuit 3 - for connection of field signals (field neutral)
AC plus - capable of accepting a No. 6 wire
AC minus - capable of accepting a No. 6 wire

1112
 922.03

Ground lug - capable of accepting a No. 6 wire.

922.03 Signal Head Components

The components shall be in accordance with the Institute of Transportation
Engineers for Adjustable Face Vehicular Traffic Control Signal Heads. All new traffic
650 signal and flasher installations that include new indications shall be fitted with LED
modules. All LED indications shall be selected from the Department’s list of approved
Traffic Signal and ITS Control Equipment.

(a) General
The signal faces shall be sectional in construction, requiring one section for each
lens and furnished in the nominal size of 12 in. Each section of a face shall have a
rectangular silhouette when viewed from the front or the rear.

(b) Housing, Door, and Visor

660 The top and bottom of each housing shall have an integral locking ring with 72
serrations to enable rotation of the signal housing in 5° increments. Hub openings in
the top and bottom of the signal housing shall accommodate standard 1 1/2 in. bracket
arms. The thickness of the hub at the top and bottom of the housing shall be a
maximum of 1 in. and a minimum of 3/8 in. The 12 in. door shall have two simple
locking devices. The door on the hinged side shall be attached with hinge pins. Each
lens shall have the standard cap type visor. All screws, latching bolts, locking devices,
and hinge pins shall be stainless steel.

(c) Signal Indications

670
1. LED Signal Indications
All LED indications shall be selected from the Department’s list of approved
Traffic Signal and ITS Control Equipment.

All LED indications shall have a permanent indelible sticker affixed to the back
of the module indicating month and year of initial installation.

All LED indications provided shall be individually listed on a parts list indicating
the contract number, vendor, category, manufacturer, model, serial number, and
680 inventory number. Hard copy and electronic copies shall be provided. The electronic
document format and the blank worksheet shall be obtained from the Department’s
Logistical Support Center.

2. Incandescent Signal Indications

All new traffic signal and flasher installations that include new indications shall
be fitted with LED’s. The minimum design requirements for replacement incandescent
light bulbs to be used in a traffic signal face shall be in accordance with the Institute
of Transportation Engineers standard for traffic signal bulbs.

1113
 922.03

690 (d) Wiring

The field wiring leads shall be terminated with screw spade lug type connectors.
The LED module wiring leads shall be terminated with 1/4 in. female type connectors
for ease of connection to the terminal block.

(e) Section Coupling

Any method to connect two or more sections together may be used, if the
following requirements are met:

1. Two or more sections, when jointed together, shall

700 maintain structural integrity when loaded in accordance
with Institute of Transportation Engineers Standards.

2. The opening between joined sections shall accommodate

two 1/2 in. cables.

3. The maximum length of bolts used to connect sections

together shall be 4 in.

Nuts, bolts, and lock washers shall be galvanized in accordance with ASTM A
710 153 or be mechanically galvanized and be in accordance with the coating thickness,
adherence, and quality requirements of ASTM A 153, class C.

(f) Terminal Block

The center section of the three-section signal head, both center sections of the
four-section head, one section of the two-section signal head, and each one-section
signal head shall be equipped with a five-position terminal block for termination of
field wiring. Each section shall have provisions for two five-position terminal blocks.
Each terminal screw shall have a 1/4 in. corresponding spade tab. The terminal block
shall have a minimum spacing between screw connections of 1/2 in. The height of the
720 insulating ridge between screw connections shall be a minimum of 19/32 in. from the
base of the terminal blocks.

(g) Material Requirements

1. Polycarbonate Signal Head

The housing, door, and visor of the section shall be made of ultraviolet and heat
stabilized polycarbonate. The black color shall be permanently molded into the
components.

730 2. Die-Cast Aluminum Signal Head

The housing, door, and visor of the section shall be made of a die-cast, corrosion
resistant, copper free, non-ferrous metal which shall be in accordance with ASTM B
85. All surfaces of the housing, doors, and visor shall be shop painted or powder
coated. The finish shall be nonreflecting flat black, color No. 37038, in accordance
with SAE-AMS-STD-595.

1114
 922.04

(h) Signal Backplates

The traffic signal backplate shall be one piece and made of sheet aluminum. The
sheet aluminum shall have a nominal thickness of 0.063 in. and shall be according to
740 ASTM B 209, alloy 5052. The backplate shall be designed to be attached to a signal
face without interfering with the opening and closing of the traffic signal door. It shall
be rectangular in shape with round corners and shall be of such dimensions as to give
an exposed margin of 5 in. on each side.

The backplate shall have a 2 in. wide yellow retroreflective strip applied to the
outside perimeter of the backplate. The sheeting shall be Type IV in accordance with
919.01(b) and applied in the orientation for the maximum angularity according to the
manufacturer’s recommendations.

750 The aluminum backplates shall be shop painted or powder coated. The finish shall
be nonreflecting flat black, color No. 37038, in accordance with SAE-AMS-STD-595.

(i) Certification
A material certification shall accompany each order certifying that a signal head
from a normal production run within the past 12 months, passed the Institute of
Transportation Engineers criteria for breaking strength and deflection. Deflection
testing is not required in the certification for polycarbonate signal heads.

922.04 Pedestrian Signal Components

760
(a) Pedestrian Signal Head
A pedestrian signal shall be one section and rectangular in shape. The dimensions
of each side may vary from 18 to 19 in., including the visor and the hinges. The signal
shall contain two figures with two different colored messages. The first figure shall
transmit an upraised hand symbol message, and the second figure shall transmit a
walking person symbol message. All new installations including new pedestrian
indications shall use Light Emitting Diodes with countdown displays. All pedestrian
LED indications shall be selected from the Department’s list of approved Traffic
Signal and ITS Control Equipment. The pedestrian signal shall be in accordance with
770 the standard of the Institute of Transportation Engineers for Pedestrian Traffic Control
Signal Indications.

1. Housing, Door, and Visor

The housing shall be equipped with mounting device hardware, such as a
clamshell, with round openings at the top and bottom for mounting with brackets made
of iron pipe standard, to fit the 1 1/2 in. pipe. The round openings shall have a common
vertical centerline through the housing to allow for rotation. The round openings shall
have a serrated ring, with 72 serrations, which enables locking of the housing in 5°
increments. The brackets or the clamshell shall serve as the electrical conduit for the
780 pedestrian signal. The housing shall be black and made of die-cast, corrosion resistant,
copper free, non-ferrous metal which shall be in accordance with ASTM B 85.

1115
 922.04

The door on the front of the housing may be hinged from any side. The door shall
be gasketed to maintain a weather-tight enclosure when secured to the housing. The
door and the visor shall be made of the same material as the housing or of
polycarbonate. All materials shall be clean, smooth, and free from flaws, cracks,
blowholes, or other imperfections.

The polycarbonate components shall be black in color. The metal components

790 shall be painted or powder coated. The finish shall be nonreflecting flat black, color
No. 37038, in accordance with SAE-AMS-STD-595.

2. Message
The upraised hand and walking person symbols shall each be a minimum of 11
in. in height. The width of the upraised hand symbol shall be a minimum of 7 in. The
width of the walking person symbol shall be a minimum of 6 in. Message
configuration, color, and size shall be in accordance with the standard of the Institute
of Traffic Engineers for Pedestrian Traffic Control Signal Indications.

800 Each pedestrian signal shall be completely wired internally, and ready for
connection of the field wiring. A suitable terminal block for connection of the internal
wiring and the incoming field wires to the pedestrian signal head shall be provided in
the signal housing.

The light source shall be designed and constructed so that if an electrical or

mechanical failure occurs, the upraised hand and walking person symbols shall also
remain dark.

(b) Pedestrian Push-Button

810 Pedestrian push-button assemblies shall meet the standards of the MUTCD and
Americans with Disabilities Act, ADA. Pedestrian push-button assemblies shall be
vandal and weather resistant, be pressure activated with minimal movement, and
cannot be stuck in a closed or constant call position. A red latching LED and audible
tone shall be provided for confirmation of an actuation call.

A type D certification in accordance with 916 shall be provided. Such certification

shall contain the contract number, manufacturer's name, model name, supplier's name,
location or intersection name, and for a type APS pedestrian push button, the sound
level measurement of the audible features of the device.
820
1. Housing
The pedestrian push-button housing shall be constructed of cast aluminum, cast
zinc alloy, or stainless steel and powder coated yellow, and furnished with suitable
mounting hardware.

2. Latching LED
The normal state of the LED shall be off. When the push button is pressure
activated, the LED shall be lighted and remain on until the beginning of the walk

1116
 922.04

phase. The latching relay shall be mounted in the signal cabinet, controlling two
830 pedestrian phases.

3. Actuator
The actuator shall be stainless steel or aluminum with a minimum diameter of 2
in. and a solid state electronic Piezo switch rated for a minimum of 20 million cycles
with no moving plunger or moving electrical contacts. The operating voltage shall be
12-24V. The actuator’s nominal operating force shall not exceed 5 lb.

4. Sign
The pedestrian sign shall be the R10-3e in accordance with the MUTCD, unless
840 a different MUTCD sign code is indicated on the plans. The sign base shall be sheet
aluminum in accordance with 919.01(b).

5. Accessible Pedestrian Push Buttons

When accessible pedestrian signals, APS, are specified, the push-button shall have
audible and tactile features. The push-button shall activate both the Walk interval and
the APS. The color of the actuator shall contrast visually with the housing or mounting.
A standard manufacturer’s warranty shall be provided.

a. Audible Features
850 The pedestrian push-button assembly shall include an audible indication of the
Walk interval by either tone or voice and shall be audible from the near side of the
associated crosswalk. If the tone for the Walk interval is the same as the locator tone
of the push-button, it shall have a faster repetition rate than the associated locator tone.
The volume of the audible features shall have automatic volume adjustment based on
the ambient noise levels. Audible features shall be at least 2 dB but no more than 5 dB
louder than ambient sound, up to a maximum volume of 89 dB measured at 36 in. from
the device. Audible features may be integral to the pedestrian push-button assembly
or through a separate speaker housing.

860 When push buttons are separated by 10 ft or more, the audible indication shall be
a tone.

When push buttons are separated by less than 10 ft, the indication shall be a voice
message. When voice messages are used, they shall include a clear message that the
walk interval is in effect and shall indicate to which crossing it applies.

The pedestrian push button shall have an audible locator tone feature. The locator
tone shall have a duration of 0.15 seconds or less and shall repeat at 1 second intervals.

870 b. Tactile Features

The push button assembly shall incorporate a raised arrow. The arrow shall be
raised 0.03125 in. minimum and shall be 1.5 in. minimum in length. The arrow color
shall contrast with the background. The raised arrow shall vibrate to indicate that the
walk interval is in effect.

1117
 922.05

922.05 Blank

922.06 Disconnect Hanger Junction Box

Traffic signal disconnect hanger junction boxes shall consist of a span hanger, a
880 balance adjuster, a disconnect hanger clevis, and a housing with a hinged door with a
positive latching device. The span hanger, balance adjuster, and all related hardware
shall be galvanized in accordance with ASTM A 153 or be mechanically galvanized
and conform to the coating thickness, adherence, and quality requirements of ASTM
A 153. The housing shall be made of a die-cast, corrosion resistant, copper free, non-
ferrous metal which shall be in accordance with ASTM B 85. The balance adjuster
fitting shall be made of ferrous or non-ferrous metal. When made of ferrous metal it
shall be galvanized in accordance with the requirements for the components and
related hardware as set out above.

890 The disconnect hanger shall be designed so that the maximum allowable space or
play between the span hanger and the eye-bolt of the balance adjuster and between the
balance adjuster and the disconnect hanger clevis, at points where they are attached to
each other by rivet pins or hex head bolts and nuts with lock washers, shall be 0.062
in. The span hanger bolt where the eye-bolt or the balance adjuster is attached shall be
5/8 in. diameter.

When serrated locking rings are not integrally cast in the components, the
component and locking ring shall be designed so that when the locking ring is placed
flush against the component, the component and locking ring shall not rotate or slide
900 when torque is applied. The serrated components shall have 72 serrations to enable
rotation of the disconnect hanger clevis, hub plate, or signal head in 5° increments.

There shall be no thread in contact with a wearing surface. Locking rings shall be
a minimum thickness of 3/16 in. and a maximum thickness of 1/4 in. from the base of
the ring to the serration peaks. The inside diameter shall be 2 in. and the outside
diameter shall be 2 7/8 in.

The terminal block shall have an 18-point terminal block permanently engraved
or etched with sequential numbers indicating the circuits. The terminal block shall not
910 have a method of connection which allows a screw point to damage wires when the
wires are securely connected. Each point of connection shall accommodate a minimum
of four No. 14 gauge wires.

The disconnect hanger shall have two side entrance holes on opposite sides
capable of receiving a 1 1/2 in. plastic or rubber insert to reduce water infiltration. It
shall be capable of supporting signal faces in the ambient temperature range of -35 to
120°F without failure.

The balance adjuster shall have hex head bolts, lock washers, and nuts for securing
920 the main body of the balance adjuster firmly onto and around the eye-bolt to prevent

1118
 922.07

any twisting or turning of the head suspended below it. The span hanger shall have
two J-bolts, lock washers, and hex head nuts adequate in size to securely fasten the
hanger to a messenger cable up to 1/2 in. in diameter.

A type C certification in accordance with 916 shall be provided.

922.07 Signal Support Assemblies

(a) Clearance
930 The maximum allowable space or play between the hanger assembly and the
eyebolt of the balance adjuster and between the balance adjuster and the weatherhead
clevis, at points where they are attached to each other by rivet pins or hex head bolts
and nuts with lock washers, shall be 0.062 in. No bushings or shims will be allowed
in this assembly.

(b) Balance Adjuster

The balance adjuster shall consist of a hex head bolt, a lock washer, and nuts for
securing the main body of the balance adjuster onto and around the threads of the eye-
bolt to prevent any twisting or turning of the adjuster.
940
(c) Span Hanger
The span hanger, balance adjuster, weatherhead, and all related hardware shall be
made of a non-corrosive metal or shall be galvanized in accordance with ASTM A 153
or be mechanically galvanized and conform to the coating thickness, adherence, and
quality requirements of ASTM A 153. The weatherhead shall have a minimum of 2
1/2 in. of exposed threads. The weatherhead shall have two set screws to fasten the
nipple to the weatherhead. If the weatherhead and threaded pipe has a slip-in
connection, the locking device shall be a double nut assembly. If the weatherhead and
threaded pipe has a screw-in connection, the locking device shall be a double set screw
950 assembly.

The span hanger shall be furnished with two each of J-bolts, lock washers, and
hex head nuts. The J-bolt shall be a minimum of 1/4 in. diameter and shall have
sufficient threads to be able to secure the hanger to a 1/4 in. or to a 1/2 in. span cable.

(d) Tether Bracket

The tether bracket shall attach to a 1/4 in. tether and prevent the bottom of the
head from moving side-to-side on the tether. Where backplates are installed on the
signal heads, the tether bracket shall be of the proper length for the backplate so that
960 the cable is mounted below the bottom of the backplate to avoid interference with head
alignment and damage to the backplate. Three bolts, nuts, and washers, shall be used
to secure the tether bracket to a three-section or four-section signal head. A wire rope
clamp in accordance with 922.10(e)4c, shall be used to secure the tether bracket to the
tether. The tether bracket shall have predrilled 1/2 in. diameter holes. In lieu of the
wire rope clamp and 1/2 in. diameter holes, a beveled tether plate that completely fills
in the extruded portion of the tether bracket may be used to secure the tether bracket
to the tether. The tether bracket shall not extend more than 2 in. below the tether.
1119
 922.08

(e) Pipe Arm Assemblies

970 The multiple pipe arm assembly shall consist of a span hanger assembly, a balance
adjuster, a signal weatherhead, a two, three, or four- way pipe arm, 1 1/2 in. pipe, a
lower arm assembly, and all related hardware necessary for a complete assembly.

The two, three, or four-way pipe arms shall have a minimum of 2 in. of exposed
thread. Each arm of the pipe arm shall be furnished with two 72 serration locking rings.
One locking ring shall have a 3 in. outside diameter and one locking ring shall have a
2 3/8 in. outside diameter.

Maximum
Assembly
Allowable Weight
Two-way 19 lbs
Three-way 25 lbs
Four-way 28 lbs

980 922.08 Signal Cantilever Mount Signal Bracket

The bracket shall allow the following four adjustments:

(a) rotational adjustment about bracket axis;

(b) vertical adjustment;
(c) rotational adjustment about signal cantilever arm; and
(d) rotational adjustment right and left from vertical plane

The bracket shall be fastened to the supporting arm or structure with stainless steel
bands. The bracket shall adjust to fit all sizes of round, octagonal, elliptical, or other
990 shape structure without special tools or equipment.

The bracket shall attach to the signal by clamping the signal head both top and
bottom and shall be designed to accommodate the specified signal configuration. Each
bracket shall be complete with all necessary hardware to attach the traffic signal to the
bracket and the bracket to the support.

All electrical wiring shall be concealed within the bracket, except that which runs
from the bracket to the signal cantilever arm.

1000 Upper and lower arms shall be cast from aluminum in accordance with ASTM B
26, alloy 713.0-T5 or 356.0-T6. The vertical support tube shall be extruded from
aluminum in accordance with to ASTM B 241, alloy 6061-T6 or 6063-T6, and the
strapping to attach the bracket to the arm shall be stainless steel. All steel or malleable
iron parts shall be galvanized in accordance with ASTM A 153 or be mechanically
galvanized and conform to the coating thickness, adherence, and quality requirements
of ASTM A 153, class C.

1120
 922.09

922.09 Pedestal Poles and Cast Aluminum Pedestal Bases

The pedestal base used for mounting pedestrian signal heads or control cabinets
1010 shall be in accordance with 922.09(a). The length of the pedestal pole shall be as shown
in the plans.

(a) Cast Aluminum Pedestal Base

A pedestal mounted G cabinet shall have a cast aluminum pedestal base. The
cabinet and pedestal base shall be ground mounted on a concrete type A foundation at
locations and dimensions as shown on the plans.

The cast aluminum base shall be made of aluminum in accordance with ASTM B
179, alloy ANSI 319.1 or 319.2, or in accordance with ASTM B 26, alloy ANSI 356.0
1020 - T6. The square base shall include an access door and anchor bolts with nuts and
washers. The base shall be 13 3/8 in. square and 15 in. in height ±1/4 in. The weight
shall be 22 lbs ±5%.

The base shall be designed to support a 150 lbs axial load and 11 sq ft of signal
head area rigidly mounted. For design purposes, the distance from the bottom of the
base to the center of the signal head area is 18 ft. In addition to the dead load, the base
shall be designed to withstand wind and ice loads on the specified signal head area and
on all surfaces of the support, in accordance with the AASHTO Standard Specification
for Structural Supports for Highway Signs, Luminaires and Traffic Signals. Wind
1030 speeds used for design shall be based on a 10 year mean recurrence interval and a wind
drag coefficient of 1.2 or as shown in the plans. The base shall contain an access door,
which is 8 by 8 1/4 in. ±1/4 in. with a stainless steel hex head bolt for attaching the
door.

The base shall be attached to a foundation by four anchor bolts, with an anchor
bolt circle of 12 3/4 in. Slotted lugs shall be integrally cast into the four corners of the
base for attachment of the anchor bolts. The anchor bolts shall be steel in accordance
to ASTM A 36. The diameter of the anchor bolt shall be 3/4 in. with a minimum length
of 18 in. ±1/2 in., plus 2 1/2 to 3 in. right angle hook on the unthreaded end. The top
1040 4 in. of the bolt shall be threaded with 10 NC threads. The threads, plus 3 in., shall be
coated after fabrication in accordance with ASTM A 153 or be mechanically
galvanized and in accordance with the coating thickness, adherence, and quality
requirements of ASTM A 153, class C. Each anchor bolt shall be provided with two
hex head nuts in accordance with ASTM F 3125, grade A 325 and three washers. Two
of the washers shall have a minimum 2 in. and maximum 2 1/8 in. outside diameter
and be in accordance to ANSI B 27, type B regular series and one shall be a nominal
3/4 in. series W washer, in accordance with ASTM F 436.

The cast aluminum pedestal base shall be in accordance with the dimensions and
1050 requirements shown in the plans. The casting shall be true to pattern in form and
dimensions; free from pouring faults, sponginess, cracks, and blowholes; and free from
other defects in positions affecting the strength and value of the intended use for the

1121
 922.10

casting. The base shall not have sharp unfilleted angles or corners. The surface shall
have a workmanlike finish.

The door and bolt for the door shall be interchangeable on cast bases from the
same manufacturer.

(b) Pedestal Pole

1060 The top of the base shall accommodate a pole having a 4 1/2 in. outside diameter.
The threads inside the top of the base shall be 4 in. national standard pipe threads. The
pole shall be either a steel pedestal pole or an aluminum pedestal pole.

A steel pedestal pole shall be a seamless Schedule 40 carbon steel pipe in

accordance with ASTM A 53, grade B. The pole shall have an outside diameter of 4
1/2 in. The pole shall weigh approximately 10.8 lbs/ft. The length of the pole shall be
as shown on the plans. The pole shall have full depth national standard pipe threads
on one end of the pole. The length of threads shall be 2 1/2 in. The pole shall be
galvanized, after threading, in accordance with ASTM A 123. The threads shall be
1070 cleaned of all excess galvanizing and protected by a suitable shield.

An aluminum pedestal pole shall be in accordance with ASTM B 241 for seamless
aluminum alloy, Schedule 40, 6061-T6. The outside diameter of the pole shall be 4
1/2 in. The length of the pole shall be as shown on the plans. The pole shall weigh
approximately 3.7 lbs/ft. The pole shall have full depth national standard pipe threads
on one end of the pole. The length of threads shall be 2 1/2 in. and protected by a
suitable shield. The pole shall have a spun finish.

(c) Pole Cap

1080 A pole cap shall be supplied for the top of the pole if the pole is used for the
mounting of pedestrian signal faces or side mounted signal control cabinets. The pole
cap shall be either a cast pole cap of aluminum or a pole cap of spun aluminum.

A cast pole cap shall be made of aluminum, in accordance with ASTM B 179,
alloy ANSI 319.1 or 319.2. The cap shall fit freely on the 4 1/2 in. outside diameter
pole. A set screw using a 3/4 in. No. 12 hex head machine screw shall be supplied to
hold the cap on the pole. A standard foundry draft will be allowed on the casting.

A pole cap made from spun aluminum shall be in accordance with ASTM B 209,
1090 alloy 1100-0. The cap shall fit tightly when placed on the end of the pole.

922.10 Signal Supports

All welding shall be in accordance with 711.32. Welds shall generate the full
strength of the shaft. Only longitudinal continuous welding will be allowed on the pole
shaft. Contacting joint surfaces shall be cleaned before fabrication then sealed by
means of welding. Working drawings shall be submitted in accordance with 105.02.

1122
 922.10

(a) Steel Strain Pole

The steel strain pole shall be an anchor base type pole and shall include a handhole
1100 and a pole top or cap. The poles shall be furnished in lengths specified.

The pole shall have a handhole within 18 in. of the base. The pole shall have a top
or cap with a set screw that can be removed with small hand tools.

The pole material shall be in accordance with ASTM A 595 or A 572 with a
minimum yield strength of 50,000 psi. The pole shall be galvanized after fabrication
in accordance with ASTM A 123.

All hardware, handhole cover and latching device, band-type steel polebands,
1110 steel bolts, nuts, and washers shall be galvanized in accordance with ASTM A 153 or
be mechanically galvanized and conform to the coating thickness, adherence, and
quality requirements of ASTM A 153, class C. All nuts and bolts, except anchor bolts,
shall be in accordance with ASTM A 307. If a cast pole top or cap is used it shall be
in accordance with ASTM A 126 and shall be galvanized with a minimum coating of
2 oz/sq ft.

The polebands shall fit the pole as planned. The wire rope shall not be in contact
with any 90° edges or with any threads on the band. The pole band material shall be
in accordance with ASTM A 572, grade 50; ASTM A 606; or ASTM A 36 with
1120 minimum yield of 50,000 psi. The minimum width of the bands shall be 3 in. and the
bands shall be capable of supporting the pole design load. Each half of the band shall
be stamped with the corresponding size number.

The pipe coupling for the weatherhead and base plate shall be installed prior to
galvanizing. The threads shall be cleaned of all excess galvanizing. An internal J-hook
shall be installed near the top of the pole for wire support.

The steel strain pole shall be capable of supporting an 8,000 lb load applied
horizontally 18 in. below the top of the pole with a maximum allowable deflection of
1130 0.16 in. per 100 lb of load. The pole shall be tapered 0.14 in./ft of length.

A one-piece base plate shall be secured to the base of the pole and shall develop
the full strength of the pole. The base plate material shall be in accordance with ASTM
A 36, ASTM A 572, or ASTM A 588. The base plate shall have four holes of adequate
size to accommodate 2 1/4 in. anchor bolts. The bolt circle shall have a 22 in. diameter
and bolt square of 15 1/2 in.

Four high strength steel anchor bolts, 2 1/4 in. in diameter and 96 in. long,
including the hook, shall be furnished with each pole. Each bolt shall have two hex
1140 nuts and two washers in accordance with ASTM A 307, grade A. The anchor bolt
material shall be in accordance with ASTM A 576 or ASTM A 675 with a minimum
yield strength of 55,000 psi or ASTM A 36, special quality, modified to 55,000 psi or
approved equal. The threaded end of the anchor bolt shall have 12 in. of 4 1/2 NC

1123
 922.10

threads and shall be galvanized the length of the threads, plus 3 in. The threaded end
shall be coated after fabrication in accordance with ASTM A 153 or be mechanically
galvanized and be in accordance with the coating thickness, adherence, and quality
requirements of ASTM A 153, class C. The unthreaded end of the anchor bolt shall
have a standard L bend for a distance of 9 in. from the centerline of the anchor bolt to
the end of the L. In lieu of the standard bend a steel plate 4 1/2 sq in. and 1 1/4 in. thick
1150 may be welded to the embedded end of the anchor bolt.

(b) Timber Strain Pole

Timber strain poles shall be made from southern yellow pine and shall be in
accordance with the current ANSI Specifications and Dimensions for Wood Poles No.
05.1. They shall be of the length and class specified.

All poles shall be full length pressure treated by the full cell process in accordance
with current specifications as set forth in the AWPA Standards T1 and U1, Commodity
Specification D: Poles, use category UC4B using preservative as outlined in 911.02(h).
1160
Treatment, handling, and storage methods shall be in accordance with the current
AWPA Standards.

(c) Signal Cantilever Structures

1. General
All traffic signal cantilever structures, with or without combination arm, shall be
as shown on the plans.

1170 There shall be no threads in the wearing surface plane at the point of connection
between the clevis clamp and the signal face assembly. The clevis clamp shall have an
11/16 in. diameter bolt hole to receive the signal face assembly.

The signal cantilever structure pole, sections 1 and 2, signal arm, and combination
arm shall be a round or multi-sided tapered tube, except the upper 4 to 6 ft of a signal
pole may be non-tapered. The pole and arms taper rate shall be 0.14 in./ft. A 1/2 in. 13
NC threaded grounding nut or approved equivalent shall be provided and be accessible
through the handhole. The pole cap shall be secured in place with setscrews. The pole
shall be provided with a removable pole cap and integral wire support hook for the
1180 luminaire electrical cable. The cable shall be attached to the hook by a service drop
clamp.

The signal cantilever arm and combination arm, if required, shall be attached to
the pole as shown on the plans. The arms shall have cable inlets as shown on the plans.
All signal heads on the arm shall be attached as shown on the plans and installed
parallel to the horizontal plane and centered to the cantilever arm. The cantilever arms
shall be used as an enclosed raceway for wiring and shall be free of burs or rough
edges.

1124
 922.10

1190 The pole top luminaire for roadway lighting, if required, shall be installed on these
structures as shown on the plans.

2. Base Plate
A one-piece anchor base shall be supplied as shown on the plans. Four removable
bolt covers shall be provided with each base and each cover shall attach to the upright
portion of the body of the base by means of one-hex head cap screw.

3. Materials
The signal cantilever pole, arms, base plates, arm flange plates, gusset plates, ring
1200 stiffeners, and pole splice plates shall be in accordance with ASTM A 595 or A 572
with a minimum yield strength of 50,000 psi.

4. Hardware
Bolts for the pole splice shall be in accordance with ASTM F 3125, grade A 490
and shall be galvanized. The contact area for both pole splice plates shall be class B in
accordance with AASHTO Standard Specifications for Highway Bridges, Table
10.32.3C with a minimum slip coefficient of 0.5. The surfaces shall be blast cleaned
with class B coatings. The arm flange plate connection bolts shall be in accordance
with ASTM F 3125, grade A 325. All other hardware shall be in accordance with
1210 ASTM A 307 and galvanized in accordance with ASTM A 153, or be mechanically
galvanized and in accordance with the coating thickness, adherence, and quality
requirements of ASTM A 153, class C. A cast pole cap shall be in accordance with
ASTM A 126 and shall be galvanized with a minimum coating of 2 oz/sq ft.

5. Anchor Bolts
Four steel anchor bolts, each fitted with two hex nuts and two flat washers, shall
be furnished with each pole. The anchor bolt shall be as shown on the plans with a
minimum of 15 in. of seven NC threads on the upper end. The threads, nuts, and
washers shall be galvanized in accordance with ASTM A 153 or be mechanically
1220 galvanized and conform to the coating thickness, adherence, and quality requirements
of ASTM A 153. The steel for the bolt shall be in accordance with ASTM F 1554,
with a yield strength of 36,000 or 55,000 psi.

6. Finish
All steel material shall be fully galvanized. Galvanizing shall take place after all
welding is accomplished and holes cut.

7. Working Drawings
Working drawings and design calculations shall be submitted in accordance with
1230 105.02.

(d) Downguys, Anchors, Rods, and Guards

Pole anchors shall be eight way expanding with a minimum area of 135 sq in.
when expanded or a 10 in. diameter screw anchor. They shall have a minimum holding
strength of 10,000 lb. They shall be painted and in accordance with ASTM A 575.

1125
 922.10

Anchor rods for expanded anchors shall be 3/4 in. diameter steel and for screw anchors
shall be 1 1/4 in. diameter steel, 8 ft long, in accordance with ASTM A 659, and be
galvanized in accordance with ASTM A 153.

1240 Guy guards shall be made of 18 gauge galvanized steel, polyethylene, polyvinyl
chloride, or melamine phenolic, and shall be 7 ft long. The steel guy guard shall have
a tight gripping, non-scarring hook for quick attachment to the guy wire. The bottom
shall have a clamp that fits over the anchor rod and securely grips by tightening the
bolt. Steel guy guards shall be in accordance with ASTM A 659. The nonmetallic guy
guard shall be a helical pigtail which shall resist upward movement, a lock strap to
secure the lower end, and a guy guard sleeve. Non-metallic guy guards shall be gray
or yellow.

(e) Support Cable

1250
1. Messenger Cable
Messenger cable shall be zinc-coated steel wire strand, contain seven wires, and
have a nominal diameter of 3/8 in. The cable shall be in accordance with ASTM A
475, Siemens-Martin Grade.

2. Span, Catenary, and Downguy Cable

Span, catenary, and downguy cable, shall be aircraft cable for non-aircraft use,
and shall be 3/8 in. nominal diameter, made of stainless steel wire, and consist of
seven, 19-wire flexible steel strands. The 3/8 in. cable shall have a minimum breaking
1260 strength of 12,000 lbs. It shall be in accordance with Military Specifications MIL-W-
83420D.

3. Tether and Support Cable

Tether and support cable shall be aircraft cable, for non-aircraft, and shall be 1/4
in. nominal diameter, made of stainless steel wire, and consist of seven, 19-wire
flexible steel strands. The 1/4 in. cable shall have a minimum breaking strength of
6,400 lbs. It shall be in accordance with Military Specifications MIL-W-83420D.

4. Cable Hardware
1270
a. Messenger Hangers
Messenger hangers shall be either a 3-bolt clamp or a 3/8 by 1 3/4 in. steel hanger
with a 90° bend extending from the pole 3 3/4 in. The hanger shall have a curved
groove and clamp capable of receiving a 5/16 to 1/2 in. cable.

The messenger shall be clamped by two 1/2 in. high carbon steel bolts. The angle
hanger shall be mounted with a 5/8 in. through bolt and a 1/2 in. lag screw. The three-
bolt clamp shall be mounted with a 5/8 in. through bolt. The angle hanger shall be in
accordance with ASTM A 575. The bolts shall be in accordance with NEMA PH 23.
1280

1126
 922.11

b. Cable Ring
Cable rings shall be galvanized steel in accordance with IMSA 51-1.

c. Clamps
Clamps shall be made of 3/8 in. steel and in accordance with ASTM A 575.

Two bolt clamps shall be a minimum of 3 3/4 in. long and 1 1/4 in. wide with two
1/2 in. bolts which shall clamp cable of 1/8 to 1/2 in. diameter.

1290 Three bolt clamps shall be a minimum of 6 in. long and 1 5/8 in. wide with three
5/8 in. bolts which shall clamp cable of 5/16 to 1/2 in. diameter.

The bolt heads shall be large enough to provide maximum clamping area and shall
have oval shoulders to prevent the bolts from turning while tightening. The bolts shall
be in accordance with NEMA PH 23.

d. Servi-Sleeves
Servi-sleeves shall be 1 1/4 to 2 1/4 in. in length and shall hold the size of the
cable specified. The sleeves shall be in accordance with ASTM A 659.
1300
e. Straight Eye-Bolts
Straight eye-bolts shall be 3/4 in. diameter drop forged steel, a minimum of 14 in.
long, and have 6 in. of thread. The steel washers shall be 2 1/4 by 2 1/4 by 3/16 in. in
size with a 13/16 in. hole in the center. All parts shall be in accordance with ASTM A
575 and shall be galvanized in accordance with ASTM A 123.

f. Hub-Eyes
Hub-eyes shall be made of drop forged steel and in accordance with ASTM A
575. They shall receive a 3/4 in. mounting bolt and have a full rounded thimble eye
1310 for protection of the guy cable.

922.11 Signal Cable

(a) Hook-up Wire

Signal hook-up wire shall be stranded one conductor wire, type THW seven strand
No. 14 AWG, with a thermoplastic sheath 3/64 in. thick and a 600 volt rating.
Insulation shall be color coded, as required, and labeled with gauge, voltage rating,
and insulation type.

1320 (b) Signal Control Cable

Signal control cable shall be in accordance with IMSA 19-1 or 20-1 and shall be
stranded No. 14 AWG wire.

(c) Service Cable

Traffic signal service cable shall be color coded, stranded copper No. 8 AWG
wire, three conductor cable, type THWN.

1127
 922.12

922.12 Signal Interconnect

1330 (a) Integral Messenger Interconnect Cable

Integral aerial interconnect cable shall be figure “8” self-supporting type cable
consisting of a messenger cable and seven conductors No. 14 AWG signal cable in
accordance with IMSA 20-3.

(b) 6 Pair/19 Telemetry Cable

Six pair telemetry cable shall contain six twisted pairs of 19 gauge conductors and
shall be in accordance with IMSA 40-2 for underground application and IMSA 40-4,
integral messenger, for aerial application.

1340 (c) Fiber Optic Interconnect Cable

Fiber optic cable shall contain 12-strand multimode, graded index, optic fibers
with a minimum of one non-metallic central strength member. The cable shall be gel-
free design, loose tube, all dielectric construction, suitable for outdoor use in conduit
or on aerial supports. Each length of fiber optic cable in nonmetallic conduit shall
include a No. 14 AWG aluminum or No. 6 AWG copper tracer wire.

Each individual fiber shall be 2.5/5 mils (62.5/125 µm) diameter, core/color-
coded clad, and each color-coded set of fibers shall be encased in a loose tube buffer
with water blocking tape on the outside and fully water blocked inside using craft-
1350 friendly, water-swellable yarns. The fiber optic cable shall be constructed with Kevlar
braid and outer polyethylene jackets as a minimum. If an inner jacket is used it shall
be PVC. Maximum attenuation of the cable shall be 4.0 dB/km nominal, measured at
room temperature at 850 nm. The bandwidth shall not be less than 160 MHz/km, also
at 850 nm. Each fiber shall be continuous with no factory splices except for joining
standard length cables to form longer, continuous jacketed cable to fit installation
requirements. The cable shall have standard nylon rip cords. Kevlar rip cords will not
be accepted.

The cable shall be in accordance with the generic requirements for optical fiber
1360 and optical fiber cable per ANSI/ICEA S-104-696 design and test criteria.

The exterior of the polyethylene outer cable jacket shall be stenciled so that every
16.4 ft on each reel is marked with a number. The 16.4 ft of each reel shall be marked
with a 5, the 32.8 ft marked with a 10, and so on until the end of the reel. The stencil
shall be applied to the outer jacket using permanent ink and shall be permanently
engraved into the jacket to provide long lasting readability.

(d) Radio Interconnect Using Spread Spectrum Radio Modems

Spread spectrum radio modems for communications between local controllers and
1370 the system master controller shall be on the Department’s list of approved Traffic
Signal and ITS Control Equipment.

1128
 922.16

922.13 Detection Components

(a) Loop Detector Lead-in Cable

Runs 700 ft and less of loop detector lead-in cable shall be in accordance with
IMSA 50-2 and shall be stranded two conductor No. 16 AWG, 19 strands of No. 29
wire.

1380 Runs greater than 700 ft shall use 14 AWG wire. The nominal capacitance
between conductors shall be 57 pF/ft and 98 pF/ft between one conductor and the other
conductor connected to the shield.

(b) Roadway Loop Wire

Roadway loop wire shall be 14 AWG gauge IMSA 51-7 duct-loop wire with
polyvinyl chloride or polyethylene outer jacket of 1/4 in. diameter.

(c) Other Vehicle Detection Systems

Other vehicle detection systems shall be selected from the Department’s list of
1390 approved Traffic Signal and ITS Control Equipment.

922.14 Ground Wire

The ground wire shall be copper wire No. 6, AWG soft-drawn, solid copper in
accordance with ASTM B 3.

922.15 Splicing Kit

Splicing kits shall contain a two-piece, transparent snap-together mold body and
include an epoxy and sealing compound contained in a unipak. It shall be capable of
insulating and splicing nonshielded cables rated up to 5 kilovolts and multi-conductor
1400 cables rated up to 600 volts.

922.16 Ground Rod and Connections

Ground rods shall be 1/2 in. in diameter by 8 ft long with a machined point and
chamfered top. They shall be made of steel with a molecularly bonded outer layer of
electrolytically applied copper. A single electrode shall have a maximum resistance to
ground of 25 ohms. Single electrodes that do not have resistance to ground of 25 ohms
or less shall be augmented by additional electrodes, grids, or plates until resistance to
ground of 25 ohms or less is achieved. Resistance shall be measured using a three-
point ground tester using the fall of potential method. Data, graphs, resistance in ohms,
1410 date of test, make and model of ground tester, and the individual’s initials performing
the test shall be recorded and submitted to the District Office. Resistance in ohms shall
be tagged at the ground connection.

The finished rod shall be cold-drawn and shall have the following minimum
physical properties:

1129
 922.17

Physical Property Value

Tensile strength, min. 97,000 psi
Yield strength, 0.2% offset, min. 85,000 psi
% of elongation 13 - 40

The ground rod and wire connection shall be made by a thermo weld process or
1420 approved equal. The welding material shall cover and secure the conductor to the rod
and shall be porous free.

An acceptable alternate shall be a ground grid connection properly sized and shall
consist of a shear head bolt, a “C” shaped body, nest, and wedge. The connector
components shall be fabricated from an aluminum-bronze alloy, silicone-bronze alloy,
or copper.

922.17 Handholes

1430 (a) Type I (Concrete Handhole)

A Type I handhole shall be made of class III reinforced concrete pipe with a cast
iron ring and cover. The concrete shall be in accordance with section 907.02.
Reinforcement shall be provided as shown on the plans or in accordance with the
manufacturer’s design. If reinforcement deviates from the plans, provide calculations
showing that the modified design supports HS-20-44 loading. The ring and cover for
handholes shall be in accordance with 910.05(b).

(b) Type II (Polymer Concrete Handhole)

A Type II handhole shall be made of polymer concrete. The handhole box of
1440 polymer concrete shall be reinforced with a heavy weave fiberglass. The box and cover
shall meet or exceed ANSI/SCTE Tier 15 requirements. The handhole shall be
stackable.

1. Polymer Concrete Handhole Box

The handhole box shall be heavy duty. The inner surface of the handhole shall be
smooth and free from cracks and imperfections.

2. Polymer Concrete Handhole Cover

The cover shall be marked with logo imprints of “TRAFFIC SIGNAL” and the
1450 ANSI/SCTE Tier rating - “TIER XX”. The cover shall be secured with stainless steel,
300 series, 3/8 in., 16 NC hex bolts and washers. The cover shall have a friction
coefficient of at least 0.5.

922.18 Entrance Switch

The entrance switch shall be a double pole, 50A, 120V AC circuit breaker in a
NEMA type 3R enclosure in accordance with NEMA 250-2008. The minimum
dimensions of the enclosure shall be 5 in. wide, 3 3/4 in. deep and 9 1/4 in. high. A 1
in. rain-tight detachable hub shall be supplied in the top of the enclosure. The enclosure
shall have knockouts on the sides, bottom and back with diameters of 7/8 in. to 1 3/4

1130
 922.19

1460 in. The enclosure shall contain the circuit breaker, an insulated solid bar for connection
of AC neutral, a separate lug for attachment of earthground, have provisions for a
padlock, and shall be surface mounted.

The enclosure shall be made of galvanized steel with a rust inhibiting treatment
and finished in the manufacturer’s standard color of baked enamel.

All wire terminations and breaker to buss-bar contact points inside the enclosure
shall be coated with an anti-oxidant to prevent oxidizing and corrosion of components.

1470 922.19 Conduit and Fittings

(a) Steel Conduit

Steel conduit, couplings, and elbows shall be galvanized rigid steel conduit in
accordance with UL 6. The conduit shall be galvanized by the hot dip method on the
interior and exterior surfaces. Conduit threads shall be cut after galvanizing. The
conduit shall be supplied with a threaded coupling attached to one end and the other
threaded end protected by a suitable shield.

The various conduit fittings such as bands, bodies, straps, lock nuts, and threadless
1480 connectors, shall be in accordance with Federal Specifications A-A-50553 and shall
be galvanized if not stainless steel. Conduit straps shall be two hole straps with a
minimum thickness of 1/8 in. Conduit lock nuts 3/8 to 1 1/2 in. in size shall be made
of steel. Other sizes shall be made of either steel or malleable iron. All conduit lock
nuts shall be galvanized. Other nuts shall be either stainless steel or galvanized steel.

(b) PVC Schedule 40 or 80 Conduit

Conduit, fittings, and accessories shall be manufactured from PVC meeting
ASTM D 1784 and shall comply with all the applicable requirements of NEMA TC2
and UL 651. Each length of pipe shall include a coupling.
1490
(c) Fiberglass Conduit
Rigid fiberglass conduit and fittings shall be filament wound consisting of E-glass
and corrosion resistant epoxy resin manufactured for use at temperatures from -40 to
230°F. Rigid fiberglass conduit shall be pigmented with carbon black for ultraviolet
protection and fire resistant per UL 94. All rigid fiberglass conduit shall have tracer
wire, be heavy walled, HW, and meet the specifications, labeling and testing of
ANSI/NEMA TC9.

(d) HDPE Schedule 40 or 80 Conduit

1500 Conduit shall be smooth wall, Type III, Grade P-33, Category 5, Class C, coilable,
HDPE. Standard dimension ratio, SDR, 13.5 may be used for Schedule 40 HDPE and
SDR 11 may be used for Schedule 80. Conduit and fittings shall meet the applicable
requirements of ASTM D 1248, ASTM D 3350, ASTM F 2160 and UL 651.

Schedule 40 or 80 HDPE conduit shall be marked in accordance with ASTM D

3485 with the producer code and designation type indicated. HDPE conduit shall be
1131
 922.20

produced from material with an orange color and ultraviolet stabilization code of C,
D, or E in accordance with ASTM D 3350. Schedule 40 HDPE conduit for use above
ground shall be black.
1510
922.20 Detector Housing
The entire housing casting shall be made from aluminum alloy in accordance with
ANSI 320.

922.21 Certification
Unless otherwise specified, all materials covered herein shall have a type C
certification in accordance with 916.

SECTION 923 – TEMPORARY TRAFFIC CONTROL DEVICES

923.01 Temporary Pavement Marking Tape

Temporary pavement marking tape shall be furnished in three colors and two
types. It shall consist of a white or yellow reflecting film on a conformable backing
which is a minimum of 4 in. wide, and is designed for marking either asphalt or
concrete pavements. Black temporary pavement marking tape shall consist of a matte
film on a conformable backing which is designed for marking asphalt pavement. White
and yellow temporary pavement marking tape shall be in accordance with ASTM D
10 4592.

Type I tape shall be selected from the Department’s list of approved Temporary
Pavement Marking Tape, Type I. Temporary pavement marking tape type I will be
placed and maintained on the Department’s approved list in accordance with ITM 806,
Procedure H.

Type I tape furnished under this specification shall be covered by a type C

certification in accordance with 916.

20 923.02 Temporary Raised Pavement Marker

Temporary pavement markers shall be designed to be affixed with adhesive to the
pavement surface and shall be in accordance with ASTM D 4280. Adhesive shall be
in accordance with the manufacturer’s recommendations.

Markers shall be selected from the Department’s list of approved Temporary

Raised Pavement Markers. Temporary raised pavement markers will be placed and
maintained on the approved list in accordance with ITM 806.

923.03 Construction Warning Lights

30 Construction warning lights shall be self-illuminated by means of an electric lamp
behind the lens. Types A and C shall also be externally illuminated by reflex-reflective
elements built into the lens to enable it to be seen by the light from the headlights of
oncoming traffic.

1132
 923.03

The batteries shall be entirely enclosed in a case. The case shall be secured by a
locking device which can be opened with a special tool.

(a) Flash Requirements

40 1. Flash Rate
The light from types A and B shall have a flash rate of 65 ±10 pulsations per
minute from -20°F to 150°F.

2. On-Time
On-time is defined as the period of the flash when instantaneous intensity is equal
to or greater than the effective intensity as specified in 923.03(b)1.

a. Type A
The light shall have an on-time of no less than 10% of the flash cycle.
50
b. Type B
The light shall have an on-time of no less than 8% of the flash cycle.

(b) Optical Requirements

1. Effective Intensity
The light beam projected upon a surface perpendicular to the axis of the light
beam shall produce a lighted area within the solid angle bounded by the two vertical
planes 9° from the vertical plane through the axis of the optical system and two planes
60 5° above and below the horizontal plane through the optical axis of the system.

For type A, the effective intensity shall not drop below 4.0 candles within the area
specified herein during the first 336 h of continuous flashing.

For type B, the effective intensity shall not drop below 35 candles within the area
specified herein during the first 168 h of continuous flashing.

For type C, the effective intensity shall not drop below 2.0 candles within the area
specified herein during the first 168 h of continuous burning.
70
2. Lens Illumination
The illuminated lens shall be uniformly bright in appearance over its entire
illuminated surface when viewed from any point within the angle defined in 923.03(b).

3. Reflex-Reflective Performance
For types A and C the specific intensity of the lens when acting as a
reflex-reflector at an observation angle of 0.2 of a degree shall be no less than the
following.

1133
 923.03

Entrance Angle Specific Intensity

degrees Candles per Footcandle
0 18
10 14
20 7
80
4. Testing Procedure
The effective intensity of types A and B lights shall be calculated using the Guide
for Calculating the Effective Intensity of Flashing Signal Lights as approved by the
Illuminating Engineering Society, June, 1961. The intensity of the type C light shall
be tested in accordance with SAE Standard J 575d, Lighting Equipment and
Photometric Tests. Reflex-reflection shall be tested in accordance with SAE Standard
J 594d.

(c) Lens Requirements

90
1. Size of Lens
The lens shall be no less than 7 in. in diameter including for a reflex-reflector ring
of 1/2 in. minimum width around the periphery for types A and C.

2. Directional Lenses
Unless otherwise directed, types A, B, and C shall have uni-directional lenses.

3. Lens Chromaticity
If the light uses an incandescent lamp, the chromaticity of the lens color shall be
100 defined by the tri-stimulus coordinates of the Commission International d'Eclairage
Standards. When tested with illuminants from 2856 K to 2366 K, the lens color shall
fall within the area of the chromaticity diagram in accordance with the 1931
Commission International d'Eclairage Standard Observer as defined by the following
coordinates.

X Y Z
0.543 0.452 0.005
0.548 0.452 0.000
0.584 0.411 0.005
0.589 0.411 0.000

If the light uses other than an incandescent lamp, the light output shall be in the
same range as the light obtained with the incandescent lamp and the specific lens.

110 4. Lens Luminous Transmittance

The minimum relative luminous transmittance of the lens with illuminant at
2856 K shall be 0.440.

1134
 923.04

5. Lens Material
The lens shall be plastic of one-piece construction and shall meet the test
requirements in accordance with SAE J 576b, except that the exposure time and
condition, paragraph 3.4.3, for the purposes of this standard shall be one year.

(d) Head and Case

120
1. Swivel Head
If swivel capabilities as described herein are not incorporated in the device used
to mount a type A or C light on a barricade or sign, the head shall be mounted on the
housing in a manner allowing it to be swiveled through a minimum 90° arc in a
horizontal plane. If swiveling is accomplished by rotation of the head, construction
shall be such that the head rotation shall not damage the wiring.

2. Case
The case shall be so constructed and closed as to exclude moisture that would
130 affect the specified operation of the light. The case shall have a weephole to allow the
escape of moisture from condensation.

(e) Photoelectric Controls

Photoelectric controls, if provided on types A or C lights, shall keep the light
operating whenever the ambient light falls below 20 footcandles.

923.04 Flashing Arrow Sign

The flashing arrow sign shall be an all weather, self-contained, flashing sign
designed to display the required flashing messages continuously for a minimum of 24
140 h without servicing. A reserve storage battery shall be provided to automatically
operate the flashing arrow sign for a minimum period of 8 h if there is a power failure
of the primary source.

The flashing arrow sign shall have a control unit which incorporates a
photo-controlled transfer relay for automatic lamp intensity settings. The highest
photo-controlled setting shall be full intensity for daylight operation. The lowest
photo-controlled setting shall be for night-time operation and shall be 50% of full
intensity when the ambient light level drops below five footcandles. A minimum of
two interim photo-controlled settings shall automatically increase or decrease the lamp
150 intensity in direct proportion to the ambient light level.

The flashing arrow sign shall have a manual control unit for adjusting lamp
intensity when automatic operation becomes unsatisfactory. The manual control shall
be fully adjustable between the minimum limit of 30% of full lamp voltage and
maximum limit of full lamp voltage.

An indicator light shall be provided on the back of the sign to provide

confirmation that the flashing arrow sign is operating. The indicator light shall be
visible for 500 ft.

1135
 923.04

160
(a) Solar Powered
Solar power assisted units shall incorporate a target sight device and leveling
mechanism to aid the user for positioning of the unit prior to use. The device shall be
attached to the elevated portion of the flashing arrow sign and not to the fixed support
frame.

The lamps shall be electronically operated by means of a solid state controller. An

automatic lamp intensity regulator shall hold the lamp output constant with varying
battery voltage. The control system shall incorporate a full time tracking system
170 designed to track ambient light for 24 h a day. The control system shall adjust lamp
intensity to provide maximum system efficiency. The controller shall be in a
weatherproof, ventilated, lockable enclosure.

The lamps shall provide amber beams with a minimum of 20° horizontal and 6°
vertical field of view. The minimum effective luminance within the required beam
shall not be less than one-half the effective luminance at the beam center.

The battery bank shall consist of 12V, deep cycle, batteries. The battery bank shall
be of sufficient capacity to power the unit for 15 days with no assistance from the sun.
180 A battery condition indicator and a test switch shall be provided to monitor the
system’s battery charge. The batteries shall be secured in a well ventilated,
weatherproof lockable housing. A low battery charge indicator which shall be visible
to maintenance personnel driving past the sign shall be provided to indicate the need
to recharge the batteries. The battery bank shall be at full charge when delivered to the
project site.

The unit shall be equipped with a sign/solar panel lifting mechanism. The lifting
mechanism shall be designed to safely carry the capacity of the sign’s load. The lifting
mechanism shall incorporate a positive locking device to secure the panel in a raised
190 or lowered position.

Solar power assisted flashing arrow signs to be used shall be selected from the
Department’s list of approved Solar Power Traffic Control Devices.

(b) Diesel Powered

Flashing arrow sign shall be fueled by diesel fuel only.

(c) AC Powered
When connected to an AC electrical power source, provisions shall be made to
200 prevent electrocution.

1136
 FLASHING ARROW SIGN GENERAL SPECIFICATIONS

Type A Type B Type C SOLAR POWER ASSISTED

Minimum Board Size 2 ft high by 4 ft wide** 2.5 ft high by 5 ft wide 4 ft high by 8 ft wide 4 ft high by 8 ft wide
Minimum No. of Lamps
Flashing Arrow 5 in. head, 5 in. shaft* 5 in. head, 5 in. shaft*
Flashing Double Arrow 5 in. head, 4 in. shaft* (See Note) Same as Type A 5 in. head, 3 in. shaft*
Sequential Chevron (3 5 in. head 7 in. shaft
heads minimum)
Sealed Beam: 12.8V, not to exceed 3A
Sealed Beam: 12.8V, not to exceed 3A
Average rated life: 300 h minimum
Average rated life: 300 h minimum
Lamp Type Candlepower: (See Note) Same as Type A
Candlepower: 600 candles at normal
1000 candles minimum
voltage and > 250 candles at low voltage
9700 candles maximum
Lens Color Amber Amber Amber Amber
Board Color Flat Black Flat Black Flat Black Flat Black
1137

30-50 F.P.M. 25-40 F.P.M. 30-50 F.P.M. 25-40 F.P.M.

Flashing Rate
(50% on time) (50% on time) (50% on time) (50% on time)
Flashing Arrow, Flashing Double Flashing Arrow, Flashing Arrow, Flashing Arrow, Flashing Double
Message (Left or Right)
Arrow, or Sequential Chevron Flashing Double Arrow Flashing Double Arrow Arrow, or Warning Bar
Minimum mounting
7 ft 7 ft 7 ft 7 ft
height (to bottom of board)
All rural and urban Stationary Operations
Where Allowed Where normal speed limit is < 40 mph (See Note)
locations Tangent Sections (See 801.15(a))
Required minimum
0.5 mi 0.75 mi 1 mi 1 mi
Visibility
* When flashing a single or double arrow(s), the lamp(s) nearest the arrow points shall not be illuminated.
** Either rectangular or arrow shaped black background sign will be allowed.
Note: General specifications for a type B flashing arrow sign are shown in the MUTCD.

923.04
 923.05

923.05 Portable Changeable Message Sign

Portable changeable message signs shall be capable of displaying 3 lines with of
8 characters per line. Letter height shall be a minimum of 18 in. The sign shall have
automatic dimming capability for nighttime operation.

210 Portable changeable message signs shall be selected from the Department’s list of
approved Solar Power Traffic Control Devices.

923.06 Temporary Worksite Speed Limit Sign Assembly

The temporary worksite speed limit sign assembly shall be an all weather,
self-contained unit designed to display speed limit signs in accordance with the
MUTCD and as shown on the plans. The signs shall be installed on frangible posts or
mounted on movable stands or trailers in accordance with 910.14(f). The power source
shall be capable of operating the strobe lights, without service, for the period which
the sign is in effect. An on/off switch will be required.
220
923.07 Tubular Marker
The vertically placed portion of this device shall consist of high density
polyethylene plastic in accordance with ASTM D 5203. The base material shall be
butyl rubber in accordance with ASTM D 5900 or high impact polystyrene in
accordance with ASTM D 4549. Epoxy material used to attach the base to the roadway
surface shall be in accordance with the manufacturer’s recommendations. The tubular
portion shall be reflectorized with high intensity reflective sheeting in accordance with
919.01(b)1 as shown on the plans.

230 923.08 Automated Flagger Assistance Device

The Automated Flagger Assistance Device, AFAD, shall alternately display either
a STOP sign and a SLOW sign or a steadily illuminated CIRCULAR RED and a
flashing CIRCULAR YELLOW lens to control traffic while being operated by a
handheld remote control. AFADs shall meet the requirements of the Indiana Manual
on Uniform Control Devices, Chapter 6E. Each AFAD shall be equipped with two
handheld remote controls. Trailer mounted AFAD’s shall be equipped with a gate arm.

Only automated flagger assistance devices from the List of Approved Solar
Powered Traffic Control Devices shall be used. Automated flagger assistance devices
240 will be placed and maintained on the list of approved Solar Powered Traffic Control
Devices in accordance with ITM 955.

(a) Signs

1. STOP/SLOW AFAD
The STOP and SLOW signs shall have a minimum width of 24 in. with lettering
that is at least 8 in. in height. The WAIT ON STOP sign shall be visible along the same
line of view of the STOP sign face.

1138
 923.08

250 2. RED/YELLOW Lens AFAD

A “STOP HERE ON RED”, R10-6 or R10-6a, sign shall be installed on the right-
hand side of the approach at the point at which drivers are expected to stop when the
CIRCULAR RED lens is illuminated.

(b) Signals
Red/Yellow lens AFAD shall have at least one set of CIRCULAR RED and
CIRCULAR YELLOW lenses that are 12 in. in diameter and in accordance with the
Institute of Transportation Engineers, ITE, Purchase Specification for Vehicle Traffic
Control Signal Heads.
260
(c) Supplemental Conspicuity Devices
The STOP sign face in STOP/SLOW AFAD shall be supplemented by a circular,
red stop beacon. The SLOW sign face shall be supplemented by either: a circular,
yellow warning beacon, or Type B warning lights with a minimum viewing distance
of 1,000 ft.

(d) Gate Arm

Gate arms shall be made of reinforced thermoplastic or tubular aluminum. When
in the horizontal positions the arm shall have a 2 ft to 4 ft mounting height above the
270 pavement surface.

(e) Cabinets and Controller

The battery and controller cabinets shall be in accordance with NEMA Standard
250 Enclosure 3R requirements and be provided with a hasp and lock. The AFAD
shall include a manual override of the handheld remote at the device. The AFAD shall
not have any means by which it can operate on a pre-set or pre-timed basis.

(f) Remote Control Device

Two handheld, cordless remote controls shall be provided with each AFAD. The
280 remote control shall be waterproof and display signal receipt confirmation. The remote
shall use a frequency hopping, spread spectrum radio signal with frequencies outside
the 700 MHz band, 698 MHz to 806 MHz. The remote control device shall be
programmable to control either one unit or two units simultaneously and shall control
the units over a one-mile range.

(g) Batteries and Charging System

Batteries shall be deep cycle type and be capable of operating the AFAD
continuously for two days, 24 hrs per day without a need of re-charging. An audible
low battery voltage alarm sound system shall be provided. The battery charging system
290 shall consist of a solar panel. Solar panels shall be UL 1703 certified.

(h) Trailer
The trailer, if used, shall be designed to withstand a 60 mph wind loading with a
1.3 gust factor when the AFAD is set up in operating position. The trailer shall be
painted safety orange, SAE-AMS-STD-595, color No. 12300. The trailer shall be

1139
 923.09

provided with a minimum of two leveling jacks, each operated by a crank which locks
in place.

923.09 Acceptance of Temporary Traffic Control Devices

300 Temporary traffic control devices will be accepted by visual inspection unless
otherwise indicated.

SECTION 924 – WELDING SUPPLIES

924.01 Welding Supplies

(a) Aluminum Alloy Base Metals

1. Bare Wire Electrodes and Welding Rods

Bare wire electrodes for use with the gas metal arc welding process and welding
rods for use with the gas tungsten-arc welding process shall be in accordance with
10 AWS A5.10. Tungsten electrodes for the gas tungsten-arc welding process shall be in
accordance with the Specifications for Tungsten-Arc Welding Electrodes, AWS
A5.12.

2. Filler Metal
Filler metals to be used with particular base metals shall be as shown in the table
below. Other filler metals may be used if approved.

Base Metal Filler Metal

3003 to 3003 ER1100
3004 to 3004 ER4043
5052 to 5052 ER5356*
5083 to 5083 ER5183
5086 to 5086 ER5356*
5456 to 5456 ER5556
6061 to 6061 ER5356*
6063 to 6063 ER5356*
356.0 to 6061 ER4043
356.0 to 6063 ER4043
*ER5183, ER5356, and ER5556 may be used
interchangeably for these base metals.

Filler metals shall be kept covered and stored in a dry place at relatively uniform
20 temperatures. Original rod and wire containers shall not be opened until time to be
used. Rod and wire shall be free of moisture, lubricant, or other contaminants. Spools
of wire temporarily left unused on the welding machine shall be kept covered to avoid
contamination by dirt and grease collecting on the wire. If a spool of wire is to be
unused for more than a short length of time, it shall be returned to the carton and the
carton tightly sealed.

1140
 925.01

3. Shielding Gases
Shielding gases shall be welding grade or better. Shielding gas for gas metal-arc
welding shall be argon, helium, or an approximate 75% helium and 25% argon
30 mixture. Shielding gas for gas tungsten-arc welding done with alternating current shall
be argon. Shielding gas for gas tungsten-arc welding done with direct current, straight-
polarity, shall be helium.

Hose used for shielding gases shall be made of synthetic rubber or plastic. Hose
which has been previously used for acetylene or other gases shall not be used.

(b) Blank

SECTION 925 – ITS CONTROLLER CABINET

925.01 General Requirements

ITS controller cabinets shall be constructed such that it has a NEMA 3R rating.
The cabinet shall be a rainproof cabinet with dimensions of 66 in. by 24 in. by 30 in.
in depth. The cabinet top shall be crowned or slanted to the sides to prevent standing
water.

The cabinet, sunshields, doors, and all panels shall be fabricated of 1/8 in.
10 minimum thickness aluminum. The only exception to this aluminum thickness is the
detector rack, which shall be fabricated of 0.090 in. thickness aluminum. All exterior
seams for the cabinets and doors shall be continuously welded. All exterior welds shall
be ground smooth. All edges shall be filed to a radius of 5/16 in. minimum.

The cabinet, sunshields, doors, and all panels shall be fabricated from aluminum
sheet in accordance with ASTM B 209, 5052-H32 aluminum sheet.

Welding on aluminum shall be done by the gas metal arc welding process using
bare aluminum welding electrodes. Electrodes shall be in accordance with AWS A5.10
20 for ER5356 aluminum alloy bare welding electrodes.

Procedures, welders, and welding operators for welding on aluminum shall be

qualified in accordance with the requirements of AWS B2.1 “Specification for
Welding Procedure and Performance Qualification” or AWS D9.1M/D9.1 Sheet Metal
Welding Code.

Each aluminum surface shall be finished in accordance with Military

Specification MIL-A-8625F(1), “Anodic Coatings for Aluminum and Aluminum
Alloys”, type II, class I coating, except that the anodic coating shall have a minimum
30 thickness of 0.0008 in. and a minimum coating weight of 0.04 mg/sq mm. The anodic
coating shall be sealed in a 5% aqueous solution of nickel acetate (pH 5.0 to 6.5) for

1141
 925.01

15 minutes at 206°F. The anodized coating shall be silver in color. Prior to applying
the anodic coating, the cabinets shall be cleaned and etched as follows:

(a) Clean by immersion in inhibited alkaline cleaner such

as Oakite 61A or Diversey 909, or equivalent, 45 to 60
g per liter, 160°F for 5 minutes.

(b) Rinse in cold water.

40
(c) Etch in a solution of 11 g of sodium fluoride, plus 30
to 45 g of sodium hydroxide per liter of distilled water
at 140 to 150°F for 5 minutes.

(d) Rinse in cold water.

(e) Dissolve in a 50% by volume nitric acid solution at

room temperature for 2 minutes.

50 (f) Rinse in cold water.

The cabinet shall have single front and rear doors equipped with a lock. The doors
shall use a Corbin lock No. 2, and each cabinet shall be equipped with two No. 2 keys.
When each door is closed and latched, the door shall be locked. Keys shall be
removable in both the locked and unlocked positions. The door handles shall have
provision for padlocking in the closed position. The handle shall have a minimum
length of 7 in. and shall be provided with a 5/8 in., minimum, steel shank. The handle
shall be fabricated of cast aluminum or stainless steel. The cabinet door frame shall be
designed so that the latching mechanism shall hold tension on and form a firm seal
60 between the door gasket and the door frame.

The cabinet shall not include a police door or have provisions for a police door.

The latching mechanism shall be a three-point cabinet latch with nylon rollers.
The center catch and pushrods shall be zinc-plated or cadmium-platted steel. Pushrods
shall be turned edgewise at the outer supports and shall be 1/4 by 3/4 in, minimum.
The nylon rollers shall have a minimum diameter of 3/4 in. and shall be equipped with
ball bearings.

70 All cadmium plating shall be in accordance with the Society of Automotive

Engineers, SAE-AMS-QQ-P-416, “Plating, Cadmium (Electrodeposited)”. All zinc
plating shall be in accordance with ASTM B 633-98E1, “Electrodeposited Coatings
of Zinc on Iron and Steel”.

The door’s hinging shall be three or four bolt butt hinges. Each hinge shall have
a fixed pin. Doors larger than 22 in. in width or 6 sq ft in area shall be provided with
catches to hold the door open at both 90° and 180°, ±10°. The catches shall be 1/3 in.

1142
 925.03

diameter, minimum, plated steel rods. The catches shall be capable of holding the door
open at 90° in a 56 mi/h wind at an angle perpendicular to the plane of the door. Door
80 hinges, pins, and bolts shall be made of stainless steel. The hinges shall be bolted to
the cabinet. The hinge pins and bolts shall not be accessible when the door is closed.

Door gaskets shall be provided on all door openings and shall be dust tight.
Gaskets shall be permanently bonded to the metal. The mating surface of the gasket
shall be covered with a silicone lubricant to prevent sticking to the mating surface.

Both cabinet doors shall have louvered openings and shall provide ventilation. A
filter shall be provided over the louvers and shall include an aluminum filter cover
secured with a spring loaded latch as shown on the plans. The filter shall be 12 by 16
90 by 1 in. Two spare filters shall be provided with each cabinet.

The cabinet shall be provided with two metal lifting eyes to be used when placing
the cabinet on the foundation. Each eye shall have a minimum diameter of 3/4 in. and
shall be capable of lifting 990 lbs.

Machine screws and bolts shall not protrude beyond the outside wall of the
cabinet.

925.02 Model Approval

100 Each cabinet model shall be approved prior to use. A period of evaluation will
commence when the Department receives a preliminary product evaluation form
accompanied by the product brochure, detailed electrical schematics, and cabinet
assembly drawings. The Operations Support Division will advise the manufacturer or
vendor, in writing, of the date and location to deliver the cabinet for which model
approval is requested. Electrical schematics for the cabinet, cabinet assembly
drawings, and parts lists shall be furnished with the controller when it is submitted to
the Operations Support Division for evaluation and testing.

A list of approved models will be maintained by the Department. Only models

110 from the Department’s list of approved ITS Controller Cabinets in effect as of the date
of letting, or as otherwise specified, shall be used on the contract. Continued failure
and repeated malfunctions of an approved controller or control equipment shall be
cause to remove that model from the Department’s list of approved products. A design
change to an approved model or cabinet will require re-submittal of the model for
testing, evaluation, and approval. Permanent addition or removal of component parts
or wires will be considered to be a design change.

925.03 Warranty
The cabinet, sunshields, doors, and all other exterior surfaces shall carry a five
120 year warranty against all material imperfections. All other electrical components and
wiring shall carry a three year warranty against all imperfections in workmanship or
materials.

1143
 925.04

925.04 Cabinet Accessories

The following accessories shall be furnished and installed with each ITS cabinet.

(a) Rack Frame Assembly

The cabinet shall come equipped with standard Electronic Industries Alliance
19 in. rack frame assembly. The rack frame assembly shall have standard Electronic
130 Industries Alliance vertically spaced threaded holes for attachment of equipment,
mounting angles, and shelves. Frame mounting of equipment and shelves shall be
available on both door sides of the cabinet.

(b) Equipment Shelves

The equipment rack shall be furnished with two adjustable equipment shelves. A
3 in. hole shall be provided in each shelf. The hole shall be fitted with a nylon snap
bushing liner with an outside diameter of 3.16 in., inside diameter of 2 1/2 in. and a
height of 0.72 in. The shelves shall be constructed of an aluminum screen tack welded
between the shelf bottom and upper ribs. The shelves shall be capable of being moved
140 in any location.

(c) Sunshield
An aluminum panel sunshield shall be mounted on standoffs on the top and each
side of each cabinet.

(d) Side Panels

Two aluminum side panels shall be provided and mounted on the Electronic
Industries Alliance rack parallel to the cabinet sides. One panel shall be designated as
the “power distribution panel” and the other panel shall be designated the “heater
150 panel”.

(e) Data Pocket

The data pocket is to be large enough to hold several drawings, a maintenance log
notebook, and several pieces of reference material but not so large as to contact any of
the installed equipment.

(f) Equipment Labels

The labels shall have a non-reflective, exterior grade, low glare matte surface
finish applied to flexible ABS plastic. The labels shall be black with white lettering
160 and have an engraving depth of 0.002 to 0.003 in. Labels shall conform to the
designations on the cabinet diagrams.

(g) Primary Power Terminal Block

A power distribution terminal block shall be mounted on the power distribution
panel. The power distribution block shall be a mechanical three-pole connector. The
connectors for the incoming power shall be able to accept wire sizes between 12 AWG
and 2/0 AWG. The load side connectors shall be able to accept wire sizes between 14
AWG and 4 AWG. The rating of the connector shall be 195 amps per pole. The
connector elements shall be made from a tin plated, high conductivity aluminum alloy

1144
 925.04

170 and insulated with high strength thermoplastic housing with a relative temperature
index of 260°F. It shall be rated 600 volt, AL9CU. The dimensions shall be 4 by 5.2
by 3.23 in. high. The block shall come with one polycarbonate safety cover per pole.
Mounting screws shall be No. 10, 0.19 in. diameter. The block shall be UL Listed. The
terminal block shall be a Burndy Model BDB-11-2/0-3.

(h) Ground Lug

The ground lug mounted on the power distribution panel shall be a heavy-duty
one-hole ground lug, manufactured from electrolytic copper tubing and strip stock. UL
Listed and CSA certified for stranded CU wire and for 600 volts. Wire range: 6 AWG
180 to 14 AWG. Bolt size: #10. Tang length shall be 1/2 in. Width shall be 5/16 in. The
lug shall be an Ilsco Model SLUH-35.

(i) Ground Bus

The ground bus shall be rated to 600 volts. A maximum of 12 taps per ground bar
suitable for wire ranging from 6 AWG to 14 AWG will be allowed. The main ground
connection wire shall have a range from 4 AWG to 14 AWG. The ground bar shall be
5 15/16 in. by 3/4 in. by 11/32 in. and shall be UL Listed. The ground bus shall be an
Ilsco Model D167-12.

190 (j) Transient Voltage Surge Suppression

The transient voltage surge suppression, TVSS, shall have individually fused
suppression modes, thermal cutout, LED operational indicators to indicate loss of
protection or circuit fully operational, including neutral-to-ground, AC tracking filter
with EMI/RFI filtering up to -50dB from 100 kHz to 100 MHz, and a short circuit
current rating of 200,000 rms symmetrical amperes. Surge suppression shall be
provided for each mode (L-N or L-L, L-G, N-G). The TVSS shall be UL 1449 Second
Edition Listed and UL 1283 Recognized. The TVSS shall have 120/240 volt split
phase service voltage and dry contacts for each phase providing a summary alarm. The
contacts shall be terminated in a DB-9 connector.
200
The surge capacity shall be 80 kA/phase. The response time shall be less than 1/2
nanosecond. The unit shall withstand 5000 category C3 impulses with less than 10%
drift. It shall be suitable for use under non-condensing relative humidity range of 0 -
95%. The suppressed voltage rating shall be 330 volts L-N, L-G, N-G and 700 volts
L-L. Operating frequency: 47 - 63 Hz. Operating temperature: -40°F to 140°F.
External mount NEMA 1 standard enclosure. Standard size: 6 in. by 6 in. by 4 in.
depth. Weight: 8 lbs. The unit shall be an Advanced Protection Technologies Model
TE/1XF.

210 (k) Load Center Main Breaker

The load center main breaker shall be an enclosed, two-pole, 240/240V AC, 60
amp breaker. It shall have a 10,000 rms symmetrical ampere short circuit current
rating. The circuit breaker enclosure shall be a Square D, Model QO2TR.

1145
 925.04

(l) Load Center Panelboard

The panelboard shall be a 120/240V AC, 600 volt, eight pole panelboard. The
panelboard shall have a neutral bus bar with three 10 amp breakers, four 15 amp
breakers and one spare. The load center shall be main lug only Square D, Model QO.
The circuit breakers shall be Square D, Model QO.
220
(m) GFI Duplex Receptacle
The convenience receptacle shall be a duplex, three-prong, NEMA type 5-15R
grounding type outlet and shall be in accordance with UL 943.

(n) Duplex Receptacle

A standard three-prong, NEMA type 5-15R grounding type outlet shall be
mounted on the power distribution panel.

(o) Terminal Strip Surge Protector

230 One 48 in. surge protected terminal strip with ten 15A outlets shall be furnished
and installed.

The terminal strip shall have a low profile aluminum housing measuring 1 1/2 by
1 3/16 in. and have a 14/3 SJT cord and a NEMA 5-15P plug. The spacing between
the outlets shall be 4 in. and the grounding pin shall be positioned so that it is oriented
toward the bottom of the cabinet. The unit shall be in accordance with UL 1449 with
a 330 volt clamping level. The unit shall be a Wiremold Model 4810BCS with a 6 ft
cord.

240 (p) Door Open Switches

Four dry-contact, one-pole-form-C (single-pole, double throw), switches shall be
provided and installed. Switch poles are to be electrically isolated. One set of switches
shall be rated for 5 amp at 120 volt AC to be used to automatically turn the lights off
when both cabinet doors are closed. The other set shall be rated for 1 amp at 5 volt DC
and are to be used to send a door open alarm. The switches shall be Omron part No.
Z-15GQ-B.

(q) Light Switch

A toggle switch 20 amp, DPDT with 1/8 in. diameter hole in solder lugs shall be
250 provided and installed that will manually switch on the lights regardless of the door
switch position. The switch shall be McGill Mfg. Co., part No. 0121-7013 or Eaton
part No. 7803K13.

(r) Lamp Holders

Each cabinet shall be furnished with two lamp holders. The UL Listed device shall
have a medium phenolic base measuring 1.9 by 1.9 by 1.5 in. and rating 660 watt and
250 volt. The lampholder shall be a Leviton Model 9063.

(s) Lamps
260 Each lamb holder shall be provided with a 100 watt rugged service incandescent
bulb.
1146
 925.04

(t) Circulating Fans

Three 110 cu ft/min, 4.7 by 4.7 by 1.5 in. cooling fans shall be installed within the
cabinet to circulate internal air. The fans shall have an allowable ambient temperature
range of 14°F to 158°F and a voltage rating of 115 volt. The fan casings shall be
aluminum alloy. The impeller shall be UL94V-O reinforced plastic. The fans shall
have ball bearings and an impedance protected, shaded pole induction motor. The fans
shall not be exposed or routed to the external environment. The environmental
270 controller shall control fan operation. The fans shall activate at 80°F. The fans shall be
NMB Model 4715FS-12T-B50-D00.

(u) Enclosure Heaters

Two 250 watt ceramic insulated strip heaters shall be furnished and installed in
the cabinet to protect against condensation damage and to keep the electronic
components above freezing in the winter. The strip heaters shall have a seamless
stainless steel sheath with ceramic element support and magnesium oxide packing.
The environmental controller shall control enclosure heater operation. Heating strips
shall not be installed on either door. The heaters shall be 8 in. long by 1 1/2 in. wide
280 and shall have two wire terminals. The strip heaters shall be UL Recognized. The
heaters shall be Hotwatt Model CS-8.

(v) Heater Relays

Two solid state SPST-NO heater relays shall be installed on the power distribution
side panel. Load current range 0.04 to 25 amp, one-cycle surge 250 amp peak. Rated
for 120 volt AC and UL Recognized.

(w) Thermostats
The cabinet shall be furnished with two thermostats installed. One thermostat
290 shall activate the enclosure heaters and circulating fan with the internal cabinet
temperature goes below 35°F. The other thermostat shall activate the two circulating
fans at the top of the cabinet when the internal cabinet temperature goes above 80°F.
The thermostats shall be Thermodisc, Type AL-1.

(x) Detector Card DIN Rail Terminal Blocks

Double-deck compression clamp DIN rail terminal blocks shall be hard wired to
the Canoga Card Racks. A total of 64 terminal blocks shall be mounted to an aluminum
panel that is secured to the Electronic Industries Alliance rack. The terminal blocks
shall allow wires between 24 AWG and 10 AWG. Each measures 2.5 in. by 0.2 in.
300 The terminal blocks shall be the Entretec part number 011527122 type M 4/6 D2.

(y) I/O Module

An isolated 8-Bit digital input module shall be provided and installed. It shall have
six fully isolated inputs and two share common ground inputs. High voltage inputs.
Logic levels: LOW +1.0 volt DC max, HIGH +3.5 to +30 volt DC. Input impedance:
3 kohm. Input isolation: 3000 vrms. Power consumption: 0.4 watt. Operating

1147
 925.05

temperature: 14°F to 158°F. The I/O module shall be a Measurement Computing,

Model CB-7052.

310 (z) Detector Card Rack

The detector card rack shall be as shown on the plans.

(aa) Padlocks
Padlocks shall be classified as a high security padlock with hardened shackles,
laminated body, a minimum four-pin cylinder, and come complete with a weather
cover to protect the lock body and cylinder from sand, dirt, water, and ice. A wafer
cylinder shall not be used. Keys shall not be provided with each padlock supplied. All
padlocks shall be keyed alike and shall be keyed identical to the keys currently in use
by the Department. The main body width of the padlock shall not exceed 3 in. and
320 shall have a shackle length of 2 1/4 to 3 3/4 in. and a shackle diameter of 5/16 in. For
padlock information, contact the ITS Operations Engineer.

(bb) Other Cabinet Equipment

In addition to the equipment specified above, the cabinet shall be furnished with
all ancillary equipment, brackets, wiring ducts, and hardware as is necessary to provide
a neat and finished appearance. These items along with all associated cables,
connectors, wiring, and other incidental items shall be labeled on the required
submittal drawings.

330 925.05 Cabinet Wiring

All conductors used in ITS cabinet wiring shall be in accordance with the
following color-code requirements.

(a) The AC neutral conductor of a circuit shall be

identified by a continuous white or natural gray color.

(b) The equipment grounding conductor shall be identified

by a continuous green color or by a continuous green
color with one or more yellow stripes.
340
(c) The ungrounded conductors shall be identified by any
color not specified in (a) or (b) above.

All wire shall be type THHN with color and gauge as shown on the plans with the
exception of the microloop card rack wiring which will be two-pair twisted with a
shield and plenum rated.

Connectors used for interconnecting various portions of circuits together shall be

designed and constructed for the application involved. Connectors shall be designed
350 to provide positive connection of all circuits, and easy insertion and removal of mating
contacts. Connections shall be permanently keyed to prevent improper connection of
circuits.

1148
 926.01

925.06 Drawings
The Contractor shall provide three sets of cabinet wiring diagrams. The diagrams
shall be non-proprietary and shall identify all circuits, as installed, in such a manner
as to be readily interpreted. In addition, three cabinet drawings shall be provided with
each cabinet to show the component layout in elevation views from the front and rear.
An elevation of both aluminum side panels shall also be shown. Elevation views are
360 to be detailed down to the level showing mounting brackets and wiring ducts. All other
mounting hardware and cable ties need not be shown. All cables and connectors shall
be clearly labeled. Any data sheets for internal cabinet components that have been
made available by the manufacturer shall also be provided. One set of the wiring
diagram and cabinet drawing shall be placed in a heavy-duty side-opening clear plastic
pouch and inserted into the data pocket. The pouch shall be of such design and material
that it provides adequate storage and access to the drawings. The other two sets of
drawings shall be delivered to the attention of the ITS Field Engineer.

SECTION 926 – MISCELLANEOUS MATERIALS

926.01 Flexible Delineator Posts

Flexible delineator posts shall be made of impact resistant thermoplastics. The
post shall be straight along its center line and have a smooth surface free from cracks,
flaws, seams, laps, blisters, and edges affecting the strength, durability, or appearance.
The cross section width shall not exceed 6 in.

The reflective sheeting on all posts shall be in accordance with 919.01(b)1 and
10 shall have minimum dimensions of 3 by 8 in. Reflective sheeting shall be applied
directly to the post and protected in a manner that minimizes damage to the sheeting
upon impact.

The color of the post and the reflective sheeting shall match the color of the
adjacent edgeline.

Only flexible delineator posts from the Department’s list of approved Flexible
Delineator Posts shall be used. Flexible delineator posts will be placed and maintained
on the Department’s approved list in accordance with ITM 806, Procedure H.
20
(a) Type I. Ground Mounted Flexible Delineator Post
Roadside delineator post shall use an anchor sufficient to keep the post securely
embedded in the soil.

(b) Type II. Surface Mounted Flexible Delineator Post

Surface-mounted post shall have either a surface-mounted base capable of bolting
or adhering to the pavement or an anchor cup embedded in the pavement. Bases shall
be made of materials suitable for securely mounting the vertical portion to the

1149
 926.02

roadway. Materials used to attach the base or in-pavement anchor cup to the roadway
30 surface shall be in accordance with the manufacturer's recommendations.

The reflective sheeting on surface-mounted posts shall consist of two 3 in. wide
wraps around the post separated by a 3 in. gap beginning 1 in. down from the top, or
as shown on the plans.

926.02 Delineators

(a) Acrylic Plastic Delineators

Acrylic plastic delineators shall consist of a hermetically sealed optical system
40 with a circular plastic face and prismatic molded rear surface. The optical system shall
have a minimum diameter of 3 in. with a minimum area of approximately 7 sq in. The
trademark of the manufacturer shall be molded legibly into the face of the lens. Color
shall be clear, red, or yellow in daylight as well as when viewed by reflected light at
night. Photometric or optical requirements shall equal or exceed the following
minimum values.

Specific Intensity,
Observation Angle, Entrance Angle,
Candle Power/Footcandle
Degrees Degrees
Clear Yellow Red
0.1 0 119 79 28
0.1 20 47 28 11
Note: The observation angle is the angle at reflector between the observer’s line of sight
and direction of light incident on reflector. The entrance angle is the angle at the
reflector between the direction of light incident on it and the direction of reflector
axis. The specific intensity is the candlepower returned at the chosen observation
angle by a reflector or reflective surface for each footcandle of illumination at
the reflector.

The opaque backing shall be made from aluminum sheet having a minimum
thickness of 0.02 in. The backing shall form an integral part of the delineator and shall
50 retain the optical system securely. A single aluminum grommeted hole in the center of
the reflector shall be provided for mounting. The inside diameter of the grommet hole
shall be 3/16 in.

Only acrylic plastic delineator models and colors from the Department’s list of
approved Delineators shall be used. Acrylic plastic delineators will be placed and
maintained on the Department’s approved list in accordance with ITM 806, Procedure
G.

(b) Reflective Sheeting Delineators

60 Reflective sheeting delineators shall consist of reflective sheeting affixed to an
aluminum backing material. The white delineator shall be 3 by 8 in. ±1/8 in. The
yellow delineator shall be 5 by 5 in. ±1/8 in. The backing material shall be in
accordance with 919.01(a) except the minimum thickness shall be 0.064 in. Reflective
sheeting shall be in accordance with 919.01(b)1.
1150
 926.03

There shall be two mounting holes, 3/16 in. in diameter, with one at the top and
one at the bottom. The holes shall be 6 in. ±1/16 in. center to center and in the corners
of the square units. Completed delineators shall be dip coated with a high gloss clear
finish coat as specified and supplied by the sheeting manufacturer. The finished units
70 shall be clean cut, sharp, and have essentially a plane surface.

Material furnished under this specification shall be covered by a type C

certification in accordance with 916.

(c) Barrier Delineators

The delineators shall consist of a transparent acrylic plastic face, herein referred
to as the lens, and an opaque back fused to the lens under heat and pressure around the
entire perimeter to form a unit permanently sealed against dust, water, and water vapor.
The reflector lens shall be colorless.
80
The lens shall consist of a smooth front surface free from projection or
indentations other than for purposes of identification or orientation of the reflector.
The rear surface shall have a prismatic configuration such that it will effect total
internal reflection of light. The manufacturer’s trademark shall be molded legibly into
the face of the lens.

The reflector lens, having a minimum effective reflex area of 6.5 sq in., shall be
methyl methacrylate in accordance with Federal Specification LP-380C, type 1, Class
3. Photometric or optical requirements shall equal or exceed the minimum values in
90 926.02(a).

Only barrier delineator models and colors from the Department’s list of approved
Delineators shall be used. Barrier delineators will be placed and maintained on the
Department’s approved list in accordance with ITM 806, Procedure G.

(d) Temporary Barrier Delineator

Temporary barrier delineators shall consist of a type III or higher sheeting in
accordance with 919.01(b)1 affixed to a reboundable substrate. The delineator shall
be 8 by 12 in. vertically mounted. The mounting bracket used to affix the delineator
100 to the barrier shall not be more than 3 in. vertical.

926.03 Alternate Material Guardrail Blockouts

Non-timber blockouts shall be dimensioned as tested and shall be used with the
type of guardrail as tested in accordance with NCHRP 350 or MASH. Blockouts shall
be accompanied by a copy of the FHWA eligibility letter stating that the product
complies with the requirements of NCHRP 350 or MASH test level 3.

Alternate material blockouts meeting the criteria may be used interchangeably

with timber blockouts as long as the line and grade of the face of the guardrail is true
110 to that shown on the plans.

1151
THIS PAGE INTENCIONALLY LEFT BLANK

1152
 INDEX OF PAY ITEMS
Pay Item Section
____, ____, Remove ........................................................................................... 201.07
____, Remove ..................................................................................................... 202.14
Aggregate for Drainage Fill ................................................................................ 732.13
Aggregate for End Bent Backfill ........................................................................ 211.10
Aggregate for Shoulder Drains ........................................................................... 608.05
Aggregate for Underdrains ................................................................................. 718.10
Arch, Structural Plate, Min. Area _____ sq ft .................................................... 717.09
Aries Field Processor for PCMS ......................................................................... 801.18
Asphalt for Dust Palliative.................................................................................. 407.08
Asphalt for Prime Coat ....................................................................................... 405.10
Asphalt for Tack Coat ......................................................................................... 406.07
Automatic Drainage Gate, _____in. x _____in. ................................................. 721.05
Automatic Drainage Gate, _____in. ................................................................... 721.05
B Borrow ............................................................................................................ 211.10
Barricade, _____ ................................................................................................. 801.18
Barricade, III, Permanent .................................................................................... 801.18
Barrier Delineator ............................................................................................... 602.06
Barrier, Direction Indicator................................................................................. 801.18
Base Seal............................................................................................................. 415.09
Bearing Assembly, PTFE ................................................................................... 726.05
Bed Course Material .............................................................................. 604.11, 605.10
Bench Mark Post................................................................................................. 615.14
Bench Mark Post, Reset ...................................................................................... 615.14
Binwall, Steel...................................................................................................... 733.08
Bolt, Remove ...................................................................................................... 711.73
Borrow ................................................................................................................ 203.28
Borrow, Cohesive ............................................................................................... 616.13
Box Truss Sign Structure Foundation, _____ ..................................................... 802.12
Breaking Pavement ............................................................................................. 203.28
Bridge Deck Overlay Budget .............................................................................. 722.16
Bridge Deck Overlay, Additional LMC.............................................................. 722.16
Bridge Deck Overlay, Additional LMC-VE ....................................................... 722.16
Bridge Deck Overlay, Additional Silica Fume Modified ................................... 722.16
Bridge Deck Overlay, Additional Surface Prep .................................................. 722.16
Bridge Deck Overlay, Latex Modified ............................................................... 722.16
Bridge Deck Overlay, LMC-VE ......................................................................... 722.16
Bridge Deck Overlay, Patching .......................................................................... 722.16
Bridge Deck Overlay, Silica Fume Modified ..................................................... 722.16
Bridge Deck Patching, Full Depth ...................................................................... 722.16
Bridge Deck Patching, Partial Depth .................................................................. 722.16
Bridge Deck, Remove Existing Concrete Overlay ............................................. 722.16
Bridge Deck, Remove Existing Concrete Surface .............................................. 722.16
Bridge Railing Pedestrian Fence ......................................................................... 706.08
Bronze Plates ...................................................................................................... 711.73
Cable Span Sign Structure Foundation, _____ ................................................... 802.12

1153
 INDEX OF PAY ITEMS
Pay Item Section
Cable, Pole Circuit, THWN, No. _____ Copper, Stranded, ____ ____/C .......... 807.19
Cable-Duct Marker ............................................................................................. 807.19
Cantilever Sign Support Foundation, _____ ....................................................... 802.12
Cased Test Holes ................................................................................................ 203.28
Casting Adjusted to Grade, Monument .............................................................. 615.14
Casting, _____, Adjust to Grade ......................................................................... 720.07
Casting, _____, Furnish and Adjust to Grade ..................................................... 720.07
Catch Basin, _____ ............................................................................................. 720.07
Cellular Concrete Fill, _____.............................................................................. 216.12
Cellular Telephone Service, _____ ..................................................................... 628.06
Cellular Telephone, _____ .................................................................................. 628.06
Cellular Telephone, Additional Data .................................................................. 628.06
Cellular Telephone, Additional Minutes............................................................. 628.06
Center Curb, _____ ............................................................................................. 605.10
Chemical Modification, Soils ............................................................................. 215.12
Circuit Installation, Str. No. _____, _____ Luminaires ...................................... 807.19
Clean Steel Bridge, Partial, QP- _____, Br. No. _____ ...................................... 619.18
Clean Steel Bridge, QP- _____, Br. No. _____ .................................................. 619.18
Clearing and Grubbing........................................................................................ 201.07
Clearing Right-of-Way ....................................................................................... 201.07
CMA Base _____ ............................................................................................... 403.12
CMA Intermediate _____ ................................................................................... 403.12
CMA Surface _____ ........................................................................................... 403.12
Cofferdam ........................................................................................................... 206.11
Cold Central Plant Recycling ............................................................................. 417.20
Cold In-Place Recycling ..................................................................................... 416.17
Compacted Aggregate, No. 2 .............................................................................. 301.10
Compacted Aggregate, No. 5 .............................................................................. 301.10
Compacted Aggregate, No. 8 .............................................................................. 301.10
Compacted Aggregate, No. 53 ............................................................... 301.10, 303.10
Compacted Aggregate, No. 73 ............................................................................ 303.10
Computer System Equipment ............................................................................. 628.06
Computer System................................................................................................ 628.06
Concrete Anchor, _____in. ................................................................................. 715.14
Concrete Anchor, Min. Area, _____ sq ft ........................................................... 715.14
Concrete Barrier Glare Screen ............................................................................ 602.06
Concrete Barrier.................................................................................................. 602.06
Concrete Barrier, Modified Section .................................................................... 602.06
Concrete Bridge Railing Transition, _____ ........................................................ 706.08
Concrete, A, Substructure ................................................................................... 702.28
Concrete, A, Superstructure ................................................................................ 702.28
Concrete, B, Above Footings .............................................................................. 702.28
Concrete, B, Footings ......................................................................................... 702.28
Concrete, C, _____ ............................................................................................. 702.28
Concrete, C, Superstructure ................................................................... 704.08, 705.05

1154
 INDEX OF PAY ITEMS
Pay Item Section
Concrete, Foundation Seal .................................................................................. 702.28
Conduit, _____ ................................................................................................... 805.16
Conduit, Steel, Galvanized, 2 in. ........................................................................ 807.19
Conical Pile Tip, _____ ...................................................................................... 701.15
Connector Kit, Fused .......................................................................................... 807.19
Connector Kit, Unfused ...................................................................................... 807.19
Construction Sign, _____ ................................................................................... 801.18
Contaminated Soil, Remove ............................................................................... 202.14
Contract Liens..................................................................................................... 109.07
Contractor's Reasonable Design Cost for CRI Proposal No. _____ ................... 109.04
Controller and Cabinet, _____ ............................................................................ 805.16
Controller Cabinet Foundation, _____ ............................................................... 805.16
Cored Hole in Rock, _____in. ............................................................................ 701.15
Coring, PCCP ..................................................................................................... 501.31
Corrective Aggregate, CCPR .............................................................................. 417.20
Corrective Aggregate, CIR ................................................................................. 416.17
Corrective Aggregate, FDR ................................................................... 307.20, 308.20
Cost Reduction Incentive Proposal No. ____ ..................................................... 109.04
Cover Aggregate, Prime Coat ............................................................................. 405.10
Cracks and Joints in Asphalt Pavement, Rout and Seal ...................................... 408.08
Cracks in Asphalt Pavement, Fill........................................................................ 408.08
Cracks in PCCP, Filled ....................................................................................... 507.10
Cracks in PCCP, Rout and Seal .......................................................................... 507.10
Curb and Gutter, _____ ...................................................................................... 605.10
Curb Painting, _____ .......................................................................................... 808.13
Curb Ramp, Concrete ......................................................................................... 604.11
Curb, _____ ........................................................................................................ 605.10
Curb, Remove ..................................................................................................... 605.10
Curb, Reset, _____ ............................................................................................. 605.10
Cut-Wall, No. _____........................................................................................... 734.08
D-1 Contraction Joint ......................................................................................... 503.08
Delineator Post.................................................................................................... 804.07
Delineator Post, Flexible, _____......................................................................... 804.07
Delineator with Post, _____................................................................................ 804.07
Delineator ........................................................................................................... 804.07
Dense Graded Subbase ....................................................................................... 302.09
Detectable Warning Surfaces.............................................................................. 604.11
Detectable Warning Surfaces, Retrofit ............................................................... 604.11
Detour Route Marker Assembly ......................................................................... 801.18
Detour Route Marker Assembly, Multiple Routes ............................................. 801.18
Disconnect Hanger.............................................................................................. 805.16
Disposal of Cleaning Waste, ______, Br. No.____ ............................................ 619.18
Diversion Interceptor Type C ............................................................................. 205.11
Drilled Hole for Flowable Backfill ..................................................................... 213.09
Drilled Hole for Underseal ................................................................................. 612.08

1155
 INDEX OF PAY ITEMS
Pay Item Section
Drilled Hole ........................................................................................................ 711.73
Drum, Permanent ................................................................................................ 801.18
Drying Soils for Embankment ............................................................................ 217.11
Dynamic Pile Load Test ..................................................................................... 701.15
Embankment Foundation Soils Treatment .......................................................... 203.28
Embankment ....................................................................................................... 203.28
Energy Absorbing Terminal, CZ, TL - ____ ...................................................... 801.18
Epoxy Injection, Crack Preparation .................................................................... 727.06
Epoxy Injection, Epoxy Material ........................................................................ 727.06
Epoxy Injection, Furnishing Equipment ............................................................. 727.06
Erosion Control Blanket ..................................................................................... 621.14
Excavation, Common ......................................................................................... 203.28
Excavation, Dry .................................................................................................. 206.11
Excavation, Foundation, Unclassified ................................................................ 206.11
Excavation, Peat ................................................................................................. 203.28
Excavation, Rock ................................................................................................ 203.28
Excavation, Unclassified .................................................................................... 203.28
Excavation, Waterway ........................................................................................ 203.28
Excavation, Wet .................................................................................................. 206.11
Excavation, X ..................................................................................................... 206.11
Excavation, Y ..................................................................................................... 203.28
Exploratory Cores ............................................................................................... 203.28
Exploratory Drilling............................................................................................ 203.28
Face Panels, Concrete ......................................................................................... 731.13
Fence Gate, _____, _____ in. x ______ ft ......................................................... 603.08
Fence, _____, ______ in. ................................................................................... 603.08
Fence, _____, Reset ............................................................................................ 603.08
Fence, Farm Field, Barbed Wire, _____ in. ....................................................... 603.08
Fence, Farm Field, Tension Wire, _____ in. ..................................................... 603.08
Fertilizer................................................................................................. 205.11, 621.14
Field Drilled Hole in Concrete............................................................................ 702.28
Field Laboratory, _____ ..................................................................................... 628.06
Field Office, _____ ............................................................................................. 628.06
Filter Sock........................................................................................................... 205.11
Fixed Temporary Signal ..................................................................................... 801.18
Flasher Installation, _____, Location No. _____ ................................................ 805.16
Flashing Arrow Sign ........................................................................................... 801.18
Flowable Backfill, Non-Removable ................................................................... 213.09
Flowable Backfill, Removable ........................................................................... 213.09
Fog Seal .............................................................................................................. 412.10
Full Depth Reclamation ......................................................................... 307.20, 308.20
Geogrid, _____ ................................................................................................... 214.06
Geotextile for Pavement, ______ ....................................................................... 214.06
Geotextile for Subgrade, ______ ........................................................................ 214.06
Geotextile for Underdrains, ______ ................................................................... 718.10

1156
 INDEX OF PAY ITEMS
Pay Item Section
Geotextiles for Riprap, _____ ............................................................................. 616.13
Grated Box End Section, _____, _____, _____in............................................... 715.14
Grated Box End Section, _____, _____, Min. Area _____ sq ft ........................ 715.14
Grates, Basins, and Fittings, Cast Iron ................................................................ 702.28
Grooving for Pavement Markings ...................................................................... 808.13
Guardrail Connector System, W-Beam, Curved, _____ ..................................... 601.14
Guardrail End Treatment, _____ ........................................................................ 601.14
Guardrail End Treatment, _____, Temporary Bridge Approaches ..................... 713.10
Guardrail Height Transition, MGS ..................................................................... 601.14
Guardrail Height Transition, VH, ____ Spacing ................................................ 601.14
Guardrail Transition, _____ ................................................................................ 601.14
Guardrail Transition, MGS, _____ ..................................................................... 601.14
Guardrail, Adjust Height..................................................................................... 601.14
Guardrail, MGS W-Beam, ____ ft ____ in. Spacing .......................................... 601.14
Guardrail, MGS W-Beam, Cable Terminal Anchor ........................................... 601.14
Guardrail, MGS W-Beam, Double Faced, ___ ft ___ in. Spacing ...................... 601.14
Guardrail, MGS W-Beam, Shop Curved, ___ ft ___ in. Spacing ....................... 601.14
Guardrail, MGS, Long Span, _____ ................................................................... 601.14
Guardrail, MGS, Structure Top-Mounted Posts ................................................. 601.14
Guardrail, Remove .............................................................................................. 601.14
Guardrail, Reset .................................................................................................. 601.14
Guardrail, Terminal System, W-Beam Curved, _____ ....................................... 601.14
Guardrail, Thrie-Beam ........................................................................................ 601.14
Guardrail, Thrie-Beam, Double Faced................................................................ 601.14
Guardrail, W-Beam, _____ft _____in. Spacing ................................................ 601.14
Guardrail, W-Beam, __ft ___in. Spacing, Temporary Bridge Approaches ........ 713.10
Guardrail, W-Beam, Cable Terminal Anchor ..................................................... 601.14
Guardrail, W-Beam, Double Faced, _____ ft _____ in. Spacing ....................... 601.14
Guardrail, W-Beam, Nested................................................................................ 601.14
Guardrail, W-Beam, Shop Curved, _____ ft ______ in. Spacing ....................... 601.14
Guardrail, WR-Beam .......................................................................................... 601.14
Gutter, Concrete, type .................................................................................... 607.06
Hand Rail, _____ ................................................................................................ 604.11
Handhole, Lighting ............................................................................................. 807.19
Handhole, Signal, _____..................................................................................... 805.16
Header, Cement Concrete, _____ ....................................................................... 614.06
Header, Cement Concrete, Reconstruct .............................................................. 614.06
High Mast Tower Winch Drive .......................................................................... 807.19
HMA for Approaches, Type _____ .................................................................... 610.06
HMA for Sidewalk ............................................................................................. 604.11
HMA for Structure Installation, Type _____ ...................................................... 715.14
HMA for Temporary Pavement, Type _____ ..................................................... 402.20
HMA for Underdrains......................................................................................... 718.10
HMA Partial Depth Patch ................................................................................... 507.10
HMA Patching, _____ ........................................................................................ 304.07

1157
 INDEX OF PAY ITEMS
Pay Item Section
HMA Transverse Rumble Strips......................................................................... 402.20
HMA Wedge and Level, Type _____ ................................................................. 402.20
Houses and Buildings, Parcel No. ____, Remove .............................................. 202.14
Hydrodemolition ................................................................................................. 722.16
Impact Attenuator, _____, _____ ....................................................................... 601.14
Impact Attenuator, Reset, _____, _____ ............................................................ 601.14
Inlet, _____ ......................................................................................................... 720.07
Inlet, Cap ............................................................................................................ 720.07
Inlet, type H with Slotted Drains ........................................................................ 720.07
Inlet, type HA with Slotted Drains ..................................................................... 720.07
Inspection Hole ................................................................................................... 616.13
Insulation Link, Non-Waterproofed.................................................................... 807.19
Insulation Link, Waterproofed ............................................................................ 807.19
ITS Controller Cabinet Foundation .................................................................... 809.09
ITS Controller Cabinet........................................................................................ 809.09
Jacking and Supporting, _____ ........................................................................... 711.73
Joint Adhesive, _____ ........................................................................... 401.22, 410.22
Joints in PCCP, Filled ......................................................................................... 507.10
Joints in PCCP, Saw and Seal ............................................................................. 507.10
Leveling Pad, Concrete ....................................................................................... 731.13
Light Pole, High Mast, _____ft E.M.H. ............................................................ 807.19
Light Pole, Roadway, _____ft E.M.H., _____ft Mast Arm, _____Base ............ 807.19
Light Structure, Remove ..................................................................................... 807.19
Lighting Foundation, Concrete, with Grounding, __in. x __in. x __in. ............. 807.19
Line, _____, _____, _____, _____in. ................................................................ 808.13
Line, Remove...................................................................................................... 808.13
Linear Grading .................................................................................................... 203.28
Liner Pipe, Thermoplastic, Circular, _____ sq ft ................................................ 725.10
Liner Pipe, Thermoplastic, Deformed, _____ sq ft............................................. 725.10
Liquid Asphalt Sealant ....................................................................................... 401.22
Loop Detector Delay Amplifier, ____, _____ Channel ...................................... 805.16
Loop Detector Rack ............................................................................................ 805.16
Lumber and Timber, Treated .............................................................................. 712.12
Lumber and Timber, Untreated........................................................................... 712.12
Luminaire, High Lumen Roadway ..................................................................... 807.19
Luminaire, High Mast ......................................................................................... 807.19
Luminaire, Low Lumen Roadway ...................................................................... 807.19
Luminaire, Low Lumen-Low Mounting Height Roadway ................................. 807.19
Luminaire, Sign .................................................................................................. 807.19
Luminaire, Underpass ......................................................................................... 807.19
Mailbox Assembly, Double ................................................................................ 611.05
Mailbox Assembly, Reset, Double ..................................................................... 611.05
Mailbox Assembly, Reset, Single ....................................................................... 611.05
Mailbox Assembly, Single .................................................................................. 611.05
Maintaining Traffic ............................................................................................. 801.18

1158
 INDEX OF PAY ITEMS
Pay Item Section
Manhole, _____ .................................................................................................. 720.07
Manufactured Surface Protection Product .......................................................... 205.11
Masonry Tree Well ............................................................................................. 622.22
Masonry Wall ..................................................................................................... 622.22
Material for Underseal ........................................................................................ 612.08
Metal Parts .......................................................................................................... 712.12
Micro-Surfacing, Warranted, for Approaches, Multiple Course ........................ 411.15
Micro-Surfacing, Warranted, for Approaches, Single Course ............................ 411.15
Micro-Surfacing, Warranted, Multiple Course ................................................... 411.15
Micro-Surfacing, Warranted, Single Course....................................................... 411.15
Milled HMA Corrugations, type ................................................................... 606.03
Milled PCCP Corrugations, Conventional .......................................................... 606.03
Milling, Approach............................................................................................... 306.11
Milling, Asphalt Removal................................................................................... 306.11
Milling, Asphalt, _____ ...................................................................................... 306.11
Milling, PCCP, _____......................................................................................... 306.11
Milling, Profile ................................................................................................... 306.11
Milling, Scarification .......................................................................................... 306.11
Milling, Transition .............................................................................................. 306.11
Miscellaneous Equipment for Traffic Signals .................................................... 805.16
Mobile Internet Service, _____ Each.................................................................. 628.06
Mobilization and Demobilization for Seeding .................................................... 621.14
Mobilization and Demobilization for Surface Stabilization ............................... 205.11
Mobilization and Demobilization ....................................................................... 110.04
Modified Posts, Nested Guardrail ....................................................................... 601.14
Modular Block Wall Erection ............................................................................. 732.13
Modular Block Wall with Ground Reinforcement.............................................. 732.13
Modular Block Wall ........................................................................................... 732.13
Monument, _____ ............................................................................................... 615.14
Monument, Re-Establish .................................................................................... 615.14
Mulched Seeding _____, _____ ......................................................................... 621.14
Mulching Material .............................................................................................. 621.14
Multiple Compression Fitting, Non-Waterproofed ............................................. 807.19
Multiple Compression Fitting, Waterproofed ..................................................... 807.19
No. 2 Stone ......................................................................................................... 205.11
Outlet Protector, _____ ....................................................................................... 718.10
Overhead Butterfly Cantilever Sign Structure Foundation, _____ ..................... 802.12
Overhead Sign Structure, _____, Remove .......................................................... 802.12
Overhead Sign Structure, Box Truss, _____....................................................... 802.12
Overhead Sign Structure, Bridge Bracket Assembly .......................................... 802.12
Overhead Sign Structure, Butterfly Cantilever ................................................... 802.12
Overhead Sign Structure, Cantilever, _____ ...................................................... 802.12
Overhead Sign Structure, Monotube................................................................... 802.12
Overhead Sign Structure, Tri-Chord, _____ ....................................................... 802.12
Overlay Dam....................................................................................................... 722.16

1159
 INDEX OF PAY ITEMS
Pay Item Section
Paint Steel Bridge, Br. No._____........................................................................ 619.18
Paint Steel Bridge, Partial, Br. No. _____ .......................................................... 619.18
Parking Barrier, Concrete ................................................................................... 615.14
Parking Barrier, Reset ......................................................................................... 615.14
Parking Barrier, Timber Post .............................................................................. 615.14
Partnering Overhead ........................................................................................... 113.04
Patching Concrete Structures .............................................................................. 710.07
Patroller .............................................................................................................. 801.18
Paved Side Ditch, type ................................................................................... 607.06
Paved Side Ditch, Break ..................................................................................... 616.13
Pavement Message Marking, _____, _____ ....................................................... 808.13
Pavement Message Marking, Remove ................................................................ 808.13
Pavement Removal ............................................................................................. 202.14
PCC Base Patching, _____ ................................................................................. 305.07
PCC Base, _____ ................................................................................................ 305.07
PCCP for Approaches, _____ ............................................................................. 610.06
PCCP for Structure Installation .......................................................................... 715.14
PCCP Patching, Full Depth ................................................................................ 506.13
PCCP Patching, Partial Depth ............................................................................ 506.13
PCCP, _____, in. ................................................................................................ 502.23
Pedestrian Push Button, _____ ........................................................................... 805.16
Pedestrian Signal Head, _____, _____ ............................................................... 805.16
Peening Weld, UIT ............................................................................................. 711.73
Perpetuation, Existing Pipe ................................................................................. 725.10
Pile Shoe, _____ ................................................................................................. 701.15
Pile, Concrete _____x_____ ............................................................................... 701.15
Pile, Prestressed Concrete _____x_____ ............................................................ 701.15
Pile, Steel H, Epoxy Coated, HP _____x_____ .................................................. 701.15
Pile, Steel H, HP _____x_____ .......................................................................... 701.15
Pile, Steel H, Reinforced Concrete Encased, HP _____x_____ ......................... 701.15
Pile, Steel Pipe, _____, _____ ............................................................................ 701.15
Pile, Steel Pipe, Epoxy Coated, _____, _____.................................................... 701.15
Pile, Timber ........................................................................................................ 701.15
Pile, Timber, Treated .......................................................................................... 701.15
Piling, Restock .................................................................................................... 701.15
Pipe Catch Basin, _____in. ................................................................................. 720.07
Pipe End Section, _____in. ................................................................................. 715.14
Pipe End Section, Min. Area, _____ sq ft........................................................... 715.14
Pipe Extension, Circular, _____in., _____ ......................................................... 715.14
Pipe Extension, Deformed, Min. Area _____ sq ft, _____ ................................. 715.14
Pipe Installation, Trenchless, _____ ................................................................... 716.05
Pipe, Bridge Deck Drain System ........................................................................ 715.14
Pipe, Drain Tile Terminal Section, _____in. ...................................................... 719.08
Pipe, Drainage through Concrete Masonry ......................................................... 715.14
Pipe, End Bent Drain, _____in. .......................................................................... 715.14

1160
 INDEX OF PAY ITEMS
Pay Item Section
Pipe, Relaid, _____in. x _____in. ....................................................................... 715.14
Pipe, Relaid, _____in.. ........................................................................................ 715.14
Pipe, Roadway Drain Casting Extension ............................................................ 715.14
Pipe, Sanitary Sewer, _____in. ........................................................................... 715.14
Pipe, Slotted Drain, _____in., _____in. .............................................................. 715.14
Pipe, Slotted Vane Drain, _____in. .................................................................... 715.14
Pipe, Type _____, Circular, _____in. ................................................................. 715.14
Pipe, Type _____, Deformed, Min. Area _____ sq ft ......................................... 715.14
Pipe, Underdrain Outlet, _____in. ...................................................................... 715.14
Plank Floors, _____ Ply ...................................................................................... 712.12
Plant, Annual ...................................................................................................... 622.22
Plant, Aquatic ..................................................................................................... 622.22
Plant, Biannual .................................................................................................... 622.22
Plant, Broadleaf Evergreen, Cone, Broad Upright, _____ .................................. 622.22
Plant, Broadleaf Evergreen, Globe, Dwarf, _____ ............................................. 622.22
Plant, Broadleaf Evergreen, Spreading, Semispreading, _____ ......................... 622.22
Plant, Coniferous Evergreen, Cone, Broad Upright, _____ ................................ 622.22
Plant, Coniferous Evergreen, Globe, Dwarf, _____ ........................................... 622.22
Plant, Coniferous Evergreen, Prostrate Broad Spreading, Semispreading, ___ .. 622.22
Plant, Deciduous Shrub, _____........................................................................... 622.22
Plant, Deciduous Tree, Multi-Stem, _____......................................................... 622.22
Plant, Deciduous Tree, Single Stem, _____........................................................ 622.22
Plant, Ground Cover ........................................................................................... 622.22
Plant, Perennial ................................................................................................... 622.22
Plant, Root Tuber, Corm, Bulb ........................................................................... 622.22
Plant, Rose Grade ............................................................................................... 622.22
Pneumatically Placed Mortar .............................................................................. 708.09
Porous Material for Root Protection ................................................................... 622.22
Portable Changeable Message Sign .................................................................... 801.18
Portable Signal .................................................................................................... 801.18
Portable Tower Lighting Drive System .............................................................. 807.19
Prebored Hole, _____in. ..................................................................................... 701.15
Present Structure, Str. No. ____, Remove Portion.............................................. 202.14
Present Structure, Str. No. ____, Remove .......................................................... 202.14
Prismatic Reflector ............................................................................................. 808.13
Profiling PCCP ................................................................................................... 507.10
Profilograph, HMA ............................................................................................. 401.22
Profilograph, PCCP ............................................................................................ 501.31
QC/QA-HMA, _____, _____, _____, _____ mm,- SMA .................................. 410.22
QC/QA-HMA, _____, _____, _____, _____...................................................... 401.22
QC/QA-PCCP, _____ ......................................................................................... 501.31
Quality Adjustments, _____ ............................................................................ 109.05.1
Quality Assurance Adjustment .............................................................. 410.22, 502.23
Railing, Concrete _____ ..................................................................................... 706.08
Railing, Steel _____............................................................................................ 706.08

1161
 INDEX OF PAY ITEMS
Pay Item Section
Redesign Engineering, CRI Proposal No. ____ .................................................. 109.04
Reference Post .................................................................................................... 802.12
Regulated Asbestos Containing Materials, Remove ........................................... 202.14
Regulated Materials, Dispose, ______ ............................................................... 202.14
Regulated Materials, Remove, ______ ............................................................... 202.14
Regulated Materials, Transport, ______ ............................................................. 202.14
Reinforced Concrete Bridge Approach, _____ in. ............................................. 609.14
Reinforced Concrete Moment Slab, _____ ......................................................... 706.08
Reinforcing Bars ................................................................................................. 703.08
Reinforcing Bars, Epoxy Coated ........................................................................ 703.08
Repair Weld ........................................................................................................ 711.73
Repointing Masonry in Structures ...................................................................... 710.07
Retrofit Load Transfer ........................................................................................ 507.10
Retrofitted Tie Bars ............................................................................................ 503.08
Retro-Reflectivity Testing .................................................................................. 808.13
Right-of-Way Marker ......................................................................................... 615.14
Right-of-Way Marker, Reset .............................................................................. 615.14
Riprap, Class ____ .............................................................................................. 616.13
Riprap, Dumped.................................................................................................. 616.13
Riprap, Grouted, _____ in. ................................................................................. 616.13
Riprap, Precast Concrete..................................................................................... 616.13
Riprap, Revetment .............................................................................................. 616.13
Riprap, Uniform .................................................................................................. 616.13
Rivet, Remove .................................................................................................... 711.73
Road Closure Sign Assembly ............................................................................. 801.18
Road Closure Sign Assembly, Permanent .......................................................... 801.18
Rubblizing PCCP ................................................................................................ 305.07
Safety Metal End Section, _____, _____in......................................................... 715.14
Safety Metal End Section, _____, Min. Area _____sq ft. .................................. 715.14
Salvaged Road Material for _____ ..................................................................... 613.05
Saw Cut for Roadway Loop Detector and Sealant.............................................. 805.16
Scalping .............................................................................................................. 201.07
Seal Coat, _____ P .............................................................................................. 404.14
Seal Coat, _____ ................................................................................................. 404.14
Sediment, Remove .............................................................................................. 205.11
Seed Mixture _____, _____ ................................................................................ 621.14
Seedling .............................................................................................................. 622.22
Service Point, _____ ........................................................................................... 807.19
Settlement Plate .................................................................................................. 204.06
Sidewalk, Concrete ............................................................................................. 604.11
Sidewalk, Concrete, Reconstruct ........................................................................ 604.11
Sidewalk, Concrete, Re-Lay ............................................................................... 604.11
Sign and Supports, Wide Flange, Remove ......................................................... 802.12
Sign Post, _____ ................................................................................................. 802.12
Sign Post, Square, _____ Reinforced Anchor Base ............................................ 802.12

1162
 INDEX OF PAY ITEMS
Pay Item Section
Sign Post, Square, _____ Unreinforced Anchor Base ........................................ 802.12
Sign, “Do Not Disturb”....................................................................................... 622.22
Sign, “Do Not Mow or Spray”............................................................................ 622.22
Sign, “Do Not Spray” ......................................................................................... 621.14
Sign, Double Faced, Sheet, With Legend, _____ ............................................... 802.12
Sign, Overhead, Remove .................................................................................... 802.12
Sign, Panel, Relocate .......................................................................................... 802.12
Sign, Panel, Remove ........................................................................................... 802.12
Sign, Panel, With Legend ................................................................................... 802.12
Sign, Sheet Assembly, Relocate ......................................................................... 802.12
Sign, Sheet, and Supports, Remove .................................................................... 802.12
Sign, Sheet, Relocate .......................................................................................... 802.12
Sign, Sheet, Remove ........................................................................................... 802.12
Sign, Sheet, With Legend ................................................................................... 802.12
Sign, Sheet, With Legend, _____ ....................................................................... 802.12
Sign, Underpass, and Roadway Lighting Location Identification ...................... 807.19
Signal Cable, _____, Copper, ____C/_____....................................................... 805.16
Signal Cantilever Structure, Combination Arm _____ft .................................... 805.16
Signal Cantilever Structure, Drilled Shaft Foundation, _____ ........................... 805.16
Signal Cantilever Structure, Dual Arm _____ ft, _____ft ................................. 805.16
Signal Cantilever Structure, Single Arm _____ft .............................................. 805.16
Signal Cantilever Structure, Single Arm ___ft, Combination Arm ___ft ........... 805.16
Signal Cantilever Structure, Spread Footing Foundation, _____........................ 805.16
Signal Detector Housing ..................................................................................... 805.16
Signal Pole Foundation, _____in. x _____in. x _____in. .................................. 805.16
Signal Pole, _____, _____ft ............................................................................... 805.16
Signal Service ..................................................................................................... 805.16
Slopewall ............................................................................................................ 616.13
Slopewall, Concrete, _____ in. ........................................................................... 616.13
Snowplowable Raised Pavement Marker ........................................................... 808.13
Snowplowable Raised Pavement Marker, Remove ............................................ 808.13
Sodding ............................................................................................................... 621.14
Sodding, Nursery ................................................................................................ 621.14
Soil Pipe, Cast Iron, _____in. ............................................................................. 715.14
Span, Catenary, and Tether ................................................................................. 805.16
Splashpad ............................................................................................................ 205.11
Spring Box .......................................................................................................... 720.07
Stabilizing Material, Asphalt Emulsion .................................... 308.20, 416.17, 417.20
Stabilizing Material, Portland Cement ......................... 307.20, 308.20, 416.17, 417.20
Stake, Lateral ...................................................................................................... 204.06
Stake, Settlement ................................................................................................ 204.06
Standard Metal End Section ............................................................................... 205.11
Standpipe Piezometer ......................................................................................... 204.06
Static Pile Load Test, _____ ............................................................................... 701.15
Steps, Concrete ................................................................................................... 604.11

1163
 INDEX OF PAY ITEMS
Pay Item Section
Stockpiled Material, _____ ................................................................................. 111.12
Stockpiled Selected Material .............................................................................. 212.05
Stockpiled Selected Material, Salvaged .............................................................. 212.05
Stormwater Management Budget ....................................................................... 205.11
Structural Expansion Joint Seal, _____, Replace................................................ 724.05
Structural Expansion Joint, _____ ......................................................... 111.12, 724.05
Structural Expansion Joint, _____, Replace ....................................................... 724.05
Structural Member, Concrete, _____, _____ ...................................................... 707.12
Structural Members, Concrete ............................................................................ 111.12
Structural Steel....................................................................................... 111.12, 711.73
Structural Steel, Breakaway ................................................................................ 802.12
Structural Steel, Field Cut................................................................................... 711.73
Structure Backfill, Type ____ ............................................................................. 211.10
Structure Extension, Coated Reinforced Concrete, Box Sections, __ft x __ ft ... 714.12
Structure Extension, Coated Reinforced Concrete,
Three-Sided Sections,_____in. x _____in. ........................................... 723.18
Structure Extension, Reinforced Concrete, Box Sections, __ft x __ ft ............... 714.12
Structure Extension, Reinforced Concrete, Three-Sided Sections, __in. x _in. .. 723.18
Structure, _____, Reconstructed ......................................................................... 720.07
Structure, Coated Reinforced Concrete, Box Sections, __ft x __ ft .................... 714.12
Structure, Coated Reinforced Concrete, Three-Sided Sections, __in. x __in. .... 723.18
Structure, Reinforced Concrete, Box Sections, __ft x __ ft ................................ 714.12
Structure, Reinforced Concrete, Three-Sided Sections, __in. x __in.................. 723.18
Structures and Obstructions, Remove ................................................................. 202.14
Stud Shear Connectors ........................................................................................ 711.73
Subbase for PCCP............................................................................................... 302.09
Subgrade Treatment, Type ____ ......................................................................... 207.06
Surface Seal ........................................................................................................ 709.08
SWQCP Preparation and Implementation, Level 1 ............................................ 205.11
SWQCP Preparation and Implementation, Level 2 ............................................ 205.11
Temporary Bridge and Approaches .................................................................... 713.10
Temporary Bridge ............................................................................................... 713.10
Temporary Buzz Strips ....................................................................................... 801.18
Temporary Check Dam, Revetment Riprap........................................................ 205.11
Temporary Check Dam, Traversable .................................................................. 205.11
Temporary Crossover Drainage Pipe .................................................................. 801.18
Temporary Crossover, _____ ............................................................................. 801.18
Temporary Crossover, _____, Refurbish ............................................................ 801.18
Temporary Filter Berm ....................................................................................... 205.11
Temporary Filter Stone ....................................................................................... 205.11
Temporary Geotextile ......................................................................................... 205.11
Temporary Illumination ...................................................................................... 801.18
Temporary Inlet Protection ................................................................................. 205.11
Temporary Mulch Stabilization .......................................................................... 205.11
Temporary Mulch ............................................................................................... 205.11

1164
 INDEX OF PAY ITEMS
Pay Item Section
Temporary Panel Sign Supports ......................................................................... 801.18
Temporary Panel Signs ....................................................................................... 801.18
Temporary Pavement Marking, _____ in. ......................................................... 801.18
Temporary Pavement Marking, Removable, _____ in. ..................................... 801.18
Temporary Pavement Message Marking, _____ ................................................ 801.18
Temporary Pavement Message Marking, Removable, _____ ............................ 801.18
Temporary Pipe and Approaches ........................................................................ 713.10
Temporary Pipe .................................................................................................. 713.10
Temporary Raised Pavement Marker, _____ ..................................................... 801.18
Temporary Revetment Riprap ............................................................................ 205.11
Temporary Sediment Basin ................................................................................ 205.11
Temporary Sediment Trap .................................................................................. 205.11
Temporary Seed .................................................................................................. 205.11
Temporary Silt Fence ......................................................................................... 205.11
Temporary Slope Drain ...................................................................................... 205.11
Temporary Traffic Barrier, _____ ...................................................................... 801.18
Temporary Traffic Barrier, Anchored, _____ ..................................................... 801.18
Temporary Transverse Pavement Marking, _____ in. ....................................... 801.18
Temporary Transverse Pavement Marking, Removable, _____ in. ................... 801.18
Temporary Wall Erection ................................................................................... 735.09
Temporary Wire-Facing ..................................................................................... 735.09
Temporary Worksite Speed Limit Sign Assembly ............................................. 801.18
Terminal Joint ..................................................................................................... 503.08
Test Pile, Dynamic, _____, Non-Production ...................................................... 701.15
Test Pile, Dynamic, Production .......................................................................... 701.15
Test Pile, Dynamic, Restrike .............................................................................. 701.15
Test Pile, Indicator, _____, Non-Production ...................................................... 701.15
Test Pile, Indicator, Production .......................................................................... 701.15
Test Pile, Indicator, Restrike............................................................................... 701.15
Test Pile, Static Load, _____, Non-Production .................................................. 701.15
Testing for Asbestos ........................................................................................... 202.14
Testing for Wastes, _____ .................................................................................. 202.14
Threaded Tie Bar Assembly ............................................................................... 703.08
Threaded Tie Bar Assembly, Epoxy Coated....................................................... 703.08
Topsoil ................................................................................................................ 621.14
Traffic Signal Equipment, Remove .................................................................... 805.16
Traffic Signal Head _____, Section, _____ ........................................................ 805.16
Traffic Signal Head _____, Section, Retrofit ..................................................... 805.16
Traffic Signal Installation, _____, Location No. _____ ..................................... 805.16
Transportation of Salvageable Signal Equipment ............................................... 805.16
Transverse Grooving .......................................................................................... 722.16
Transverse Marking, _____, _____, ______, _____in. .................................... 808.13
Transverse Marking, Remove ............................................................................. 808.13
Tri-Chord Sign Structure Foundation, _____ ..................................................... 802.12
Tubular Marker, Permanent ................................................................................ 801.18

1165
 INDEX OF PAY ITEMS
Pay Item Section
Ultrathin Bonded Wearing Course for Approaches, _____ ................................ 414.20
Ultrathin Bonded Wearing Course, _____.......................................................... 414.20
Underdrain, Patching .......................................................................................... 718.10
Underground Storage Tank, Liquid Waste Disposal, ______ ............................ 202.14
Underground Storage Tank, Remove and Dispose, _______ ............................. 202.14
Video Inspection for Pipe ................................................................................... 715.14
Video Inspection for Underdrain ........................................................................ 718.10
Wall Erection ...................................................................................................... 731.13
Water for Shale ................................................................................................... 203.28
Water Monitoring Borehole ................................................................................ 204.06
Water .................................................................................................................. 621.14
Weekly Inspection .............................................................................................. 205.11
Welded Steel Wire Reinforcement ..................................................................... 708.09
Wide Flange Sign Post Support Foundation, _____ ........................................... 802.12
Widening with HMA, _____ .............................................................................. 304.07
Widening with PCC Base, _____ ....................................................................... 305.07
Wire, _____, No. _____Copper, in _____, _____ ______/C ............................. 807.19

1166
 INDEX OF PAY ITEMS IN RECURRING SPECIAL PROVISIONS
Pay Item RSP No.
Aerial Inspection and Annual Rebulb, Flasher ............................................. 805-T-086
Aerial Inspection and Annual Rebulb, Signal ............................................... 805-T-086
Aerial Inspection and Annual Relamp, Flasher ............................................ 805-T-085
Aerial Inspection and Annual Relamp, Signal .............................................. 805-T-085
Anchor Bolt Repair ....................................................................................... 805-T-086
Anchor Bolt, Repair ...................................................................................... 807-T-087
Breakaway Coupling .................................................................................... 807-T-087
Cable Barrier System, Type TL-___ ............................................................ 627-R-546
Cable Barrier System, Type TL-___, Spare Parts ........................................ 627-R-546
Callout, Repair .............................................................................................. 807-T-087
Cement Concrete Pavement Cracking and Seating ...................................... 305-R-431
Compacted Aggregate No. 53, Temporary for Driveways .......................... 801-R-471
Construction Engineering and Inspection, Utility Relocation ..................... 105-C-224
Construction Engineering, GPS Rover ........................................................ 105-C-235
Contact Closure Card .................................................................................... 805-T-173
Controller, Reset Timing .............................................................................. 801-T-089
CPM Schedule ............................................................................................. 108-C-215
Debris, Remove, Str. No___. .......................................................................201-M-030
Drilled Shaft, _____..................................................................................... 728-B-203
Drilled Shaft, Exploratory Core ................................................................... 728-B-203
Drilled Shaft, Permanent Casing.................................................................. 728-B-203
Electrician ..................................................................................................... 807-T-087
Emergency Response Maintenance, ________ ............................................ 805-T-086
Expansion Joint, Sliding Plate ..................................................................... 724-B-200
Fence Gate, Chain Link, PVC Coated, _____ in. ........................................ 603-R-414
Fence, Chain Link, PVC Coated _____ in. x ______ in. ............................. 603-R-414
Fence, Chain Link, PVC Coated, Reset ....................................................... 603-R-414
Flasher Installation, _____, Location No. _____ .......................................... 805-T-036
Gabions, Metallic Coated ............................................................................ 625-R-194
Gabions, PVC Coated .................................................................................. 625-R-194
Gate Barricade ............................................................................................. 603-R-109
Grading in Gore Area .................................................................................. 208-R-111
Herbicide Treatment ....................................................................................624-M-024
High Friction Surface Treatment .................................................................. 617-T-213
HMA for Approaches .................................................................................. 208-R-111
Inspection Hole, 3 ft Deep or less ................................................................ 107-C-243
Inspection Hole, Deeper than 3 ft ................................................................ 107-C-243
Integrated Video Vehicle Detector System ................................................... 805-T-124
Lane Separator .............................................................................................. 804-T-204
Law Enforcement Officer ............................................................................ 801-R-672
Lens Replacement, Pedestrian Signal, _____ in. .......................................... 805-T-085
Lens Replacement, Traffic Signal, ______ in............................................... 805-T-085
Lighting Support ........................................................................................... 807-T-087
Loop, Reseal ................................................................................................. 805-T-085
Luminaire, High Mast, High Pressure Sodium, ______Watt ....................... 807-T-217

1167
 INDEX OF PAY ITEMS IN RECURRING SPECIAL PROVISIONS
Pay Item RSP No.
Luminaire, Roadway, High Pressure Sodium, _____ Watt .......................... 807-T-217
Luminaire, Underpass, High Pressure Sodium, ____ Watt........................... 807-T-217
Magnetometer Detector ................................................................................ 805-T-191
Median Crossover, Remove ......................................................................... 610-R-100
Microloop Detector Probe ............................................................................ 805-T-191
Mowing, Cycle _____ .................................................................................623-M-025
PCCP Stitching ............................................................................................ 503-R-516
Pipe, PVC, _______in. _______ .................................................................. 807-T-087
Plant Growth Layer...................................................................................... 629-R-630
Polymeric Concrete Bridge Deck Overlay................................................... 738-B-297
Project Estimate Adjustment ....................................................................... 109-C-212
Radio Antenna .............................................................................................. 805-T-192
Radio Splitter ................................................................................................ 805-T-192
Radio, Interconnect ....................................................................................... 805-T-192
Radio, Interconnection System Testing ........................................................ 805-T-192
Receiver Processor........................................................................................ 805-T-173
Relief Joint ................................................................................................... 305-R-431
Revet Mattress, Metallic Coated .................................................................. 625-R-194
Revet Mattress, PVC Coated ....................................................................... 625-R-194
Routine Maintenance, Luminaire, ______, _____ W ................................... 807-T-087
Safety Terminal, Type TL-___ .................................................................... 627-R-546
Saw Slot for Roadway Loop and Sealer ....................................................... 805-T-086
Sheet Piling, Steel, S= ___........................................................................... 206-B-026
Signal Cable, Preformed Pave-Over Loop.................................................... 805-T-195
Signal Head, Relocate ................................................................................... 801-T-089
Snowplowable Raised Pavement Marker Casting, Install ............................ 808-T-151
Sound Barrier Design and Layout................................................................ 620-R-483
Sound Barrier Erection, ______, ______..................................................... 620-R-483
Sound Barrier Panels, ______, ______........................................................ 620-R-483
Span, Catenary and Fittings .......................................................................... 805-T-086
Straighten Steel Member ............................................................................. 729-B-204
Structural Expansion Joint, Sealing System ................................................ 724-B-145
Temporary Pole, Wood, with Down Guys and Anchors .............................. 801-T-089
Temporary Portable Rumble Strips .............................................................. 801-T-209
Temporary Traffic Signal Installation, Maintain .......................................... 801-T-089
Temporary Turbidity Curtain....................................................................... 205-C-231
Traffic Signal Installation, _____, Location No. .......................................... 805-T-036
Video Vehicle Detector System .................................................................... 805-T-123
Visor Replacement, Pedestrian Signal .......................................................... 805-T-085
Visor Replacement, Traffic Signal ............................................................... 805-T-085
Wireless Magnetometer Detector ................................................................. 805-T-173
Wireless Repeater ......................................................................................... 805-T-173

1168